Journal of Materials Processing Technology最新文献_第4页

Investigating the effects of powder feeding rate on microstructure transformation in linear laser beam additive manufactured thick-walled structures 研究粉末进料速度对线性激光束添加剂制造厚壁结构微观结构转变的影响

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-21 DOI: 10.1016/j.jmatprotec.2024.118642

Tao Yang , Yi Luo , Chencheng Zheng , Chenlin Yang , Hui Huang

The coarse columnar crystals that grow through multiple layers are commonly observed in laser additive manufactured structures, with fractures tending to occur in regions where there are abrupt changes in grain morphology. This can lead to a degradation of the mechanical properties of the samples. In this study on laser additive manufacturing, thick-walled structures made of 304 stainless steel were created using a linear beam spot with a rectangular powder feeding nozzle. By adjusting the powder feeding rate to influence the thermal cycling characteristics during the laser additive manufacturing process, a hierarchical grain structure that combines coarse and fine equiaxed grains was achieved, enhancing the forming efficiency and overall mechanical performance of the structure. The results from the thermal cycling characteristics and microstructure analysis indicate that increasing the powder feeding rate during the additive manufacturing process can decrease the hierarchical cooling rate, temperature gradient, and heat accumulation effect. This reduction in turn decreases the grain size and facilitates the transformation of columnar crystals into equiaxed crystals. Furthermore, the transformation of low-angle grain boundaries into high-angle grain boundaries in the interlayer region helps to reduce stress concentration, weaken anisotropic tendencies, and mitigate intergranular fracture tendencies, ultimately improving the mechanical properties of the overall structure. In actual engineering applications, the powder flow can be adjusted to control the temperature gradient and cooling rate of the deposition layer, thereby altering the grain morphology and optimizing the mechanical properties of additive manufacturing parts.

在激光添加剂制造的结构中经常可以观察到通过多层生长的粗柱状晶体，而断裂往往发生在晶粒形态发生突然变化的区域。这会导致样品的机械性能下降。在这项关于激光快速成型的研究中，使用带有矩形送粉喷嘴的线性光束光斑制造了由 304 不锈钢制成的厚壁结构。在激光增材制造过程中，通过调整送粉速度来影响热循环特性，实现了粗细等轴晶粒相结合的分层晶粒结构，提高了结构的成型效率和整体机械性能。热循环特性和微观结构分析的结果表明，在增材制造过程中提高粉末喂料速率可降低分层冷却速率、温度梯度和热累积效应。这种降低反过来又会减小晶粒尺寸，促进柱状晶向等轴晶的转变。此外，层间区域的低角度晶界转变为高角度晶界有助于减少应力集中，削弱各向异性倾向，减轻晶间断裂倾向，最终改善整体结构的机械性能。在实际工程应用中，可以通过调整粉末流动来控制沉积层的温度梯度和冷却速度，从而改变晶粒形态，优化增材制造部件的机械性能。

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引用次数: 0

On influence of microstructural anisotropy of additive manufactured structures upon machining dynamics: An example of milling of Ti6Al4V thin-walled parts 增材制造结构的微结构各向异性对加工动力学的影响：以铣削 Ti6Al4V 薄壁零件为例

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-20 DOI: 10.1016/j.jmatprotec.2024.118644

