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

Revealing the three-dimensional morphology and evolution mechanism of porosity at the flow end in non-heat-treated high-pressure die-cast AlSi9MnVZr alloy 揭示了非热处理高压压铸AlSi9MnVZr合金流动端孔隙度的三维形态和演化机制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-08 DOI: 10.1016/j.jmatprotec.2026.119209

Zunian He , Yixian Liu , Aoxiang Wan , Pengzhan Wang , Zhengda Lu , Zhihong Jia , Shoumei Xiong

Under high-pressure die casting (HPDC) conditions, extensive porosity forms at the late stage of flow, which significantly deteriorates the mechanical properties of the casting. Due to experimental precision and complexity, observing the evolution of these pores through 3D reconstruction is challenging. In this work, a lamellar hole formation phenomenon at the end of the flow samples was found, accompanied by substantial microstructure changes of the AlSi9MnVZr alloy. Based on this, the length of the flow end is defined. The subsequent evolution of pores after lamellar hole formation was studied under different gate speeds. A Lattice Boltzmann Method (LBM) based simulation framework was employed to model the flow behavior in the flow end region of casting samples under different Reynolds numbers (Re) and effective flow cross sections, showing agreement with experimental observations. By introducing the concepts of critical gate speed and stoppage point, the changes in fluidity and mechanical properties at different gate speeds were discussed. The findings establish a mechanism for porosity evolution at the flow end and highlight the limited benefits of increasing gate speed beyond the critical value. The presented results demonstrate that maintaining the gate speed close to the critical gate speed enables both high fluidity and reduced porosity at the flow end.

在高压压铸条件下，铸件在流动后期会形成大量的孔隙，使铸件的力学性能显著恶化。由于实验精度和复杂性，通过三维重建来观察这些孔隙的演化是具有挑战性的。在本工作中，AlSi9MnVZr合金在流动试样的末端出现了片层状空穴形成现象，并伴有明显的显微组织变化。在此基础上定义流端长度。研究了不同浇口速度下层状孔洞形成后孔隙的演化过程。采用基于晶格玻尔兹曼方法（Lattice Boltzmann Method， LBM）的模拟框架，对不同雷诺数（Re）和有效流动截面下铸件流动端区流动行为进行了模拟，结果与实验结果吻合。通过引入临界浇口速度和停止点的概念，讨论了不同浇口速度下流体的流动性和力学性能的变化。研究结果建立了流动端孔隙演化的机制，并强调了超过临界值时增加浇口速度的有限效益。结果表明，保持浇口速度接近临界浇口速度可以在流动端获得高流动性和降低孔隙率。

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引用次数: 0

A theoretical model for predicting multi-cracking susceptibility in Ni-based superalloys fabricated by additive manufacturing 增材制造镍基高温合金多重裂纹敏感性预测的理论模型

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-12 DOI: 10.1016/j.jmatprotec.2026.119219

Mingjie Li, Fu Wang, Qiang Yang, Dichen Li

Aiming to predict the occurrence of cracks in additively manufactured (AM) Ni-based superalloys, this study proposed a novel integrated multi-cracking susceptibility model and index (CSI). The model comprehensively accounts for key thermophysical and microstructural factors, including the viscosity of the alloy melt, the presence of carbides and γ/γ΄ eutectic, as well as the influence of stacking fault energy and grain boundary (GB) energy on crack formation during rapid solidification of AM. To experimentally validate the susceptibility model, CM247LC superalloys with varied (Hf+C) contents were fabricated via laser-based powder bed fusion (LB-PBF), with their cracking behavior systematically quantified. Predictions revealed that crack susceptibility initially decreased and then increased with rising (Hf+C) content, fully corroborated by experimental results. Notably, the addition of 1 wt% (Hf+C) resulted in a significant reduction in cracks, yielding minimum crack length and area densities of 0.004 mm/mm² and 0.017 %, respectively. The healing effect on cracks is attributed to two synergistic mechanisms: the backfilling effect of the Hf-rich eutectics into cracks and the dispersion-strengthening effect of more fine carbides along the GBs. The predictive capability and generalizability of the proposed CSIs were validated via literature-derived machine learning, demonstrating that CSI_SC achieves 20 % higher accuracy than Kou’s classical criterion. The developed model shows significant potential for capturing the complex cracking behavior and guiding the design of crack-free AM superalloys.

