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

Electromagnetic shielding forming: A facile approach for Lorentz force regulation and its application in tube forming

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-08 DOI: 10.1016/j.jmatprotec.2025.118795

Xinhui Zhu , Xiaofei Xu , Wang Zhang , Limeng Du , Zihao Shao , Zhipeng Lai , Xiaotao Han , Liang Li , Quanliang Cao , Shaowei Ouyang

The Lorentz force distribution is crucial in determining the deformation of workpieces in electromagnetic forming, with its spatial distribution directly influencing the resulting shape. However, achieving flexible control over this force to accommodate diverse forming requirements poses a significant challenge. To address this, an innovative electromagnetic shielding forming (EMSF) technique is proposed, which introduces a conductive metal ring positioned around the coil-tube assembly to modulate the Lorentz force distribution through its eddy current shielding effect during pulsed discharge. On this basis, we systematically explore how variations in the ring’s thickness, length, electrical conductivity, and positioning affect the shielding performance. Applying this forming method to long tubes, short tubes, and variable-diameter tubes, it is demonstrated that conventional EMF processes typically result in long tubes deforming into convex shapes and short tubes into concave shapes. In contrast, the method improves the uniformity of long-tube forming and offers the flexibility to shape short tubes into concave, flat, or convex profiles. Additionally, the method enhances the precision of variable-diameter tube forming by optimizing ring placement, enabling the production of high-accuracy tubes of various sizes. This advancement introduces a versatile and effective strategy for managing the Lorentz force via electromagnetic shielding effect, which enables more precise and flexible control over the deformation of workpieces during the electromagnetic forming process.

{"title":"Electromagnetic shielding forming: A facile approach for Lorentz force regulation and its application in tube forming","authors":"Xinhui Zhu , Xiaofei Xu , Wang Zhang , Limeng Du , Zihao Shao , Zhipeng Lai , Xiaotao Han , Liang Li , Quanliang Cao , Shaowei Ouyang","doi":"10.1016/j.jmatprotec.2025.118795","DOIUrl":"10.1016/j.jmatprotec.2025.118795","url":null,"abstract":"<div><div>The Lorentz force distribution is crucial in determining the deformation of workpieces in electromagnetic forming, with its spatial distribution directly influencing the resulting shape. However, achieving flexible control over this force to accommodate diverse forming requirements poses a significant challenge. To address this, an innovative electromagnetic shielding forming (EMSF) technique is proposed, which introduces a conductive metal ring positioned around the coil-tube assembly to modulate the Lorentz force distribution through its eddy current shielding effect during pulsed discharge. On this basis, we systematically explore how variations in the ring’s thickness, length, electrical conductivity, and positioning affect the shielding performance. Applying this forming method to long tubes, short tubes, and variable-diameter tubes, it is demonstrated that conventional EMF processes typically result in long tubes deforming into convex shapes and short tubes into concave shapes. In contrast, the method improves the uniformity of long-tube forming and offers the flexibility to shape short tubes into concave, flat, or convex profiles. Additionally, the method enhances the precision of variable-diameter tube forming by optimizing ring placement, enabling the production of high-accuracy tubes of various sizes. This advancement introduces a versatile and effective strategy for managing the Lorentz force via electromagnetic shielding effect, which enables more precise and flexible control over the deformation of workpieces during the electromagnetic forming process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118795"},"PeriodicalIF":6.7,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143609154","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

Effects of asymmetric rolling with tilted material entry on texture and mechanical properties of aluminium

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-06 DOI: 10.1016/j.jmatprotec.2025.118796

D. Byrska-Wójcik , M. Ostachowska , J. Gibek , K. Wierzbanowski , M. Wróbel , R. Błoniarz , A. Baczmański , M. Kopyściański , I. Kalemba-Rec

This research focuses on optimizing rolling geometry to achieve a uniform texture throughout the thickness of aluminium alloy 1050 plates. Traditional symmetric rolling techniques often lead to non-homogeneous textures; therefore, the study explores asymmetric rolling and its variations as potential solutions. In this investigation, asymmetric rolling was implemented by using rolls of differing diameters that rotate at the same angular velocity, along with adjusting the inclination of the rolled strip, either flat or tilted, as it enters the rolls. A thickness reduction of 84 % was achieved over six rolling passes. The resulting crystallographic texture variations within the rolled material were analysed through X-ray diffraction and predicted using the Finite Element Method (FEM) in conjunction with two crystalline deformation models. The findings reveal that the texture modifications induced by the shear strain and stress components during asymmetric rolling lead to shifts in selected texture maxima in the orientation space. These variations in texture distribution across the material's thickness have a direct impact on its mechanical properties, which were assessed through tensile testing. A key contribution of this work is its examination of how the angle of material entry influences texture homogenization during multi-pass asymmetric rolling, as well as its effect on the mechanical characteristics of the final product. The study concludes by identifying the most effective rolling configurations, providing practical recommendations for industrial applications.