Dongbo Hong , Shusong Zan , Kieran Winter , Zhirong Liao , Dragos Axinte

Thin-walled structures, as common component specification for aerospace components, easily experience deformation and chatter issues during machining (e.g. milling) operations. With Additively Manufactured (AM) materials being increasingly applied in these areas, it is found that their microstructural anisotropy can lead to varied mechanical properties and machinability in different directions. However, former research on thin-walled parts mainly focused on bulk materials, while the machining performance of these thin-wall structures produced from AM processes remains unclear. In this view, this research aims to reveal the effect of microstructural anisotropy resulting from AM process on the machining (deformation and stability) of thin-walled parts by taking Ti6Al4V as an example. Three kinds of AM Ti6Al4V thin-walled parts were fabricated with different laser scanning strategies, in which the prior columnar β grains were found to grow along the building direction and led to a variation in mechanical properties. Owing to this, the deformation and machining stability varied in the AM thin-walled parts with different β phase crystallization orientations on the same milling directions, which could be attributed to the changes of cutting force and dynamic parameters (e.g., frequency, stiffness (determined by elastic modulus), damping ratio) in different orientations. This investigation could provide a reference for the selection of printing strategies and follow-up machining process of AM thin-walled parts when considering their microstructural anisotropy.

薄壁结构作为航空航天部件的常见组件规格，在加工（如铣削）过程中很容易出现变形和颤振问题。随着快速成型（AM）材料越来越多地应用于这些领域，人们发现其微观结构的各向异性可导致不同方向的机械性能和可加工性。然而，以往对薄壁零件的研究主要集中在块体材料上，而对 AM 工艺生产的这些薄壁结构的加工性能仍不清楚。有鉴于此，本研究旨在以 Ti6Al4V 为例，揭示 AM 工艺产生的微观结构各向异性对薄壁零件加工（变形和稳定性）的影响。采用不同的激光扫描策略制造了三种 AM Ti6Al4V 薄壁零件，发现先期柱状 β 晶粒沿构建方向生长，并导致了机械性能的变化。因此，在同一铣削方向上，不同β相结晶取向的 AM 薄壁零件的变形和加工稳定性也不同，这可能是由于不同取向的切削力和动态参数（如频率、刚度（由弹性模量确定）、阻尼比）发生了变化。考虑到 AM 薄壁零件的微观结构各向异性，这项研究可为选择打印策略和后续加工工艺提供参考。

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引用次数: 0

Graphene reinforced magnesium metal matrix composites by infiltrating coated-graphene preform with melt 通过将涂覆石墨烯预型件渗入熔体实现石墨烯增强镁金属基复合材料

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-19 DOI: 10.1016/j.jmatprotec.2024.118639

Kang Yun , Jiming Zhou , Chentong Zhao , Xuemeng Jiang , Lehua Qi

Graphene’s exceptional mechanical, electrical, and thermal conductivity capabilities make it an ideal reinforcement for metal matrix composites. However, graphene is hard to be dispersed in the melt metal due to its high surface energy, non-wetting nature, and strong van der Waals interactions between graphene sheets, which weaken the reinforcing eﬃciency of composites. A novel process by infiltrating the coated-graphene preform with melt magnesium was proposed to improve the dispersion of graphene in the magnesium matrix. Graphene preforms with oriented pores were prepared by a directional freeze-drying method. Magnesium oxide coatings were deposited on the surface of graphene inside the graphene preform using the evaporation of magnesium atoms to enhance the strength as well as the wettability between the preform and magnesium matrix. Magnesium matrix composites were fabricated by liquid-solid pressure inﬁltrating coated-graphene preform with molten magnesium. The microstructure of graphene preforms and composites and mechanical properties of the composites were characterized. The results show that graphene is uniformly dispersed in the matrix and presents a reticular structure, and the hardness, elastic modulus, and compressive strength of the composite were improved apparently compared to the matrix. This study suggests that the method of preparing composites by inﬁltration provides a novel strategy for fabricating nano-material reinforced magnesium matrix composites.

