Journal of Materials Processing Technology最新文献

英文中文

Unveiling the correlation between weld structure and fracture modes in laser welding of aluminum and copper using data-driven methods

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-05 DOI: 10.1016/j.jmatprotec.2025.118752

Kyubok Lee , Teresa J. Rinker , Changbai Tan , Masoud M. Pour , Peihao Geng , Blair E. Carlson , Jingjing Li

In laser welding, the complex characteristics of weld structure features, including weld geometry and defects such as porosities and cracks, pose significant challenges in analyzing the relationship between weld structure and mechanical performance. This study tackles this issue by introducing a data-driven approach to quantify the significance of specific weld structure features and their correlation with mechanical performance in laser-welded aluminum-copper thin sheets. High-resolution, three-dimensional micro-X-ray tomography provides detailed characterization of weld structure features, including weld geometry and defect attributes. Advanced deep learning techniques and interpretable machine learning models are employed to analyze weld geometry and defect features with precision. Importance analysis identifies a strong correlation between weld geometry and fracture behavior. Further investigation demonstrates that weld geometry exerts a significant influence on other structural features, such as porosity and crack characteristics, highlighting its critical role in predicting fracture behavior. To improve predictions of fracture mode, a novel dimensionless failure mode index is proposed and validated using data from this study and existing literature. This index establishes a robust relationship between weld geometry, defect features, and fracture modes, offering a practical and reliable tool for evaluating weld performance.

{"title":"Unveiling the correlation between weld structure and fracture modes in laser welding of aluminum and copper using data-driven methods","authors":"Kyubok Lee , Teresa J. Rinker , Changbai Tan , Masoud M. Pour , Peihao Geng , Blair E. Carlson , Jingjing Li","doi":"10.1016/j.jmatprotec.2025.118752","DOIUrl":"10.1016/j.jmatprotec.2025.118752","url":null,"abstract":"<div><div>In laser welding, the complex characteristics of weld structure features, including weld geometry and defects such as porosities and cracks, pose significant challenges in analyzing the relationship between weld structure and mechanical performance. This study tackles this issue by introducing a data-driven approach to quantify the significance of specific weld structure features and their correlation with mechanical performance in laser-welded aluminum-copper thin sheets. High-resolution, three-dimensional micro-X-ray tomography provides detailed characterization of weld structure features, including weld geometry and defect attributes. Advanced deep learning techniques and interpretable machine learning models are employed to analyze weld geometry and defect features with precision. Importance analysis identifies a strong correlation between weld geometry and fracture behavior. Further investigation demonstrates that weld geometry exerts a significant influence on other structural features, such as porosity and crack characteristics, highlighting its critical role in predicting fracture behavior. To improve predictions of fracture mode, a novel dimensionless failure mode index is proposed and validated using data from this study and existing literature. This index establishes a robust relationship between weld geometry, defect features, and fracture modes, offering a practical and reliable tool for evaluating weld performance.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118752"},"PeriodicalIF":6.7,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387637","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Corrigendum to “Influence of weld size on energy input and interfacial strength during dissimilar ultrasonic welding of stainless steel to titanium” [J. Mater. Process. Technol. 337 (2025) 118727]

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-05 DOI: 10.1016/j.jmatprotec.2025.118750

Jhe-Chen Liao , Yun-Ta Chung , Jhong-Ren Huang , Pei-Chun Wong , Jhe-Yu Lin

引用次数: 0

Towards understanding the structure-property evolution mechanisms in wrought-to-printed and printed-to-printed linear friction welded Ti alloy near net blanks for aerospace applications

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-04 DOI: 10.1016/j.jmatprotec.2025.118756

Mohan Raj Pandiyan , Arjun Pankajakshan , Chandra Sekhar Perugu , Buchibabu Vicharapu , Satish Vasu Kailas