{"title":"Effects of asymmetric rolling with tilted material entry on texture and mechanical properties of aluminium","authors":"D. Byrska-Wójcik , M. Ostachowska , J. Gibek , K. Wierzbanowski , M. Wróbel , R. Błoniarz , A. Baczmański , M. Kopyściański , I. Kalemba-Rec","doi":"10.1016/j.jmatprotec.2025.118796","DOIUrl":"10.1016/j.jmatprotec.2025.118796","url":null,"abstract":"<div><div>This research focuses on optimizing rolling geometry to achieve a uniform texture throughout the thickness of aluminium alloy 1050 plates. Traditional symmetric rolling techniques often lead to non-homogeneous textures; therefore, the study explores asymmetric rolling and its variations as potential solutions. In this investigation, asymmetric rolling was implemented by using rolls of differing diameters that rotate at the same angular velocity, along with adjusting the inclination of the rolled strip, either flat or tilted, as it enters the rolls. A thickness reduction of 84 % was achieved over six rolling passes. The resulting crystallographic texture variations within the rolled material were analysed through X-ray diffraction and predicted using the Finite Element Method (FEM) in conjunction with two crystalline deformation models. The findings reveal that the texture modifications induced by the shear strain and stress components during asymmetric rolling lead to shifts in selected texture maxima in the orientation space. These variations in texture distribution across the material's thickness have a direct impact on its mechanical properties, which were assessed through tensile testing. A key contribution of this work is its examination of how the angle of material entry influences texture homogenization during multi-pass asymmetric rolling, as well as its effect on the mechanical characteristics of the final product. The study concludes by identifying the most effective rolling configurations, providing practical recommendations for industrial applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118796"},"PeriodicalIF":6.7,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143609153","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

Comprehensive regulation of carbon nanotubes on laser welded joints of aluminum alloy: From morphology, solidification, microtexture to properties

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-05 DOI: 10.1016/j.jmatprotec.2025.118793

Tianyu Xu , Xiuquan Ma , Chaoqun Wu , Jinliang Zhang , Wenchao Ke , Minghui Yang

Laser welding of aluminum alloys is prone to porosity formation, which significantly compromises joint strength. In this study, the successful incorporation of carbon nanotubes(CNTs) into aluminum alloy welds not only increased welding speed but also enhanced joint strength while maintaining comparable weld penetration depth. The key point is that the comprehensive impact of CNTs on the joint has been systematically studied. Differential scanning calorimetry(DSC) and phase diagram analysis revealed that the exothermic reaction between CNTs and the aluminum matrix promoted the formation of Al₄C₃. Mechanical properties analysis demonstrated that the maximum tensile strength of the CNTs reinforced joint reached 326 MPa, outperforming most laser welding processes. On a microstructural level, CNTs refined the grain size of the weld fusion zone by 35.5 %, facilitating dynamic recrystallization and resulting in anisotropic grain structures. Microtexture analysis showed that some CNTs were dispersed within the weld, providing a stress transfer pathway at the CNTs/aluminum interface. This work comprehensively reveals the enhancement effect of carbon nanotubes on joints, and provides new potential solutions for optimizing the welding process of power battery casings.