石墨烯具有优异的机械、导电和导热性能，是金属基复合材料的理想增强材料。然而，由于石墨烯的高表面能、非润湿性以及石墨烯片之间强烈的范德华相互作用，石墨烯很难分散在熔融金属中，从而削弱了复合材料的增强能力。为了提高石墨烯在镁基体中的分散性，研究人员提出了一种新工艺，即在涂覆石墨烯预型件中渗入镁熔体。通过定向冷冻干燥法制备了具有定向孔隙的石墨烯预型件。利用镁原子蒸发在石墨烯预型件内部的石墨烯表面沉积氧化镁涂层，以增强预型件和镁基体之间的强度和润湿性。镁基复合材料是通过将涂覆石墨烯预型件与熔融镁进行液-固压力渗透而制成的。对石墨烯预型件和复合材料的微观结构以及复合材料的机械性能进行了表征。结果表明，石墨烯均匀地分散在基体中并呈现网状结构，与基体相比，复合材料的硬度、弹性模量和抗压强度明显提高。这项研究表明，用渗透法制备复合材料的方法为制造纳米材料增强的镁基复合材料提供了一种新策略。

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引用次数: 0

Subsurface damage and brittle fracture suppression of monocrystalline germanium in ultra-precision machining by multiple ion implantation surface modification 多重离子注入表面改性在超精密加工中抑制单晶锗的表层下损伤和脆性断裂

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-18 DOI: 10.1016/j.jmatprotec.2024.118640

Yi Tan , Wai Sze Yip , Te Zhao , Suet To , Zejia Zhao

Monocrystalline germanium has been widely used in semiconductor industry and optical engineering because of its excellent electrical and optical properties. However, its hard and brittle properties present difficulties in ultra-precision machining, resulting in surface cracks due to brittle mode cutting. A lot of research has been done on ultra-precision machining of single crystal materials to improve their machinability, including ion implantation surface modification. The ultra-precision manufacturing of semiconductor single crystal materials still faces great challenges. The optimization of ion implantation strategy and the cutting mechanism of samples after ion implantation are still problems that need to be solved. This study presents a novel surface modification strategy for germanium using multi-ion implantation to improve its machinability. In this study, simulation software visualizes the distribution and induced displacement of implanted ions on the subsurface of a germanium wafer. Ultra-precision diamond scratching experiments confirm the improved cutting performance of the ion-implanted germanium, demonstrating a significant increase in the ductile cutting region. The deformation mechanism of different modified layers of germanium during cutting was studied by TEM. The results showed that the subsurface damage of germanium after ion implantation was effectively suppressed. Finally, the microcrack free microlens array was successfully fabricated on the surface of ion-implanted germanium, demonstrating the improved machinability of germanium through ion implantation. This study broke through the limitation of surface modification by single ion implantation, deepened the understanding of brittle-ductile transition in ultra-precision machining of monocrystalline germanium, and provided theoretical basis and technical support for optimizing ion implantation assisted machining of single crystal materials in the future.

单晶锗因其优异的电气和光学特性而被广泛应用于半导体工业和光学工程领域。然而，它的硬脆特性给超精密加工带来了困难，脆性模式切削会导致表面裂纹。为了提高单晶材料的可加工性，人们对其超精密加工进行了大量研究，包括离子注入表面改性。半导体单晶材料的超精密加工仍面临巨大挑战。离子注入策略的优化和离子注入后样品的切割机制仍是亟待解决的问题。本研究提出了一种新型的多离子注入锗表面改性策略，以提高其可加工性。在这项研究中，模拟软件将植入离子在锗晶片亚表面的分布和诱导位移可视化。超精密金刚石划痕实验证实，离子注入锗的切割性能得到改善，韧性切割区域显著增加。通过 TEM 研究了切割过程中不同改性锗层的变形机制。结果表明，离子注入后锗的表层下损伤得到了有效抑制。最后，在离子注入锗表面成功制造出了无微裂纹的微透镜阵列，证明离子注入技术提高了锗的可加工性。该研究突破了单离子注入表面改性的局限性，加深了对单晶锗超精密加工中脆-韧性转变的理解，为今后优化离子注入辅助加工单晶材料提供了理论依据和技术支持。

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引用次数: 0

Coupling CPFE-CA simulation for grain refinement in ultrasonic elliptical vibration diamond cutting of polycrystalline Cu 耦合 CPFE-CA 仿真用于多晶铜超声波椭圆振动金刚石切割中的晶粒细化