The near-net manufactured (NNM) blanks from linear friction welding (LFW) can significantly enhance the buy-to-fly ratio of critical Ti-alloy components for critical space, and energy applications. The severe limitations of the laser powder bed fusion, which include the limited build volume and lower material deposition rates, can be simultaneously addressed by near-net manufacturing for critical space applications that require large-sized complex parts with finer resolutions. A systematically coupled experimental and numerical investigation is presented here for the first time to reveal the feasibility of LFW for the manufacturing of novel near-net blanks in wrought-to-printed and printed-to-printed combinations. Results show that the microstructure and mechanical property evolution in the weld zone of both joints is nearly identical due to dynamic re-crystallization. However, the thermo-mechanically affected zones (TMAZ) in printed specimens exhibited the lowest hardness due to globularized needles. In contrast, the TMAZ of wrought specimen hardness increases considerably towards the weld interface due to the deformed and intact bi-modal microstructure. The proposed heat transfer model coupled with the kinetic model is sensitive enough to predict the measured hardness distribution with a maximum error of 5 %. Further, attempt to empirically relate the hardness with the corresponding yield and ultimate tensile strengths of the joints deemed appropriate for five different welding processes from five independent literature. Overall, printed-to-printed and wrought-to-printed joints exhibited excellent synergy between strength and ductility with improved elongation of 14 % and 164 %, respectively due to the closure of micropores in the printed specimen.

{"title":"Towards understanding the structure-property evolution mechanisms in wrought-to-printed and printed-to-printed linear friction welded Ti alloy near net blanks for aerospace applications","authors":"Mohan Raj Pandiyan , Arjun Pankajakshan , Chandra Sekhar Perugu , Buchibabu Vicharapu , Satish Vasu Kailas","doi":"10.1016/j.jmatprotec.2025.118756","DOIUrl":"10.1016/j.jmatprotec.2025.118756","url":null,"abstract":"<div><div>The near-net manufactured (NNM) blanks from linear friction welding (LFW) can significantly enhance the buy-to-fly ratio of critical Ti-alloy components for critical space, and energy applications. The severe limitations of the laser powder bed fusion, which include the limited build volume and lower material deposition rates, can be simultaneously addressed by near-net manufacturing for critical space applications that require large-sized complex parts with finer resolutions. A systematically coupled experimental and numerical investigation is presented here for the first time to reveal the feasibility of LFW for the manufacturing of novel near-net blanks in wrought-to-printed and printed-to-printed combinations. Results show that the microstructure and mechanical property evolution in the weld zone of both joints is nearly identical due to dynamic re-crystallization. However, the thermo-mechanically affected zones (TMAZ) in printed specimens exhibited the lowest hardness due to globularized needles. In contrast, the TMAZ of wrought specimen hardness increases considerably towards the weld interface due to the deformed and intact bi-modal microstructure. The proposed heat transfer model coupled with the kinetic model is sensitive enough to predict the measured hardness distribution with a maximum error of 5 %. Further, attempt to empirically relate the hardness with the corresponding yield and ultimate tensile strengths of the joints deemed appropriate for five different welding processes from five independent literature. Overall, printed-to-printed and wrought-to-printed joints exhibited excellent synergy between strength and ductility with improved elongation of 14 % and 164 %, respectively due to the closure of micropores in the printed specimen.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118756"},"PeriodicalIF":6.7,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348781","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Strengthening mechanism of Al/Ti friction stir butt welded joints via ultrasonic-induced fast diffusion effects

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-03 DOI: 10.1016/j.jmatprotec.2025.118754