{"title":"Comprehensive regulation of carbon nanotubes on laser welded joints of aluminum alloy: From morphology, solidification, microtexture to properties","authors":"Tianyu Xu , Xiuquan Ma , Chaoqun Wu , Jinliang Zhang , Wenchao Ke , Minghui Yang","doi":"10.1016/j.jmatprotec.2025.118793","DOIUrl":"10.1016/j.jmatprotec.2025.118793","url":null,"abstract":"<div><div>Laser welding of aluminum alloys is prone to porosity formation, which significantly compromises joint strength. In this study, the successful incorporation of carbon nanotubes(CNTs) into aluminum alloy welds not only increased welding speed but also enhanced joint strength while maintaining comparable weld penetration depth. The key point is that the comprehensive impact of CNTs on the joint has been systematically studied. Differential scanning calorimetry(DSC) and phase diagram analysis revealed that the exothermic reaction between CNTs and the aluminum matrix promoted the formation of Al₄C₃. Mechanical properties analysis demonstrated that the maximum tensile strength of the CNTs reinforced joint reached 326 MPa, outperforming most laser welding processes. On a microstructural level, CNTs refined the grain size of the weld fusion zone by 35.5 %, facilitating dynamic recrystallization and resulting in anisotropic grain structures. Microtexture analysis showed that some CNTs were dispersed within the weld, providing a stress transfer pathway at the CNTs/aluminum interface. This work comprehensively reveals the enhancement effect of carbon nanotubes on joints, and provides new potential solutions for optimizing the welding process of power battery casings.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118793"},"PeriodicalIF":6.7,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143563055","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

Observation and quantitative characterization of geometric and cyclical features associated with chip segmentation during machining of Ti6Al4V alloy

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-05 DOI: 10.1016/j.jmatprotec.2025.118794

Shoujin Sun

Chip segmentation is an important type of chip formation during machining of metals. However, there are still inconsistent variation trends in the morphological characteristics and contradictory physical models regarding chip segmentation. To better understand the chip segmentation mechanism during machining of Ti6Al4V, cyclic cutting forces during machining were recorded with a dynamometer, the periodic features on the surfaces of the chip and workpiece were observed with a scanning electron microscope (SEM) and their surface profiles and wear on tool rake face were measured with a 3D measuring laser scanning microscope in the present study. It was found that the periodic/wavy patterns on the machined surfaces of the chip and workpiece are attributed to the periodically distributed dimple/sliding rows with different spacings and heights under various cutting conditions. The observation, quantitative characterization and correlation of the periodic features on the surfaces of the chip and workpiece, cyclic cutting forces and tool wear on rake face provide useful information on how the surfaces of the chips and workpiece, and the cutting forces change during chip segmentation. This will lead to the proposal of a novel model for chip segmentation. X-ray diffraction (XRD) was also carried out to investigate the deformation mechanisms on the machined surface and longitudinal cross-section of the segmented chips.

{"title":"Observation and quantitative characterization of geometric and cyclical features associated with chip segmentation during machining of Ti6Al4V alloy","authors":"Shoujin Sun","doi":"10.1016/j.jmatprotec.2025.118794","DOIUrl":"10.1016/j.jmatprotec.2025.118794","url":null,"abstract":"<div><div>Chip segmentation is an important type of chip formation during machining of metals. However, there are still inconsistent variation trends in the morphological characteristics and contradictory physical models regarding chip segmentation. To better understand the chip segmentation mechanism during machining of Ti6Al4V, cyclic cutting forces during machining were recorded with a dynamometer, the periodic features on the surfaces of the chip and workpiece were observed with a scanning electron microscope (SEM) and their surface profiles and wear on tool rake face were measured with a 3D measuring laser scanning microscope in the present study. It was found that the periodic/wavy patterns on the machined surfaces of the chip and workpiece are attributed to the periodically distributed dimple/sliding rows with different spacings and heights under various cutting conditions. The observation, quantitative characterization and correlation of the periodic features on the surfaces of the chip and workpiece, cyclic cutting forces and tool wear on rake face provide useful information on how the surfaces of the chips and workpiece, and the cutting forces change during chip segmentation. This will lead to the proposal of a novel model for chip segmentation. X-ray diffraction (XRD) was also carried out to investigate the deformation mechanisms on the machined surface and longitudinal cross-section of the segmented chips.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118794"},"PeriodicalIF":6.7,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143594043","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

Localized high-temperature laser shock peening with adjustable metallic coatings method for mechanical properties enhancement of reflective aluminum alloys

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-05 DOI: 10.1016/j.jmatprotec.2025.118792

Xiaohan Zhang , Qingyun Zhu , Mingyi Zheng , Yaowu Hu

The importance of temperature for the quality of laser shock peening has been recognized in recent years. Heat accumulation caused by the overall heating mode adopted by the existing method will inevitably cause changes in the microstructure of the unreinforced region, which in turn will affect the mechanical properties of the overall structure. In this paper, a localized high-temperature laser shock peening with adjustable metallic coatings (Loc-HLSPwC) was proposed for the low-cost, large-scale, and highly flexible fabrication of fatigue-enhanced structural components. The experimental results showed that compared with the samples fabricated by high-temperature laser shock without coatings, the strengthened regions of Loc-HLSPwC samples exhibited significant hardness and larger peak residual compressive stresses, and the Loc-HLSPwC samples exhibited more excellent fatigue performance. The adjustable metallic coatings changed the direction of microcrack expansion during the loading process of fatigue loading. The microstructure and hardness of the unstrengthened regions of Loc-HLSPwC samples did not change significantly. Loc-HLSPwC process is expected to provide a new idea for high reliability manufacturing of new generation of construction machinery equipment.