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-18 DOI: 10.1016/j.jmatprotec.2024.118638

Wenxin Zhang , Zhanfeng Wang , Junjie Zhang

While microstructure evolution is commonly observed in severe plastic deformation of polycrystalline metals, modulating the cutting-induced grain refinement in subsurface of polycrystalline metals is promising for promoting the performance of machined surface. In this study, we demonstrate the effectiveness of applying ultrasonic vibration assistance (UVA) in effectively grain refinement of polycrystalline Cu in ultra-precision diamond cutting by experiments and multiscale coupling simulations. Specifically, ordinary cutting (OC) and ultrasonic elliptical vibration-assisted cutting (UEVC) experiments of polycrystalline Cu are carried out, and subsequent cross-sectional characterizations of microstructure evolution in subsurface by metallurgical microscope and electron backscatter diffraction, as well as instrumented nanoindentation tests, are performed, which jointly demonstrate significantly promoted grain refinement in subsurface and increased machined surface hardness by UVA, due to increased dislocation density that is beneficial for the nucleation and growth of dynamic recrystallization. In particular, the multi-scale coupling of Crystal Plasticity Finite Element (CPFE) simulation and Cellular Automata (CA) method is firstly established for exploring the microstructural evolution during UEVC and OC of polycrystalline Cu, which is capable of elucidating the underlying correlation of grain refinement behavior in subsurface with characteristics of stress and strain fields in cutting area. Furthermore, the influence of amplitude on the propensity of grain refinement is experimentally and theoretically evaluated, which suggests a critical amplitude of 4 μm that leads to a maximum reduction in grain size by 80.9 % and a maximum increase in machined surface hardness by 55.8 % in UEVC from that in OC, because of the mostly pronounced strain accumulation and dislocation activity. The findings reported in this study demonstrate the effectiveness of applying ultrasonic vibration assistance for modulating the grain refinement accompanying strengthening of machined surface in ultra-precision diamond cutting of polycrystalline metals.

多晶金属在剧烈塑性变形过程中通常会出现微观结构演变，而调节多晶金属表层下的切削诱导晶粒细化有望提高加工表面的性能。在本研究中，我们通过实验和多尺度耦合模拟证明了在超精密金刚石切削中应用超声波振动辅助（UVA）有效细化多晶铜晶粒的有效性。具体而言，对多晶铜进行了普通切削（OC）和超声椭圆振动辅助切削（UEVC）实验，随后通过金相显微镜和电子反向散射衍射以及仪器纳米压痕测试对次表层的微观结构演变进行了横截面表征，共同证明了 UVA 显著促进了次表层的晶粒细化并提高了加工表面硬度，这是由于位错密度的增加有利于动态再结晶的成核和生长。其中，首次建立了晶体塑性有限元（CPFE）模拟和细胞自动机（CA）方法的多尺度耦合，用于探索多晶铜在 UEVC 和 OC 过程中的微观结构演变，能够阐明次表层晶粒细化行为与切削区域应力场和应变场特征的内在关联。此外，还通过实验和理论评估了振幅对晶粒细化倾向的影响，结果表明 4 μm 的临界振幅可使 UEVC 中的晶粒尺寸最大减小 80.9%，加工表面硬度最大提高 55.8%，而 OC 中的晶粒尺寸减小和提高主要是由于明显的应变积累和位错活动。本研究报告的结果表明，在多晶金属的超精密金刚石切削中，应用超声波振动辅助调节晶粒细化和强化加工表面非常有效。

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引用次数: 0

An optical field regulation method for waterjet-guided laser: Reducing taper and improving deep-processing capability 用于水刀制导激光的光场调节方法：减小锥度，提高深加工能力

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-15 DOI: 10.1016/j.jmatprotec.2024.118637

Guangyi Zhang , Jiayu Wang , Zhongan Chen , Yaowen Wu , Binying Bao , Wenwu Zhang