为了预测增材制造镍基高温合金裂纹的发生，提出了一种新的综合多裂纹敏感性模型和指数（CSI）。该模型综合考虑了合金熔体粘度、碳化物和γ/γ΄共晶的存在以及层错能和晶界能对AM快速凝固过程中裂纹形成的影响等关键热物理和显微组织因素。为了实验验证磁化率模型，采用激光粉末床熔合法制备了不同（Hf+C）含量的CM247LC高温合金，并对其开裂行为进行了系统量化。预测结果表明，随着（Hf+C）含量的增加，裂纹敏感性先降低后增加，实验结果与预测结果完全一致。值得注意的是，添加1 wt% （Hf+C）可以显著减少裂纹，最小裂纹长度和面积密度分别为0.004 mm/mm2和0.017 %。对裂纹的修复作用可归因于两种协同机制：富hf共晶对裂纹的回填作用和更细碳化物沿GBs的弥散强化作用。通过文献衍生的机器学习验证了所提出的CSIs的预测能力和通用性，表明cssc比Kou的经典准则的准确率高出20% %。所建立的模型对于捕获复杂的裂纹行为和指导无裂纹AM高温合金的设计具有重要的潜力。

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引用次数: 0

Model-driven multi-step hot metal gas forming of irregular tubular aluminum components: Physically based simulation and experimental validation 不规则管状铝件模型驱动的多步热金属气成形：基于物理的仿真与实验验证

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-09 DOI: 10.1016/j.jmatprotec.2026.119213

Zhihan Wang , Pengxiao Yang , Xinyuan Gao , Zhennan Bao , Zhubin He , Kailun Zheng , Jiaxin Lv

Hot metal gas forming (HMGF) is a cutting-edge technology to integrally form hollow complex tubular parts. However, components with spatially curved centerlines and variable cross-sections are difficult to form directly from straight tubular work pieces without fracture. Therefore, a multi-step hot metal gas forming (HMGF) method, which includes CNC bending, pre-forming and hot metal gas forming is proposed and validated in this study, together with a newly developed physically based constitutive model implemented within a finite element framework to capture microstructural and mechanical inheritance across steps. First, representative segments were formed and simulated using a four-step hot metal gas forming (HMGF) route across forming temperatures, internal pressures and pressurization rates. The results indicate that the forming parameters have coupled effects on corner filling and thickness uniformity, revealing inherent trade-offs among temperature, pressure, and pressurization rate. An optimal combination of process parameters was identified, enabling accurate forming of the full-scale component without macroscopic defects at initial diameter of 142 mm. Full-scale trials at initial diameters of 140 mm and 145 mm likewise confirmed accurate prediction of defects and grain-size evolution, demonstrating robust and geometry-independent predictability of both forming defects and microstructural evolution. This study advances a general methodology for parameter optimization and defect suppression in industrial production of complex tubular components.

热金属气体成形（HMGF）是一种整体成形中空复杂管状零件的前沿技术。然而，具有空间弯曲中心线和可变截面的部件很难由直管工件直接成形而不断裂。因此，本研究提出并验证了一种多步骤金属热成形（HMGF）方法，该方法包括CNC弯曲，预成形和金属热成形，以及在有限元框架内实现的新开发的基于物理的本构模型，以捕获各步骤的微观结构和力学继承。首先，采用四步热金属气体成形（HMGF）路线，在不同的成形温度、内部压力和加压速率下，对具有代表性的管段进行了成形和模拟。结果表明，成形参数对边角填充和厚度均匀性有耦合影响，揭示了温度、压力和加压速率之间的内在权衡。确定了最优的工艺参数组合，能够在初始直径为142 mm的情况下精确成形无宏观缺陷的全尺寸部件。初始直径为140 mm和145 mm的全尺寸试验同样证实了对缺陷和晶粒尺寸演变的准确预测，证明了对形成缺陷和微观结构演变的稳健和几何无关的可预测性。本研究提出了复杂管状件工业生产中参数优化和缺陷抑制的一般方法。