{"title":"Localized high-temperature laser shock peening with adjustable metallic coatings method for mechanical properties enhancement of reflective aluminum alloys","authors":"Xiaohan Zhang , Qingyun Zhu , Mingyi Zheng , Yaowu Hu","doi":"10.1016/j.jmatprotec.2025.118792","DOIUrl":"10.1016/j.jmatprotec.2025.118792","url":null,"abstract":"<div><div>The importance of temperature for the quality of laser shock peening has been recognized in recent years. Heat accumulation caused by the overall heating mode adopted by the existing method will inevitably cause changes in the microstructure of the unreinforced region, which in turn will affect the mechanical properties of the overall structure. In this paper, a localized high-temperature laser shock peening with adjustable metallic coatings (Loc-HLSPwC) was proposed for the low-cost, large-scale, and highly flexible fabrication of fatigue-enhanced structural components. The experimental results showed that compared with the samples fabricated by high-temperature laser shock without coatings, the strengthened regions of Loc-HLSPwC samples exhibited significant hardness and larger peak residual compressive stresses, and the Loc-HLSPwC samples exhibited more excellent fatigue performance. The adjustable metallic coatings changed the direction of microcrack expansion during the loading process of fatigue loading. The microstructure and hardness of the unstrengthened regions of Loc-HLSPwC samples did not change significantly. Loc-HLSPwC process is expected to provide a new idea for high reliability manufacturing of new generation of construction machinery equipment.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118792"},"PeriodicalIF":6.7,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143563056","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

Imprinting nanostructures on metallic surface via underwater electrical wire explosion shock waves

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-28 DOI: 10.1016/j.jmatprotec.2025.118784

Xin Li, Huantong Shi, Tuan Li, Zhigang Liu, Jian Wu, Xingwen Li

Fabricating nanostructures on metallic surface is relevant to various applications, and there is growing interest in developing new methods that balance accuracy, throughput and cost. In this work, a novel method, underwater electrical wire explosion shock imprinting (UEWESI), is proposed as a versatile one-step method for imprinting large-area surface nanostructures on both thin and thick substrates. Using a polycarbonate mold, the 10 μm thickness and 40 × 40 mm² area aluminium foil was uniformly imprinted via single copper wire explosion at a 12 mm standoff distance and 1.8 kJ electrical stored energy, with a fidelity up to 80 %. A periodic imprinting mechanism based on the stress evolution in the substrate was proposed to explore the physical process and explain the effects of standoff distance, shock wave pulse width, substrate thickness and layer arrangement on imprinting performance. Additionally, a scaled-up variant of UEWESI utilizing an exploding wire array was introduced, which generates a large-area planar shock wave front through the convergence of individual shock waves, further enhancing imprinting performance. This work offers a promising alternative for large-scale fabrication of nanostructures on metallic surfaces, with potential applications in flexible electronics, rechargeable batteries, plasmonics and other related fields.

{"title":"Imprinting nanostructures on metallic surface via underwater electrical wire explosion shock waves","authors":"Xin Li, Huantong Shi, Tuan Li, Zhigang Liu, Jian Wu, Xingwen Li","doi":"10.1016/j.jmatprotec.2025.118784","DOIUrl":"10.1016/j.jmatprotec.2025.118784","url":null,"abstract":"<div><div>Fabricating nanostructures on metallic surface is relevant to various applications, and there is growing interest in developing new methods that balance accuracy, throughput and cost. In this work, a novel method, underwater electrical wire explosion shock imprinting (UEWESI), is proposed as a versatile one-step method for imprinting large-area surface nanostructures on both thin and thick substrates. Using a polycarbonate mold, the 10 μm thickness and 40 × 40 mm² area aluminium foil was uniformly imprinted via single copper wire explosion at a 12 mm standoff distance and 1.8 kJ electrical stored energy, with a fidelity up to 80 %. A periodic imprinting mechanism based on the stress evolution in the substrate was proposed to explore the physical process and explain the effects of standoff distance, shock wave pulse width, substrate thickness and layer arrangement on imprinting performance. Additionally, a scaled-up variant of UEWESI utilizing an exploding wire array was introduced, which generates a large-area planar shock wave front through the convergence of individual shock waves, further enhancing imprinting performance. This work offers a promising alternative for large-scale fabrication of nanostructures on metallic surfaces, with potential applications in flexible electronics, rechargeable batteries, plasmonics and other related fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118784"},"PeriodicalIF":6.7,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143549344","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