Waterjet-guided laser (WGL) processing technology has the advantages of low thermal damage, no contact stress and ultra-fine processing. However, the energy distribution of the existing technology in the laminar flow water column is still characterized by Gaussian distribution, which leads to taper effect in the processing of thick plate materials and affects the deep-processing capability. To address these shortcomings, a novel waterjet laser-field regulation (WLR) method is proposed in this paper. Optical simulation and coupling experiments confirm the method's ability to modulate the energy within the waterjet into a circular distribution, which solves the problem of low power density near the surface of the waterjet. Waterjet-guided laser cutting experiments were conducted based on the WLR method, and the taper was significantly reduced compared to the conventional WGL. At a power of 12 W, the taper was reduced from 5.85° to 2.28°, a reduction of 61 %. In terms of processing depth, the WLR method cuts slightly lower groove depths with a low number of cuts, but as the number of cuts increases, the groove depth steadily increases and exceeds that of the conventional WGL. At 500 cuts with a laser power of 20 W, the groove depths obtained by the WLR method increased by 115 % compared to that of the conventional WGL. This study has important implications for the processing of thick materials by waterjet-guided laser.

水刀引导激光（WGL）加工技术具有热损伤小、无接触应力和超精细加工等优点。然而，现有技术在层流水柱中的能量分布仍以高斯分布为特征，导致在加工厚板材料时产生锥度效应，影响深加工能力。针对这些不足，本文提出了一种新型水刀激光场调节（WLR）方法。光学模拟和耦合实验证实，该方法能够将水射流内的能量调制成圆形分布，从而解决了水射流表面附近功率密度低的问题。基于 WLR 方法进行了水刀引导激光切割实验，与传统的 WGL 相比，锥度明显减小。在功率为 12 W 时，锥度从 5.85°减小到 2.28°，减小了 61%。就加工深度而言，WLR 方法在切割次数较少的情况下切割的沟槽深度略低，但随着切割次数的增加，沟槽深度稳步增加，并超过了传统的 WGL 方法。在激光功率为 20 W 的情况下，切割 500 次时，WLR 方法获得的沟槽深度比传统 WGL 方法增加了 115%。这项研究对利用水刀引导激光加工厚材料具有重要意义。

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引用次数: 0

Ultrasonic vibration-assisted tube extrusion shear expansion (UVaTESE): A novel process to manipulate the texture of AZ31 magnesium alloy 超声波振动辅助管挤压剪切膨胀（UVaTESE）：操纵 AZ31 镁合金质地的新工艺

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-12 DOI: 10.1016/j.jmatprotec.2024.118634

Jianxing Zhao , Chaowei Zeng , Ting Yuan , Wenyu Du , Yujiang Liu , Yan Wang , Hongjun Hu , Zhuoran Zeng

AZ31 magnesium (Mg) alloy prepared via the extrusion process forms an immensely strong {0001} basal texture, therefore there is a necessity to improve the existing extrusion process to achieve a weakening of the {0001} basal texture of the AZ31 Mg alloy. In this study, a novel process called UVaTESE is proposed. The Mg alloy texture and slip system activation at four ultrasonic vibration (UV) frequencies have been simulated via ABAQUS-VUMAT and VPSC, individually. The simulation results indicate that UV is capable of diffusing the {0001} basal texture of the Mg alloy along the extrusion direction (ED) and transverse direction (TD) and significantly improves the activation of pyramidal slip <c+a>. The simulations are verified experimentally, and the {0001} basal texture of AZ31 Mg alloy has the identical tendency to disperse along ED and TD. Prismatic slip <a> and pyramidal slip <c+a> jointly lead to diffusion of the grain basal texture along the TD, while grains with basal texture diffused along the ED are controlled by both basal slip <a> and pyramidal slip <c+a>. UV has a positive effect on the grain refinement as well as on the homogeneity of AZ31 Mg alloy. The proportion of dynamic recrystallization (DRX) of AZ31 Mg alloy is proportional to the frequency of UV, and it is noteworthy that the mechanism of DRX behavior is not affected by UV. This novel process provides a fundamentally innovative approach to the preparation of Mg alloys and magnesium-aluminum (Mg-Al) composite tubes via extrusion.