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引用次数: 0

Ultra-smooth surface of RB-SiC generated by a piezo-Fenton chemical mechanical polishing with high material removal rate 采用压电- fenton化学机械抛光制备的RB-SiC超光滑表面，材料去除率高

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119235

Haoran Liu , Yikai Zang , Zhi Wang , Xiaoyang Jiang , Jianning Chu , Jianguo Zhang , Jianfeng Xu , Junfeng Xiao

Due to significant differences in properties of two-phase material, it is very difficult to obtain high-quality surface of RB-SiC. Reducing the hardness difference of two-phase materials and suppressing the formation of phase boundary steps are the keys to achieve a low-damage and super-smooth surface of RB-SiC. In the study, piezo-Fenton oxidation was introduced to develop a novel chemical mechanical polishing (CMP). Driven by compressive stress and friction between the polishing pad and workpiece, the surface polarization of bismuth ferrite nanoparticles (BiFeO₃) in the slurry induced a persistently stable Fenton-like reaction. The optimal slurry consisted of diamond micropowder, hydrogen peroxide, bismuth ferrite, silica sol, citric acid and deionized water achieved the ultra-smooth surface of RB-SiC. Surface roughness (Sa) was 0.887 nm over an area of

437 \times 437 {μm}^{2}

. The Sa value of 0.158 nm was obtained in SiC phases (40 × 40 μm²), while the thickness of the damage layer was 2.993 nm. The material removal rate reached a high of 5.001 μm/h. The CMP mechanism was elucidated by X-ray photoelectron, Raman and infrared spectroscopy, which shows that strong oxidizing ability of hydroxyl radicals generated relatively soft oxides on the surfaces of SiC and Si phase, with reduced the hardness difference between the two-phase materials. At the same time, diamond abrasive directly removed the oxide layer covering the material surface without damaging the matrix material. The novel CMP on RB-SiC provided new insights to gain ultra-smooth with high material removal rate for multiphase materials with soft matrix and hard particles.

由于两相材料的性能差异很大，很难获得高质量的RB-SiC表面。减小两相材料的硬度差和抑制相边界台阶的形成是实现RB-SiC低损伤超光滑表面的关键。本研究将压电芬顿氧化技术引入到化学机械抛光（CMP）的研究中。在抛光垫与工件之间的压应力和摩擦的驱动下，铋铁氧体纳米颗粒（BiFeO3）在料浆中的表面极化诱导了持续稳定的类芬顿反应。由金刚石微粉、双氧水、铁酸铋、硅溶胶、柠檬酸和去离子水组成的最佳浆料实现了RB-SiC的超光滑表面。表面粗糙度（Sa）为0.887 nm，面积为437×437μm2。SiC相（40 × 40 μm2）的Sa值为0.158 nm，损伤层厚度为2.993 nm。材料去除率高达5.001 μm/h。通过x射线光电子、拉曼和红外光谱对CMP机理进行了分析，结果表明羟基自由基具有较强的氧化能力，在SiC和Si相表面生成了较软的氧化物，减小了两相材料之间的硬度差。同时，金刚石磨料直接去除覆盖在材料表面的氧化层，而不损伤基体材料。基于RB-SiC的新型CMP为获得具有软基体和硬颗粒的多相材料的超光滑和高材料去除率提供了新的见解。

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引用次数: 0

Beyond imaging: Optical emission spectroscopy for mechanistic diagnosis of plasma plume and spatter dynamics in laser DED 超越成像：激光DED中等离子体羽流和飞溅动力学机制诊断的光学发射光谱

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-05 DOI: 10.1016/j.jmatprotec.2026.119199