Enhanced strength-ductility of deposited Al-Mg-Sc alloy through interlayer hammering and in-situ heating

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-28 DOI: 10.1016/j.jmatprotec.2025.118791

Jinsheng Ji , Leilei Wang , Jianfeng Wang , Yuchi Fang , Zhangping Hu , Qiyu Gao , Deliang Lei , Xiaohong Zhan

Wire-arc directed energy deposition (DED-Arc) combined with interlayer plastic strengthening has shown good advantages and feasibility in manufacturing high-performance components. However, simultaneously improving strength and ductility remains challenging. Based on DED-Arc technology, this study proposed a hybrid manufacturing approach integrating interlayer hammering and in-situ heating. The impacts of the novel process on pore inhibition, microstructure evolution, and mechanical properties were explored. The results indicated that, compared to the conventionally deposited alloy, the alloy produced via the novel process demonstrates increases of 28.3 % in yield strength, 22.2 % in ultimate tensile strength, and 21.8 % in ductility. The simultaneous improvement of alloy strength and ductility arose from the combined effects of the thermal and mechanical forces, primarily through pore inhibition, grain refinement, precipitation strengthening, and increased dislocation density. This study overcame the strength-ductility trade-off, providing new insights for improving techniques to enhance the performance of DED-Arc components.

{"title":"Enhanced strength-ductility of deposited Al-Mg-Sc alloy through interlayer hammering and in-situ heating","authors":"Jinsheng Ji , Leilei Wang , Jianfeng Wang , Yuchi Fang , Zhangping Hu , Qiyu Gao , Deliang Lei , Xiaohong Zhan","doi":"10.1016/j.jmatprotec.2025.118791","DOIUrl":"10.1016/j.jmatprotec.2025.118791","url":null,"abstract":"<div><div>Wire-arc directed energy deposition (DED-Arc) combined with interlayer plastic strengthening has shown good advantages and feasibility in manufacturing high-performance components. However, simultaneously improving strength and ductility remains challenging. Based on DED-Arc technology, this study proposed a hybrid manufacturing approach integrating interlayer hammering and in-situ heating. The impacts of the novel process on pore inhibition, microstructure evolution, and mechanical properties were explored. The results indicated that, compared to the conventionally deposited alloy, the alloy produced via the novel process demonstrates increases of 28.3 % in yield strength, 22.2 % in ultimate tensile strength, and 21.8 % in ductility. The simultaneous improvement of alloy strength and ductility arose from the combined effects of the thermal and mechanical forces, primarily through pore inhibition, grain refinement, precipitation strengthening, and increased dislocation density. This study overcame the strength-ductility trade-off, providing new insights for improving techniques to enhance the performance of DED-Arc components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118791"},"PeriodicalIF":6.7,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143549345","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

Ultrafast laser micro-texturing of joining surface combined with ultrasonic vibration-assisted friction stir joining to fabricate Zr-based metallic glass parts 超快激光微纹理接合表面与超声波振动辅助搅拌摩擦接合相结合，制造 Zr 基金属玻璃部件

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-26 DOI: 10.1016/j.jmatprotec.2025.118790