通过挤压工艺制备的 AZ31 镁（Mg）合金会形成非常坚固的 {0001} 基底纹理，因此有必要改进现有的挤压工艺，以减弱 AZ31 镁合金的 {0001} 基底纹理。本研究提出了一种名为 UVaTESE 的新工艺。通过 ABAQUS-VUMAT 和 VPSC 分别模拟了四种超声波振动（UV）频率下的镁合金纹理和滑移系统激活。模拟结果表明，超声波能够沿挤压方向（ED）和横向方向（TD）扩散镁合金的{0001}基底纹理，并显著改善金字塔滑移的激活<c+a>。实验验证了模拟结果，AZ31 镁合金的{0001}基底纹理沿 ED 和 TD 方向具有相同的分散趋势。棱柱滑移<a>和金字塔滑移<c+a>共同导致晶粒基底纹理沿 TD 扩散，而基底纹理沿 ED 扩散的晶粒则同时受基底滑移<a>和金字塔滑移<c+a>的控制。紫外线对 AZ31 镁合金的晶粒细化和均匀性有积极影响。AZ31 Mg 合金的动态再结晶（DRX）比例与紫外线频率成正比，值得注意的是，DRX 行为的机理不受紫外线的影响。这种新型工艺为通过挤压法制备镁合金和镁铝（Mg-Al）复合管提供了一种根本性的创新方法。

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引用次数: 0

Low-damage optical manufacturing via plasma finishing and figuring 通过等离子精加工和琢磨实现低损伤光学制造

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-11 DOI: 10.1016/j.jmatprotec.2024.118633

Zejin Zhan , Zhixian Chen , Junqi Zhang , Yi Zhang , Xingzhan Li , Qian Wang , Hui Deng

Precision optical components have stringent requirements on surface roughness, form error, and subsurface damage for superior performance. However, conventional grinding, lapping, and polishing processes of fused silica inevitably introduce subsurface damage (SSD) due to the use of abrasives. Thus, this paper proposes an abrasive-free, low-damage manufacturing process for fused silica optical components, which combines inductively coupled plasma (ICP) for SSD recovery and capacitively coupled plasma (CCP) for form error correction. This paper mainly aims to reveal the advantages and challenges of the combined plasma process. The SSD recovery capability of ICP finishing was first verified. The comparison of surface morphology after buffered oxide etch (BOE) etching and CCP etching revealed that extensive surface roughening is caused by plasma etching rather than SSD. Experimental studies on the combination of ICP and CCP demonstrated that ICP finishing can not only recover SSD but also inhibit the surface roughening by plasma etching. The investigation of form error after ICP finishing revealed that the induced form error consists of workpiece distortion and localized deformation with a crater-like structure, affecting the precision and duration of CCP figuring. The combined plasma process was conducted and a low-damage surface with roughness less than Sa 0.3 nm and form error less than RMS 20 nm was achieved.

精密光学元件对表面粗糙度、形状误差和次表面损伤有着严格的要求，以获得卓越的性能。然而，由于使用了磨料，熔融石英的传统研磨、研磨和抛光工艺不可避免地会产生表面下损伤（SSD）。因此，本文提出了一种无磨料、低损伤的熔融石英光学元件制造工艺，该工艺结合了电感耦合等离子体 (ICP) 的固态表面损伤恢复和电容耦合等离子体 (CCP) 的形状误差校正。本文主要旨在揭示组合等离子工艺的优势和挑战。首先验证了 ICP 精加工的 SSD 恢复能力。通过对比缓冲氧化物蚀刻（BOE）和电容式等离子体蚀刻后的表面形貌，发现大面积的表面粗糙是由等离子体蚀刻而非 SSD 引起的。对 ICP 和 CCP 组合的实验研究表明，ICP 光饰不仅能恢复 SSD，还能抑制等离子蚀刻造成的表面粗糙。对 ICP 精加工后形状误差的研究表明，诱发的形状误差包括工件变形和具有凹坑状结构的局部变形，影响了 CCP 图解的精度和持续时间。通过联合等离子工艺，获得了粗糙度小于 Sa 0.3 nm、形状误差小于 RMS 20 nm 的低损伤表面。