Mohit Singh , Misba Amin , Arun Kumar R , S.L. Anoop , Ravi K R

Laser-directed energy deposition (DED) is governed by complex interactions between the laser beam, powder stream, and melt pool, where plasma plume fluctuations and spatter ejection dictate process stability. High-speed imaging has provided valuable qualitative insights into these dynamics, but its limited temporal resolution, large data volume, and reliance on thresholding restrict its use for continuous monitoring. This work establishes optical emission spectroscopy (OES) as a quantitative, imaging-independent diagnostic by identifying the Fe I 520.79 nm line as a high-fidelity spectral proxy for plasma plume activity in SS316L DED. Single-layer clads were deposited across a broad range of volumetric energy densities, during which time-resolved OES (∼1 ms sampling) captured plume oscillations and their direct correlation with clad morphology and regime transitions. These transitions spanned from lack of fusion through conduction and transition to keyhole mode, as identified through depth-aspect-ratio analysis. High-speed imaging was used only for qualitative cross-validation of spatter birth and trajectory. A threshold-dependent shift in spatter formation was identified, where lower plasma-plume intensities corresponded to Kelvin–Helmholtz-driven droplet ejection, while higher intensities triggered Plateau–Rayleigh instability and high-velocity jet spatters. An exponential correlation (R² ≈ 0.98) between Fe I 520.79 nm intensity and spatter number enables compact, imaging-free quantification of instability events with millisecond precision. These results establish OES as a generalizable, physics-driven “smart-sensor” capable of resolving melt-pool instability regimes and spatter mechanisms in real time, providing a scalable foundation for closed-loop process control in industrial DED.

激光定向能量沉积（DED）是由激光束、粉末流和熔池之间复杂的相互作用控制的，其中等离子体羽流波动和飞溅喷射决定了过程的稳定性。高速成像为这些动态提供了有价值的定性见解，但其有限的时间分辨率、大数据量以及对阈值的依赖限制了其在连续监测中的应用。这项工作建立了光学发射光谱（OES）作为定量的，独立于成像的诊断，通过确定Fe I 520.79 nm线作为SS316L DED等离子体羽流活动的高保真光谱代理。单层包层沉积在很宽的体积能量密度范围内，在此期间，时间分辨OES （~ 1 ms采样）捕获了羽流振荡及其与包层形态和状态转变的直接关系。这些转变包括从缺乏融合到传导和过渡到锁孔模式，这是通过深宽比分析确定的。高速成像仅用于对飞溅产生和轨迹的定性交叉验证。在飞溅形成过程中发现了阈值相关的偏移，其中较低的等离子体羽流强度对应于开尔文-亥姆霍兹驱动的液滴喷射，而较高的强度则触发高原-瑞利不稳定性和高速射流飞溅。fei 520.79 nm强度和溅射数之间的指数相关性（R²≈0.98）使不稳定事件的量化变得紧凑，无需成像，精度达到毫秒级。这些结果表明OES是一种可推广的、物理驱动的“智能传感器”，能够实时解决熔池不稳定状态和飞溅机制，为工业DED的闭环过程控制提供了可扩展的基础。

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引用次数: 0

Morphology evolution and passivation behavior of nickel-based single crystal superalloys in laser and electrochemical hybrid machining 镍基单晶高温合金激光与电化学复合加工的形貌演变及钝化行为

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-21 DOI: 10.1016/j.jmatprotec.2026.119227

Xue Yang , Yao Yao , Hao Tong , Chengjuan Yang , Yong Li , Zhen Yang , Dawei Zhang