Zimin Tang , Yongshan Lu , Feng Ding , Lijuan Zheng , Chengyong Wang

This study aims to fabricate Zr-based metallic glass (MG) parts directly through friction stir joining (FSJ) by addressing the poor machinability of Zr-based MGs. The joining mechanism, mechanical properties, and microstructure of FSJ joints were investigated to achieve high-strength joints. The result identified uneven temperature distribution at the joint interface as a critical factor for inadequate plastic deformation or viscous flow, affecting the joint strength. Therefore, a new strategy is proposed to regulate the interface temperature and material plastic deformation during Zr-based MG joining via ultrafast laser micro-texturing of the joining surface combined with ultrasonic vibration-assisted friction stir joining (UL-UVaFSJ). The results show that ultrasonic vibrations enhance longitudinal friction and energy transfer, promoting uniform temperature distribution with improved viscous flow. Additionally, ultrafast laser-fabricated micro-textures alter heat generation, reducing temperature unevenness at the source. These factors collectively yield a uniform temperature distribution at the joint interface, crucial for reliable joining. The factors also maintain the even plastic flow of Zr-based MGs in the supercooled liquid region (SCLR) for a critical duration, essential for successful joining. Transmission electron microscopy reveals true metallurgical joining with the proposed method. The joining strength of Zr-based MGs is 1.37 GPa, reaching 91.3 % of the as-cast material and enabling the successful fabrication of a high-strength, crystallization-free MG gear shaft. The findings are pivotal for large-scale MG part fabrication and will significantly promote their industrial application.

{"title":"Ultrafast laser micro-texturing of joining surface combined with ultrasonic vibration-assisted friction stir joining to fabricate Zr-based metallic glass parts","authors":"Zimin Tang , Yongshan Lu , Feng Ding , Lijuan Zheng , Chengyong Wang","doi":"10.1016/j.jmatprotec.2025.118790","DOIUrl":"10.1016/j.jmatprotec.2025.118790","url":null,"abstract":"<div><div>This study aims to fabricate Zr-based metallic glass (MG) parts directly through friction stir joining (FSJ) by addressing the poor machinability of Zr-based MGs. The joining mechanism, mechanical properties, and microstructure of FSJ joints were investigated to achieve high-strength joints. The result identified uneven temperature distribution at the joint interface as a critical factor for inadequate plastic deformation or viscous flow, affecting the joint strength. Therefore, a new strategy is proposed to regulate the interface temperature and material plastic deformation during Zr-based MG joining via ultrafast laser micro-texturing of the joining surface combined with ultrasonic vibration-assisted friction stir joining (UL-UVaFSJ). The results show that ultrasonic vibrations enhance longitudinal friction and energy transfer, promoting uniform temperature distribution with improved viscous flow. Additionally, ultrafast laser-fabricated micro-textures alter heat generation, reducing temperature unevenness at the source. These factors collectively yield a uniform temperature distribution at the joint interface, crucial for reliable joining. The factors also maintain the even plastic flow of Zr-based MGs in the supercooled liquid region (SCLR) for a critical duration, essential for successful joining. Transmission electron microscopy reveals true metallurgical joining with the proposed method. The joining strength of Zr-based MGs is 1.37 GPa, reaching 91.3 % of the as-cast material and enabling the successful fabrication of a high-strength, crystallization-free MG gear shaft. The findings are pivotal for large-scale MG part fabrication and will significantly promote their industrial application.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118790"},"PeriodicalIF":6.7,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520594","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

A complete phase distribution map of the laser affected zone and ablation debris formed by nanosecond laser-cutting of SiC 纳秒激光切割碳化硅形成的激光影响区和烧蚀碎片的完整相位分布图

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-26 DOI: 10.1016/j.jmatprotec.2025.118782

Mehdi Rouhani , Sai Bhavani Sravan Metla , Jonathan Hobley , Dileep Karnam , Chia-Hung Hung , Yu-Lung Lo , Yeau-Ren Jeng

Laser cutting of silicon carbide (SiC) poses significant challenges due to its extreme hardness and thermal resistance, necessitating high energy input and often leading to extensive melt-zone formation and collateral damage. This study optimizes nanosecond laser cutting of SiC by systematically investigating phase transformations, melt-zone formation, and debris deposition, offering a cost-effective alternative to femtosecond laser systems. Using Raman spectroscopy, photoluminescence, and X-ray photoelectron spectroscopy, we construct a comprehensive phase distribution map of the laser-affected region, revealing key material transformations. Our results demonstrate that material removal is confined to a narrow central fissure. Meanwhile, the surrounding melt zone consists of phase-separated amorphous silicon (a-Si) and amorphous carbon (a-C). Lateral crevasses mark the interface between the melt zone and the unmodified SiC substrate. We further explore the influence of atmospheric conditions (oxygen, air, and argon) and laser pulse parameters (pulse width and repetition rate) on melt-zone formation and cutting efficiency. Oxygen-rich environments expand the melt zone and yield oxygen-rich debris, while inert atmospheres suppress oxidation, forming carbon-rich debris with less material loss. Shorter pulse widths enhance material removal while reducing melt-zone expansion, supporting a mechanistic framework in which sequential multiphoton absorption drives ablation while photothermal effects govern melt-zone formation. This study provides critical insights into optimizing nanosecond laser cutting of SiC, offering practical strategies for achieving high-precision cuts with less thermal damage and material waste. These findings contribute to advancing industrial laser machining of SiC, making high-precision, low-cost processing more accessible and efficient.