Xinchen Nan , Li Zhou , Tingxuan Sun , Mingrun Yu , Xiaoguo Song

The rapid advancement of the aerospace industry has intensified interest in Al/Ti heterostructures. However, the significant property differences between Al alloys and Ti alloys materials pose challenges for high-quality welding. The low interface bonding strength has long been a persistent issue in Al/Ti dissimilar alloy welding. Previous studies have shown that: ultrasonic vibration-assisted technology uniquely influences the types and growth sequence of interfacial compounds in dissimilar alloy friction stir butt welds, thereby improving joint properties. However, the mechanisms by which ultrasonic vibration affects the growth behavior of the compounds and enhances the properties of the joint remain unclear. In this study, ultrasonic-assisted friction stir butt welding of AA6061/Ti6Al4V dissimilar alloy was investigated. The results indicate that ultrasonic vibration induces a significant proliferation of dislocations in the joint without altering the heat input of the weld, thereby promoting element diffusion. As a result, the diffused interface (Al-TiAl₃-Ti) gradually replaces the typical mixed interface (Al-TiAl₃-TiAl-Ti) found in friction stir welding joints, leading to a reduction in lattice mismatch. In addition, ultrasonic vibration helps eliminate welding defects near the interface, further enhancing the quality and integrity of the joint. Consequently, the interface bonding strength increased from 152 MPa to 168 MPa.

{"title":"Strengthening mechanism of Al/Ti friction stir butt welded joints via ultrasonic-induced fast diffusion effects","authors":"Xinchen Nan , Li Zhou , Tingxuan Sun , Mingrun Yu , Xiaoguo Song","doi":"10.1016/j.jmatprotec.2025.118754","DOIUrl":"10.1016/j.jmatprotec.2025.118754","url":null,"abstract":"<div><div>The rapid advancement of the aerospace industry has intensified interest in Al/Ti heterostructures. However, the significant property differences between Al alloys and Ti alloys materials pose challenges for high-quality welding. The low interface bonding strength has long been a persistent issue in Al/Ti dissimilar alloy welding. Previous studies have shown that: ultrasonic vibration-assisted technology uniquely influences the types and growth sequence of interfacial compounds in dissimilar alloy friction stir butt welds, thereby improving joint properties. However, the mechanisms by which ultrasonic vibration affects the growth behavior of the compounds and enhances the properties of the joint remain unclear. In this study, ultrasonic-assisted friction stir butt welding of AA6061/Ti6Al4V dissimilar alloy was investigated. The results indicate that ultrasonic vibration induces a significant proliferation of dislocations in the joint without altering the heat input of the weld, thereby promoting element diffusion. As a result, the diffused interface (Al-TiAl<sub>3</sub>-Ti) gradually replaces the typical mixed interface (Al-TiAl<sub>3</sub>-TiAl-Ti) found in friction stir welding joints, leading to a reduction in lattice mismatch. In addition, ultrasonic vibration helps eliminate welding defects near the interface, further enhancing the quality and integrity of the joint. Consequently, the interface bonding strength increased from 152 MPa to 168 MPa.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118754"},"PeriodicalIF":6.7,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143377457","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Texture-related strength-ductility trade-off in Mg alloys: New insights from an accurate and efficient semi-analytical relaxed constraint model

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-03 DOI: 10.1016/j.jmatprotec.2025.118755

Peike Yang , Yong Hou , Wenzhen Chen , Wenjie Wu , Wenke Wang , Wencong Zhang , Myoung-Gyu Lee

A novel semi-analytical model combining relaxed constraint theory and the Sachs hypothesis was proposed to describe the plastic deformation of magnesium (Mg) alloys. The model stands out by its ability to efficiently and accurately calculate the strength-ductility of Mg alloys influenced by texture using a constitutive equation. The proposed model effectively captures the changes in tensile flow curves during the weakening process from strong basal to fiber texture. It explains how divergence weakening promotes twinning and inhibits slip, leading to reduced yield strength and increased uniform elongation. The strength-ductility relationship for the two main texture adjustment methods, divergence and deviation, is shown to vary with adjustment angles. The model emphasizes that non-basal slip dominance during early deformation significantly enhances strength, while twinning contributes the least. Conversely, basal slip dominance is optimal for improving ductility, whereas non-basal slip proves the least effective. By adjusting model parameters, the impact of alloying on strength-ductility trade-off is evaluated, revealing that reducing the activation differences in deformation mechanisms can improve the overall material performance. These findings provide valuable insights for optimizing process design to achieve a balanced strength and ductility in Mg alloys.