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引用次数: 0

Laser powder bed fusion of SiC particle-reinforced pre-alloyed TiB2/AlSi10Mg composite with high-strength and high-stiffness 具有高强度和高刚度的碳化硅颗粒增强预合金化 TiB2/AlSi10Mg 复合材料的激光粉末床熔融技术

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-11 DOI: 10.1016/j.jmatprotec.2024.118635

Long Geng , Fan Wu , Mingji Dang , Zhe Feng , Yijie Peng , Chennuo Kang , Wei Fan , Yongxia Wang , Hua Tan , Fengying Zhang , Xin Lin

Recently, laser powder bed fusion (LPBF) of particle-reinforced aluminum matrix composites (PAMCs) with high-strength and high-stiffness have attracted extensive attention in aviation and aerospace. However, performance improvement of single or dual PAMCs using traditional mechanical mixing method is still limited. Therefore, this study innovatively employed pre-alloyed ∼6.5 wt% TiB₂/AlSi10Mg composite as the matrix and mechanically mixed SiC particles with different contents (5 vol% and 10 vol%) to fabricate dual PAMCs with high particles content through LPBF. The results indicated that the 5 vol% SiC+TiB₂/AlSi10Mg composite revealed relatively weak agglomeration effect of SiC particle and highest relative density (∼99.1 %), thus exhibiting optimal processability. Using this composition material as the research object, it was found that the microstructure maintains the basic features of pre-alloyed TiB₂/AlSi10Mg composite except for the slight grain coarsening. However, SiC particles react with α-Al matrix and Al₃Ti. Then Al₄C₃ and TiC enhancement phase were formed, and micron-sized Si particles precipitated within the Al cells surrounded by the eutectic Al-Si. More importantly, due to novel preparation method of dual PAMCs powder, simultaneous enhancement in ultimate tensile strength (∼554.0 MPa), yield strength (∼376.0 MPa), and elastic modulus (∼97.4 GPa) was achieved. Total particle content (∼14.0 wt%) and tensile property were higher than those of reported other PAMCs processed by LPBF. Finally, expect for the fracture characteristics inherent to the pre-alloyed TiB₂/AlSi10Mg composite, new fracture mechanism for the tearing of SiC particles was exhibited. This work provides new insights into the preparation of high-strength and high-stiffness PAMCs processed by LPBF.

近年来，具有高强度和高刚度的激光粉末床熔融（LPBF）颗粒增强铝基复合材料（PAMC）在航空航天领域引起了广泛关注。然而，使用传统机械混合方法提高单层或双层 PAMC 的性能仍然有限。因此，本研究创新性地采用预合金化∼6.5 wt% TiB2/AlSi10Mg 复合材料作为基体，通过 LPBF 机械混合不同含量（5 vol% 和 10 vol%）的 SiC 颗粒，制备出高颗粒含量的双 PAMC。结果表明，5vol% SiC+TiB2/AlSi10Mg 复合材料的 SiC 颗粒团聚效应相对较弱，相对密度最高（∼99.1 %），因此具有最佳的加工性能。以这种成分的材料为研究对象，发现其微观结构保持了预合金化 TiB2/AlSi10Mg 复合材料的基本特征，只是有轻微的晶粒粗化。然而，SiC 颗粒会与α-Al 基体和 Al3Ti 发生反应。然后形成了 Al4C3 和 TiC 增强相，微米大小的 Si 颗粒析出在被共晶 Al-Si 包围的 Al 单元内。更重要的是，由于采用了新颖的双 PAMCs 粉末制备方法，极限拉伸强度（∼554.0 MPa）、屈服强度（∼376.0 MPa）和弹性模量（∼97.4 GPa）得到了同步提高。总颗粒含量（∼14.0 wt%）和拉伸性能均高于 LPBF 加工的其他 PAMC。最后，除了预合金化 TiB2/AlSi10Mg 复合材料固有的断裂特性外，SiC 颗粒的撕裂还表现出了新的断裂机制。这项研究为利用 LPBF 制备高强度和高刚度 PAMC 提供了新的思路。