Nickel based single crystal superalloys (NBSCs) are widely used in advanced aero-engines owing to their outstanding high-temperature strength, thermal stability, and corrosion resistance. Laser-electrochemical hybrid machining (LECM) is an emerging technique capable of achieving efficient, damage-free machining of difficult-to-machine materials. However, during LECM of NBSCs, the γ/γ′ two-phase structure exhibits phase-selective electrochemical dissolution and non-uniform passivation, leading to position-dependent material removal behavior that compromises the machining accuracy and surface integrity. The LECM based on an optical fiber inserted tubular electrode (LECM-OFTE) is employed to achieve stable coupling of laser and electrolytic energy fields, attaining higher laser transmission efficiency and realizing higher machining efficiency. In this study, the laser-induced passivation mechanisms of NBSC DD6 superalloy are systematically investigated under the LECM-OFTE process. Morphological and compositional analyses reveal the evolution of passive films and their influence on phase-selective dissolution under different laser intensities. Electrochemical measurements further elucidate the growth, breakdown, and recovery behavior of passive layers under hybrid interactions. Based on the experimental and mechanistic analysis, component-scale LECM of DD6 is further demonstrated using a miniaturized coaxial tubular electrode. Under 12.5 wt% NaNO₃ electrolyte and 5 W laser power, 5-mm-deep holes with an aspect ratio of 7 are machined with markedly reduced stray corrosion and tight dimensional repeatability (entrance: 719 ± 50 μm, exit: 773 ± 38 μm at 50 μm/s feed rate), corroborating the critical role of laser-enhanced passivation in enabling high-precision machining.

镍基单晶高温合金以其优异的高温强度、热稳定性和耐腐蚀性被广泛应用于先进的航空发动机中。激光-电化学混合加工（LECM）是一种新兴技术，能够实现对难加工材料的高效、无损伤加工。然而，在NBSCs的LECM过程中，γ/γ '两相结构表现出相选择性电化学溶解和不均匀钝化，导致与位置相关的材料去除行为，从而影响加工精度和表面完整性。采用基于光纤插管电极（LECM- ofte）的LECM实现了激光与电解能量场的稳定耦合，提高了激光传输效率，实现了更高的加工效率。在LECM-OFTE工艺下，系统地研究了NBSC DD6高温合金的激光诱导钝化机理。形貌和成分分析揭示了不同激光强度下钝化膜的演变及其对相选择性溶解的影响。电化学测量进一步阐明了被动层在杂化相互作用下的生长、击穿和恢复行为。在实验和机理分析的基础上，利用小型化的同轴管状电极进一步验证了DD6的组件级LECM。在12.5 wt%的纳米₃电解液和5 W的激光功率下，加工出宽高比为7的5mm深孔，显著降低了杂散腐蚀，尺寸重复性好（在50 μm/s的进给速率下，入口：719 ± 50 μm，出口：773 ± 38 μm），证实了激光增强钝化在实现高精度加工中的关键作用。

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引用次数: 0

High-energy metal ion-peening of brazed diamond tools and assessing its scope to enhance grinding performance 钎焊金刚石工具的高能金属离子强化及其对磨削性能的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-28 DOI: 10.1016/j.jmatprotec.2026.119239

Prakashraj E., Amitava Ghosh

In the present study, a novel ion-peening technique has been attempted to alleviate brazing process-induced tensile residual stress developed within the diamond-filler bonding region of brazed diamond tools. High brazing temperature and significant mismatch in the thermo-mechanical properties of the diamond, filler alloy, and steel substrate are the factors causing such stresses, which get pronounced during the cooling cycle, often deleteriously leading to microcrack formation in the diamond-filler interfacial region. Such a crack even propagates into the diamond grit, leading to premature grit failure during grinding. To overcome this challenge, a typical “etching” cycle of high-power impulse magnetron sputtering (HiPIMS) process was improvised to “ion-peening” in the present work under high substrate bias and applied to brazed diamond tools. During peening, the cloud of ions in the plasma was predominantly populated by metal ions (Cr-ion), preferring to mere inert gas ions, so that enhanced momentum transfer is realised. Micro-sized diamonds were brazed with C45 steels by Ni-Cr based filler alloy to produce single-grit specimens and miniature diamond tools, and subsequently subjected them to ion-peening. X-ray diffraction (XRD) and Raman spectroscopic analyses suggest a significant reduction in the brazing-induced residual stress within the carbide interlayer (+2022 MPa to +1023.5 MPa) due to ion peening. Within the diamond near bonding level, this reduction was from + 45.48 MPa to −292.21 Pa. Single-grit studies reveal an approximate increase of 85 % joint strength in ion-peened specimens. On the other hand, a maximum reduction of 35–40 % in the number of grit failures is recorded on peened diamond wheels during grinding. Significant reduction in tensile residual stress and partial healing of micro-cracks are identified to be the underlying mechanisms of such enhanced joint strength. The findings suggest that metal ion-peening could be a potential post-treatment process to produce brazed diamond tools with enhanced tool life and overall performance during grinding.