{"title":"Texture-related strength-ductility trade-off in Mg alloys: New insights from an accurate and efficient semi-analytical relaxed constraint model","authors":"Peike Yang , Yong Hou , Wenzhen Chen , Wenjie Wu , Wenke Wang , Wencong Zhang , Myoung-Gyu Lee","doi":"10.1016/j.jmatprotec.2025.118755","DOIUrl":"10.1016/j.jmatprotec.2025.118755","url":null,"abstract":"<div><div>A novel semi-analytical model combining relaxed constraint theory and the Sachs hypothesis was proposed to describe the plastic deformation of magnesium (Mg) alloys. The model stands out by its ability to efficiently and accurately calculate the strength-ductility of Mg alloys influenced by texture using a constitutive equation. The proposed model effectively captures the changes in tensile flow curves during the weakening process from strong basal to fiber texture. It explains how divergence weakening promotes twinning and inhibits slip, leading to reduced yield strength and increased uniform elongation. The strength-ductility relationship for the two main texture adjustment methods, divergence and deviation, is shown to vary with adjustment angles. The model emphasizes that non-basal slip dominance during early deformation significantly enhances strength, while twinning contributes the least. Conversely, basal slip dominance is optimal for improving ductility, whereas non-basal slip proves the least effective. By adjusting model parameters, the impact of alloying on strength-ductility trade-off is evaluated, revealing that reducing the activation differences in deformation mechanisms can improve the overall material performance. These findings provide valuable insights for optimizing process design to achieve a balanced strength and ductility in Mg alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118755"},"PeriodicalIF":6.7,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Electrohydrodynamic embedded printing of low-viscosity ink: Printability and ink rheology

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-03 DOI: 10.1016/j.jmatprotec.2025.118753

Shihao Tan , Hao Yi , Zenan Niu , Di Wu , Huajun Cao

Electrohydrodynamic (EHD) embedded printing technology offers notable advantages in non-contact printing of low-viscosity inks, including one-step manufacturing, liquid encapsulation, and higher print resolution. By incorporating a liquid substrate, this technology stabilizes the printing process, enhances overall print quality, and mitigates issues such as the coffee ring effect. Despite these benefits, printability challenges remain, primarily due to interference from residual charges and the complex solute migration influenced by ink rheology. To address these, this study employed pulse signal modulation, successfully neutralizing residual charges and enhancing printing process stability. Additionally, key EHD printing parameters—pressure, printing height, and voltage—were optimized to further improve reliability and printability. The study also delved into the impact of ink rheology on printed structure morphology and, consequently, on the embedded morphology. Specifically, it analyzed how variations in rheological properties of low-viscosity inks influenced the printed structure, which in turn affected the final embedded morphology. A comprehensive mapping of these influences was developed, revealing correlations between printed structure morphology and embedded morphology. This work provides a comprehensive process guide that helps optimize printability and ink rheology in EHD embedded printing, thereby enhancing its potential for one-step manufacturing of flexible electronics and expanding its potential applications to high-precision embedded printing of other functional materials.