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引用次数: 0

Application of hot wire laser directed energy deposition for efficient fabrication of large nickel-based alloy components: Process, microstructure, and mechanical properties

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-24 DOI: 10.1016/j.jmatprotec.2025.118789

Guoxing Su, Yu Shi, Ming Zhu, Gang Zhang

Enhancing the wire deposition rate while ensuring deposition stability is a critical challenge in fabricating large nickel-based alloy components using hot wire laser directed energy deposition (HW-LDED) technology. In this study, a preheating mathematical model for Inconel 718 wire was initially established and experimentally validated. Subsequently, based on the optimal matching between the wire feeding speed and preheating current, Inconel 718 components were efficiently fabricated with a wire deposition rate of 3.1 kg/h. Ultimately, the microstructure evolution, phase composition, and mechanical properties of the HW-LDED Inconel 718 samples were comprehensively investigated. The results revealed that the microstructure of the HW-LDED Inconel 718 samples consisted of columnar dendrites exhibiting a pronounced {100} < 001 > texture, with an average grain size of 16 μm. The primary phase in the HW-LDED Inconel 718 samples was the γ-Ni phase, accompanied by Laves and carbides in intergranular regions. The average hardness of the HW-LDED Inconel 718 samples was 253.5 HV1.0. The tensile strength and elongation were 1112.1 MPa and 36.13 %, respectively, while the impact absorbing energy reached 85.97 J. The tensile and impact fracture surfaces displayed numerous dimples, indicative of ductile fracture behavior of the alloy under applied loading. The Laves phase facilitated the initiation and propagation of cracks during the alloy's deformation process, with elongated Laves phases undergoing fragmentation and smaller Laves phases experiencing debonding from the matrix. This research presents a viable solution for the efficient fabrication of large nickel-based alloy components. Furthermore, the findings offer valuable insights into the interrelationships among the deposition process, microstructure, and properties of the HW-LDED Inconel 718 alloy.

{"title":"Application of hot wire laser directed energy deposition for efficient fabrication of large nickel-based alloy components: Process, microstructure, and mechanical properties","authors":"Guoxing Su, Yu Shi, Ming Zhu, Gang Zhang","doi":"10.1016/j.jmatprotec.2025.118789","DOIUrl":"10.1016/j.jmatprotec.2025.118789","url":null,"abstract":"<div><div>Enhancing the wire deposition rate while ensuring deposition stability is a critical challenge in fabricating large nickel-based alloy components using hot wire laser directed energy deposition (HW-LDED) technology. In this study, a preheating mathematical model for Inconel 718 wire was initially established and experimentally validated. Subsequently, based on the optimal matching between the wire feeding speed and preheating current, Inconel 718 components were efficiently fabricated with a wire deposition rate of 3.1 kg/h. Ultimately, the microstructure evolution, phase composition, and mechanical properties of the HW-LDED Inconel 718 samples were comprehensively investigated. The results revealed that the microstructure of the HW-LDED Inconel 718 samples consisted of columnar dendrites exhibiting a pronounced {100} < 001 > texture, with an average grain size of 16 μm. The primary phase in the HW-LDED Inconel 718 samples was the γ-Ni phase, accompanied by Laves and carbides in intergranular regions. The average hardness of the HW-LDED Inconel 718 samples was 253.5 HV1.0. The tensile strength and elongation were 1112.1 MPa and 36.13 %, respectively, while the impact absorbing energy reached 85.97 J. The tensile and impact fracture surfaces displayed numerous dimples, indicative of ductile fracture behavior of the alloy under applied loading. The Laves phase facilitated the initiation and propagation of cracks during the alloy's deformation process, with elongated Laves phases undergoing fragmentation and smaller Laves phases experiencing debonding from the matrix. This research presents a viable solution for the efficient fabrication of large nickel-based alloy components. Furthermore, the findings offer valuable insights into the interrelationships among the deposition process, microstructure, and properties of the HW-LDED Inconel 718 alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118789"},"PeriodicalIF":6.7,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520593","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