在本研究中，一种新的离子喷丸技术已经被尝试用来减轻钎焊过程中产生的残余拉伸应力，这些应力产生在钎焊金刚石工具的金刚石-填料结合区域。高钎焊温度和金刚石、钎料合金和钢基体的热-机械性能的显著不匹配是产生这种应力的因素，这种应力在冷却循环中变得明显，往往导致金刚石-钎料界面区域形成有害的微裂纹。这种裂纹甚至扩展到金刚石砂粒中，导致磨削过程中砂粒过早失效。为了克服这一挑战，本研究将大功率脉冲磁控溅射（HiPIMS）工艺的典型“蚀刻”周期改进为高衬底偏压下的“离子喷炼”，并应用于钎焊金刚石工具。在喷射过程中，等离子体中的离子云主要由金属离子（Cr-ion）填充，而不是惰性气体离子，因此实现了增强的动量传递。采用Ni-Cr基填充合金钎焊C45钢制备微粒度金刚石试样和微型金刚石工具，并对其进行离子强化处理。x射线衍射（XRD）和拉曼光谱分析表明，由于离子强化，钎焊诱导的碳化物夹层内残余应力（+2022 MPa至+1023.5 MPa）显著降低。在金刚石接近键合的水平，这一降低从+ 45.48 MPa到−292.21 Pa。单粒研究表明，离子喷丸试样的节理强度约增加85 %。另一方面，在磨砂过程中，经喷砂处理的金刚石砂轮的砂粒失效次数最大减少了35-40 %。拉伸残余应力的显著降低和微裂纹的部分愈合被认为是这种增强接头强度的潜在机制。研究结果表明，金属离子喷丸可能是一种潜在的后处理工艺，可以提高钎焊金刚石工具的使用寿命和磨削过程中的整体性能。

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引用次数: 0

A novel polyvinyl alcohol/guar gum hydrogel-based fluid abrasive for abrasive flow machining with enhanced processing performance 一种新型聚乙烯醇/瓜尔胶水凝胶液体磨料，用于磨料流加工，提高了加工性能

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-28 DOI: 10.1016/j.jmatprotec.2026.119238

Jingyi Liu , Xiaoyun Bai , Wenhui Li , Xiuhong Li , Xiaoming Yin , Shengqiang Yang , Kun Li

Selective laser melting (SLM)-fabricated components often exhibit high surface roughness and inherent surface defects, necessitating efficient post-processing. Hydrogel-based fluid abrasives are environmentally friendly alternatives for abrasive flow machining (AFM). However, traditional hydrogel matrices are generally based on polysaccharide polymers and suffer from limited mechanical strength and poor thermal stability, leading to water loss during processing, which restricts their practical application. To overcome these limitations, this study develops a novel polyvinyl alcohol-guar gum (PVA-GG) hydrogel-based fluid abrasive for the AFM of SLM-fabricated surfaces. In this system, the PVA provides mechanical load-bearing capacity, while the GG enhances viscoelasticity, jointly forming a tightly entangled network structure. The fluid abrasive was systematically characterized in terms of viscoelasticity, self-healing properties, thermal stability, and degradability, and its process performance was evaluated during the finishing of SLM-fabricated GH4169 alloy flow channels. The PVA-GG fluid abrasive shows significantly higher viscosity and modulus, with a weight loss of only 9.09 % below 100 °C. It also demonstrates remarkable self-healing properties and degradability. After AFM processing, the surface roughness (Ra) of the workpiece can be reduced by 90 %, and the material removal rate (MRR) reaches 0.43 mm³ /min, outperforming conventional fluid abrasives. Material removal in PVA-GG fluid abrasive is achieved through the combined actions of sliding, plowing, and micro-cutting. This study provides an efficient, sustainable, and mechanism-based approach for the precision surface finishing of SLM-fabricated components.