{"title":"Electrohydrodynamic embedded printing of low-viscosity ink: Printability and ink rheology","authors":"Shihao Tan , Hao Yi , Zenan Niu , Di Wu , Huajun Cao","doi":"10.1016/j.jmatprotec.2025.118753","DOIUrl":"10.1016/j.jmatprotec.2025.118753","url":null,"abstract":"<div><div>Electrohydrodynamic (EHD) embedded printing technology offers notable advantages in non-contact printing of low-viscosity inks, including one-step manufacturing, liquid encapsulation, and higher print resolution. By incorporating a liquid substrate, this technology stabilizes the printing process, enhances overall print quality, and mitigates issues such as the coffee ring effect. Despite these benefits, printability challenges remain, primarily due to interference from residual charges and the complex solute migration influenced by ink rheology. To address these, this study employed pulse signal modulation, successfully neutralizing residual charges and enhancing printing process stability. Additionally, key EHD printing parameters—pressure, printing height, and voltage—were optimized to further improve reliability and printability. The study also delved into the impact of ink rheology on printed structure morphology and, consequently, on the embedded morphology. Specifically, it analyzed how variations in rheological properties of low-viscosity inks influenced the printed structure, which in turn affected the final embedded morphology. A comprehensive mapping of these influences was developed, revealing correlations between printed structure morphology and embedded morphology. This work provides a comprehensive process guide that helps optimize printability and ink rheology in EHD embedded printing, thereby enhancing its potential for one-step manufacturing of flexible electronics and expanding its potential applications to high-precision embedded printing of other functional materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118753"},"PeriodicalIF":6.7,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175407","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multi-material laser powder bed fusion additive manufacturing of architecturally designed dual-phase heterostructures using heterogeneous high-entropy alloys

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118708

Guoqing Huang , Bo Li , Hanlin He , Fuzhen Xuan

Since the concept of high-entropy alloys (HEAs) was introduced, the development of HEAs with synergistic strength and toughness has posed a significant challenge to researchers. Traditional approaches based on random biphasic solid-solution designs often suffer from high variability and poor controllability. In this study, a novel method for multi-material laser powder bed fusion (MM-LPBF) with staggered printing was developed. Using AlCuCoCrFeNi-HEA and MnCoCrFeNi-HEA powders as starting materials, three heterogeneous bi-metallic structures were fabricated. These include staggered multi-layer planar, staggered multi-layer rotating grating, and staggered multi-layer checkerboard structures. The printed bi-metallic structures exhibit a dual-phase heterogeneous composition, consisting of fine body-centered cubic (BCC) crystals and coarse columnar face-centered cubic (FCC) crystals. The interfaces between the dual phases are firmly bonded by transitional “dual-phase intercalation”. Experimental evaluations demonstrate that these structures possess enhanced interfacial strengthening and crack suppression, particularly the staggered multilayer checkerboard structure, which exhibits remarkable impact resistance and energy absorption across multiple reinforcement mechanisms. This study provides valuable insights for the field of metal-based multi-material additive manufacturing, offering new perspectives and potential applications for the future design and fabrication of diverse materials.

{"title":"Multi-material laser powder bed fusion additive manufacturing of architecturally designed dual-phase heterostructures using heterogeneous high-entropy alloys","authors":"Guoqing Huang , Bo Li , Hanlin He , Fuzhen Xuan","doi":"10.1016/j.jmatprotec.2024.118708","DOIUrl":"10.1016/j.jmatprotec.2024.118708","url":null,"abstract":"<div><div>Since the concept of high-entropy alloys (HEAs) was introduced, the development of HEAs with synergistic strength and toughness has posed a significant challenge to researchers. Traditional approaches based on random biphasic solid-solution designs often suffer from high variability and poor controllability. In this study, a novel method for multi-material laser powder bed fusion (MM-LPBF) with staggered printing was developed. Using AlCuCoCrFeNi-HEA and MnCoCrFeNi-HEA powders as starting materials, three heterogeneous bi-metallic structures were fabricated. These include staggered multi-layer planar, staggered multi-layer rotating grating, and staggered multi-layer checkerboard structures. The printed bi-metallic structures exhibit a dual-phase heterogeneous composition, consisting of fine body-centered cubic (BCC) crystals and coarse columnar face-centered cubic (FCC) crystals. The interfaces between the dual phases are firmly bonded by transitional “dual-phase intercalation”. Experimental evaluations demonstrate that these structures possess enhanced interfacial strengthening and crack suppression, particularly the staggered multilayer checkerboard structure, which exhibits remarkable impact resistance and energy absorption across multiple reinforcement mechanisms. This study provides valuable insights for the field of metal-based multi-material additive manufacturing, offering new perspectives and potential applications for the future design and fabrication of diverse materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118708"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168495","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Faster surface finishing with shape adaptive grinding plus ceria