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引用次数: 0

Achieving metallurgical bonding in steel faceplate/aluminum foam sandwich via hot pressing and foaming processes: interfacial microstructure evolution and tensile behavior 通过热压和发泡工艺实现钢面板/铝泡沫夹层的冶金结合：界面微结构演变和拉伸行为

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2024-10-11 DOI: 10.1016/j.jmatprotec.2024.118636

Li Wang , Hongjie Luo , Shijie Yang , Shibo Cui , Linli Wu

This study introduces an innovative approach to fabricating aluminum foam sandwich with aluminized steel faceplates through metallurgical bonding. The process involves the use of foamable precursor, prepared via melt stirring, and subsequent hot pressing and foaming, offering a cost-effective and industrially feasible method for producing lightweight structural materials and connection of steel/aluminum dissimilar metals. This study focuses on exploring the changes in the microstructure of the bonding interface before and after foaming, and revealing the impact of these changes on the tensile results. Foaming experiment shows that foamable sandwiches have superior foaming ability, and the core layer density after foaming is between 0.283 and 0.591 g/cm ³. Microstructural characterization results demonstrate that, during the hot pressing process, fine equiaxed grains are observed on the iron side of the interface, indicating dynamic recrystallization occurred. The formation of a small amount of η-Al₅Fe₂ at the interface is a primary factor causing the deflection of the fracture path. Subsequently, during the foaming process, intermetallic compounds (IMCs) θ-Al₁₃Fe₄, τ5-Al₇Fe₂Si, and β-Al_4.5FeSi formed sequentially, mainly determined by the diffusion reaction of silicon elements. The formation of these IMCs led to an increase in microhardness at the interface and a decrease in shear strength. Digital image correlation was utilized to examine strain distribution under tensile loading. The result indicates that the damage accumulation is characterized by the formation and expansion of strain bands, with failure manifested as the interconnection of these strain bands.

本研究介绍了一种通过冶金粘合制造铝泡沫夹层和镀铝钢面板的创新方法。该工艺包括使用通过熔融搅拌制备的可发泡前驱体，以及随后的热压和发泡，为生产轻质结构材料和连接钢铝异种金属提供了一种具有成本效益和工业可行性的方法。本研究重点探讨了发泡前后粘接界面微观结构的变化，并揭示了这些变化对拉伸结果的影响。发泡实验表明，可发泡夹层具有优异的发泡能力，发泡后的芯层密度介于 0.283 和 0.591 g/cm ³ 之间。微结构表征结果表明，在热压过程中，界面铁侧观察到细小的等轴晶粒，表明发生了动态再结晶。界面上形成的少量 η-Al5Fe2 是导致断裂路径偏移的主要因素。随后，在发泡过程中，金属间化合物（IMC）θ-Al13Fe4、τ5-Al7Fe2Si 和 β-Al4.5FeSi 依次形成，这主要是由硅元素的扩散反应决定的。这些 IMC 的形成导致了界面微硬度的增加和剪切强度的降低。利用数字图像相关性研究了拉伸载荷下的应变分布。结果表明，损伤累积的特征是应变带的形成和扩展，破坏表现为这些应变带的相互连接。

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引用次数: 0