选择性激光熔化（SLM）制造的部件通常具有高表面粗糙度和固有的表面缺陷，需要有效的后处理。水凝胶基流体磨料是磨料流加工（AFM）的环保替代品。然而，传统的水凝胶基质一般以多糖聚合物为基础，机械强度有限，热稳定性差，导致加工过程中水分流失，制约了其实际应用。为了克服这些限制，本研究开发了一种新型的聚乙烯醇-瓜尔胶（PVA-GG）水凝胶基流体磨料，用于slm制造表面的AFM。在该体系中，PVA提供机械承载能力，而GG增强粘弹性，共同形成紧密纠缠的网络结构。从粘弹性、自愈性、热稳定性和可降解性等方面对该流体磨料进行了系统表征，并在slm制备的GH4169合金流道的精加工过程中对其工艺性能进行了评价。PVA-GG流体磨料的黏度和模量显著提高，在100℃下的失重率仅为9.09 %。它还具有显著的自愈性和可降解性。AFM加工后，工件表面粗糙度（Ra）可降低90 %，材料去除率（MRR）达到0.43 mm³ /min，优于传统的流体磨料。PVA-GG流体磨料的材料去除是通过滑动、犁耕和微切削的共同作用来实现的。本研究提供了一种高效、可持续和基于机制的方法，用于slm制造部件的精密表面加工。

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引用次数: 0

Reducing stripping force in ultrasonic-assisted exfoliation of laser-modified 4H-SiC wafers 激光修饰4H-SiC晶圆超声辅助剥离过程中剥离力的减小

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-20 DOI: 10.1016/j.jmatprotec.2026.119226

Hongmei Li , Hongwei Wang , Yuxin Li , Wenyang Cen , Liqun Wang , Lin Li , Yinzhou Yan , Kewen Pan , Wei Guo

High-efficiency, low-damage exfoliation of 4H-SiC wafers is critical for their application in the power electronics sector and for reducing manufacturing costs. However, the high exfoliation force required after conventional laser modification is a core challenge for this technology. This study systematically reveals two primary physical causes for the high exfoliation force. First, the laser induces a complex modified layer, comprising an amorphous phase and 3C-SiC, resulting in strong interfacial bonding with the 4H-SiC substrate. Second, the crystal’s inherent ∼4° off-axis growth mode results in a stepped and staggered crack distribution during propagation, which prevents the cracks from becoming fully interconnected. To address these issues, an innovative hybrid exfoliation technique is proposed and validated. The proposed technique combines ultrasonic cavitation with selective chemical etching using a KOH solution. Ultrasonic vibration and cavitation physically drive microcrack propagation, while selective chemical etching weakens the interfacial bonding strength of the modified layer. This synergistic method reduces the exfoliation force to 26.85 N (representing a reduction of 66.01 %). Building on this, we further optimize the laser modification process by designing a dual-modification strategy that introduces interconnection points to proactively control the crack path and ensure complete crack-network connectivity. Ultimately, this fully optimized strategy reduces the exfoliation force to 19.85 N and achieves efficient exfoliation of a complete 6-inch 4H-SiC wafer in approximately 3 min. This study elucidates the specific origins of the high exfoliation force through microstructural and elemental analysis of the modified layer and provides a new feasible and scalable solution for low-damage wafer exfoliation.

高效、低损伤的4H-SiC晶圆剥离对于其在电力电子领域的应用和降低制造成本至关重要。然而，常规激光修饰后所需的高剥离力是该技术的核心挑战。本研究系统地揭示了高剥离力的两个主要物理原因。首先，激光诱导出由非晶相和3C-SiC组成的复杂修饰层，从而与4H-SiC衬底形成强界面键合。其次，晶体固有的~ 4°离轴生长模式导致裂纹在扩展过程中呈阶梯状和交错分布，这阻止了裂纹完全互连。为了解决这些问题，提出并验证了一种创新的混合去角质技术。提出的技术结合超声空化和选择性化学蚀刻使用KOH溶液。超声振动和空化物理驱动微裂纹扩展，而选择性化学腐蚀削弱了改性层的界面结合强度。这种协同方法将剥离力降低到26.85 N（降低66.01 %）。在此基础上，我们进一步优化了激光修饰工艺，设计了引入互连点的双修饰策略，主动控制裂纹路径，确保裂纹网络完全连通性。最终，这种完全优化的策略将剥离力降低到19.85 N，并在大约3 min内实现完整的6英寸4H-SiC晶圆的有效剥离。本研究通过对改性层的微观结构和元素分析，阐明了高剥离力的具体来源，为低损伤硅片剥离提供了一种新的可行的、可扩展的解决方案。