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118704

Ashwani Pratap , Kathryn Copson , Anthony Beaucamp

Shape adaptive grinding (SAG) is a well-established approach to obtain optical smooth quality on hard ceramic and metallic surfaces. However, the process has been limited to low material removal rate (MRR) when already smooth surfaces are processed using SAG pads. In this work, shape adaptive grinding plus ceria (SAG+) is put forward as an effective approach to increase the MRR, whereby ceria is used as polishing slurry and enables softening of glass/glass-ceramic surfaces through chemical reaction and enhances subsequent material removal through mechanical action of the SAG pad. A macroscopic material removal model is established for SAG+ process on BK7 glass where the effect of ceria on the surface hardness correlates well with the material removal rate. Experiments were performed on BK7 glass with different grades of resin bonded diamond SAG tools to benchmark performance against the standard SAG process. It was observed that the material removal rate increased by 3.5–10 times for SAG+ when all other conditions remain the same. It was also determined that removal rate increases most drastically when the abrasive grit of SAG pad and ceria slurry are of comparable size. Lapped Zerodur™ samples were also processed to check the applicability in pre-polishing of rough glass-ceramic surfaces. A reduction of almost 50 % could be obtained in processing time when using the SAG+ process.

{"title":"Faster surface finishing with shape adaptive grinding plus ceria","authors":"Ashwani Pratap , Kathryn Copson , Anthony Beaucamp","doi":"10.1016/j.jmatprotec.2024.118704","DOIUrl":"10.1016/j.jmatprotec.2024.118704","url":null,"abstract":"<div><div>Shape adaptive grinding (SAG) is a well-established approach to obtain optical smooth quality on hard ceramic and metallic surfaces. However, the process has been limited to low material removal rate (MRR) when already smooth surfaces are processed using SAG pads. In this work, shape adaptive grinding plus ceria (SAG+) is put forward as an effective approach to increase the MRR, whereby ceria is used as polishing slurry and enables softening of glass/glass-ceramic surfaces through chemical reaction and enhances subsequent material removal through mechanical action of the SAG pad. A macroscopic material removal model is established for SAG+ process on BK7 glass where the effect of ceria on the surface hardness correlates well with the material removal rate. Experiments were performed on BK7 glass with different grades of resin bonded diamond SAG tools to benchmark performance against the standard SAG process. It was observed that the material removal rate increased by 3.5–10 times for SAG+ when all other conditions remain the same. It was also determined that removal rate increases most drastically when the abrasive grit of SAG pad and ceria slurry are of comparable size. Lapped Zerodur™ samples were also processed to check the applicability in pre-polishing of rough glass-ceramic surfaces. A reduction of almost 50 % could be obtained in processing time when using the SAG+ process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118704"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168493","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Curvature, microstructure, and mechanical property of an asymmetric aluminium profile produced by sideways extrusion with variable speed

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118699

Jiaxin Lv , Xiaochen Lu , Junquan Yu , Zhusheng Shi , Jianguo Lin

Sideways extrusion is an advanced technology for one-step production of curved profiles eliminating the need for subsequent bending processes. Its effectiveness in controlling the bending curvature of symmetric products has been well established in prior research. However, there is no report on the effect of asymmetric product shape on bending curvature and still lacking quantitative analysis of welding quality and microstructure of the extrudate for the sideways extrusion, limiting its application scope. In this study, an asymmetric Z-shape aluminium profile was manufactured using sideways extrusion at different speeds and the corresponding numerical simulation was conducted to analyse the extrudate shape, welding quality, microstructural and mechanical properties. The bending mechanism of extrudate, resulting from the non-uniform metal flow during extrusion, was identified. The curvature radius was found to depend on the average exit velocity and the velocity gradient along the transverse direction both of which increase with increasing extrusion speed. Improvements in welding quality and increased recrystallisation fraction during extrusion were quantitatively predicted using developed subroutines and these predications aligned well with the results from post-extrusion examination. In addition, tensile test results differed for profile sections extruded at different speeds, which were attributed to the combined effect of welding quality, work hardening, recovery and continuous dynamic recrystallisation.

{"title":"Curvature, microstructure, and mechanical property of an asymmetric aluminium profile produced by sideways extrusion with variable speed","authors":"Jiaxin Lv , Xiaochen Lu , Junquan Yu , Zhusheng Shi , Jianguo Lin","doi":"10.1016/j.jmatprotec.2024.118699","DOIUrl":"10.1016/j.jmatprotec.2024.118699","url":null,"abstract":"<div><div>Sideways extrusion is an advanced technology for one-step production of curved profiles eliminating the need for subsequent bending processes. Its effectiveness in controlling the bending curvature of symmetric products has been well established in prior research. However, there is no report on the effect of asymmetric product shape on bending curvature and still lacking quantitative analysis of welding quality and microstructure of the extrudate for the sideways extrusion, limiting its application scope. In this study, an asymmetric Z-shape aluminium profile was manufactured using sideways extrusion at different speeds and the corresponding numerical simulation was conducted to analyse the extrudate shape, welding quality, microstructural and mechanical properties. The bending mechanism of extrudate, resulting from the non-uniform metal flow during extrusion, was identified. The curvature radius was found to depend on the average exit velocity and the velocity gradient along the transverse direction both of which increase with increasing extrusion speed. Improvements in welding quality and increased recrystallisation fraction during extrusion were quantitatively predicted using developed subroutines and these predications aligned well with the results from post-extrusion examination. In addition, tensile test results differed for profile sections extruded at different speeds, which were attributed to the combined effect of welding quality, work hardening, recovery and continuous dynamic recrystallisation.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118699"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A novel strengthening method using Al3Ti for oscillation laser-MIG hybrid welded joints of Al-Zn-Mg-Cu alloy

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118695

Zhuoming Tan , Xiaohui Zhou , Bin Wang , Weining Qi , Peng Li , Fuyun Liu , Zhao Zhang , Tao Yu , Caiwang Tan

Al-Zn-Mg-Cu alloys are extensively utilized in lightweight structural applications, with Al-Mg wires commonly employed to mitigate solidification cracking during fusion welding. However, the suboptimal properties of welded joints have remained a persistent challenge, particularly when paired with low-strength wires. Currently, the strength of fusion welded joints in Al-Zn-Mg-Cu alloys typically achieves about 60% of the base material (BM). This study employed an oscillation laser-MIG hybrid welding technique incorporating a titanium interlayer, and the influence of Al₃Ti on microstructural features and mechanical properties was analyzed. Results demonstrated that the mechanical performance of welded joints was significantly enhanced by the presence of Al₃Ti. Numerical simulations indicated that oscillation laser-induced stirring improved melt fluidity in the molten pool, leading to the formation and uniform distribution of Al₃Ti throughout the weld. Al₃Ti particles as nucleation substrates, facilitating grain refinement. A strengthening mechanism for Al₃Ti applicable to fusion welded joints in Al-Zn-Mg-Cu alloys was proposed, incorporating grain boundary strengthening and particle strengthening. The tensile strength and elongation of the welded joints increased to 401.74 MPa (71% of BM) and 7.27%, respectively. This work demonstrated an innovative processing and an unconventional reinforcement phase which provided guidance for fusion welding of high-strength aluminum alloys in practical applications.

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