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引用次数: 0

The regulation mechanism of processing parameters on the microstructural evolution and mechanical properties of 7A52 aluminum alloy fabricated by additive friction stir deposition 研究了工艺参数对添加剂搅拌摩擦沉积制备7A52铝合金组织演变及力学性能的调控机理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-13 DOI: 10.1016/j.jmatprotec.2026.119220

Huan Liu , Huanyong Cui , Zongqing Ma , Chengcheng Shi , Wenhao Shang , Hongjia Zhang , Guannan Chu , Xiangxue Li , Guofeng Han

Additive friction stir deposition (AFSD) represents a novel additive manufacturing (AM) technique with significant potential for producing Al-Zn-Mg-Cu alloys, which helps overcome common issues such as thermal cracking and porosity associated with traditional AM. This study systematically investigates the relationships between heat input, process parameters, microstructure, and mechanical properties. Research indicates that heat input determines the microstructural characteristics of AFSD deposition layers by regulating the relative dominance of dynamic recrystallisation and dynamic recovery. Due to the intense thermo-mechanical coupling during AFSD, the grains within the deposited layer are significantly refined, with an average grain size reaching 2.68 μm under the optimized parameters. Meanwhile, under high temperature and plastic deformation, a part of the coarse Al₂FeSi phase in the feedstock fractures, while a part of it transforms into the α-Al₁₂(Fe, Mn)₃Si phase with the involvement of Mn elements. The ultrafine grains, high-density dislocations, and fragmented second-phase particles generated during the AFSD, significantly enhance the diffusion rate of solute atoms. Meanwhile, the high-temperature environment induced by the deposition process induce partial dissolution of precipitates, allowing AFSD-fabricated 7A52 alloy to achieve complete solution treatment within an extremely short timeframe. The deposits subjected to a short-duration solution treatment followed by aging exhibited a yield strength of 488.36 MPa, an ultimate tensile strength of 535.27 MPa, and an elongation of 12.83 %. This work systematically investigates the optimization of the AFSD process, providing a solid theoretical foundation and practical guidance for fabricating high-strength aluminum alloys using AFSD.

添加剂搅拌摩擦沉积（AFSD）是一种新型的增材制造（AM）技术，具有生产Al-Zn-Mg-Cu合金的巨大潜力，有助于克服传统增材制造相关的常见问题，如热裂和气孔。本研究系统地探讨了热输入、工艺参数、微观结构和力学性能之间的关系。研究表明，热输入通过调节动态再结晶和动态恢复的相对优势决定了AFSD沉积层的微观组织特征。由于AFSD过程中强烈的热-力耦合作用，沉积层内晶粒明显细化，在优化参数下，平均晶粒尺寸达到2.68 μm。同时，在高温和塑性变形作用下，原料中的一部分粗Al2FeSi相断裂，一部分在Mn元素的参与下转变为α-Al12(Fe, Mn)3Si相。AFSD过程中产生的超细晶粒、高密度位错和破碎的第二相颗粒显著提高了溶质原子的扩散速率。同时，沉积过程产生的高温环境诱导析出相部分溶解，使afsd制备的7A52合金在极短的时间内实现完全固溶处理。经短时间固溶后时效处理的镀层屈服强度为488.36 MPa，极限抗拉强度为535.27 MPa，伸长率为12.83 %。本工作系统地研究了AFSD工艺的优化，为利用AFSD制备高强度铝合金提供了坚实的理论基础和实践指导。

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引用次数: 0