Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118697
Jun Zha , Guoqing Zu , Zhiping Xiong , Weiwei Zhu , Liying Wang , Ying Han , Xu Ran , Xingwang Cheng
Seashells have a typical brick-and-mortar structure (BMS) composed of tiny mineral particles and organic matter. Such BMS has inspired the development of advanced composite materials with high strength and toughness, yet it is challenging to implement in metallic systems. This study employs the foil-to-foil method combined with hot-press sintering to fabricate layered TiNi/Ti₂Ni intermetallic composite material(ICM). The layered ICM is further subjected to hot rolling with varying deformation, successfully producing ICM with a unique brick-and-mortar structure. The BMS-ICM has an ultra-high content of Ti2Ni reinforcement phase. The olive-shaped brittle phase of Ti2Ni is evenly distributed within the TiNi mortar as bricks, with a volume fraction of the Ti2Ni phase as high as 79 %. The compressive strength of 60 % BMS-ICM perpendicular to the loading direction of the laminate reaches 1963.50 MPa, accompanied by a fracture strain of 24.5 %. Additionally, the unique Ti₂Ni brick and TiNi mortar structure provides multiple toughening mechanisms for BMS-ICM. Compared to conventional materials, BMS-ICM demonstrates significant advantages in crack propagation resistance, thus holding great potential for applications in the military and aerospace fields.
{"title":"Efficient manufacture of TiNi/Ti2Ni intermetallic composites with a unique brick-and-mortar structure in a single hot rolling process","authors":"Jun Zha , Guoqing Zu , Zhiping Xiong , Weiwei Zhu , Liying Wang , Ying Han , Xu Ran , Xingwang Cheng","doi":"10.1016/j.jmatprotec.2024.118697","DOIUrl":"10.1016/j.jmatprotec.2024.118697","url":null,"abstract":"<div><div>Seashells have a typical brick-and-mortar structure (BMS) composed of tiny mineral particles and organic matter. Such BMS has inspired the development of advanced composite materials with high strength and toughness, yet it is challenging to implement in metallic systems. This study employs the foil-to-foil method combined with hot-press sintering to fabricate layered TiNi/Ti₂Ni intermetallic composite material(ICM). The layered ICM is further subjected to hot rolling with varying deformation, successfully producing ICM with a unique brick-and-mortar structure. The BMS-ICM has an ultra-high content of Ti<sub>2</sub>Ni reinforcement phase. The olive-shaped brittle phase of Ti<sub>2</sub>Ni is evenly distributed within the TiNi mortar as bricks, with a volume fraction of the Ti<sub>2</sub>Ni phase as high as 79 %. The compressive strength of 60 % BMS-ICM perpendicular to the loading direction of the laminate reaches 1963.50 MPa, accompanied by a fracture strain of 24.5 %. Additionally, the unique Ti₂Ni brick and TiNi mortar structure provides multiple toughening mechanisms for BMS-ICM. Compared to conventional materials, BMS-ICM demonstrates significant advantages in crack propagation resistance, thus holding great potential for applications in the military and aerospace fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118697"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169453","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118666
Viktor Arne , Daniel Spies , Dirk Alexander Molitor , Fuzhang He , Peter Groche
The development of novel forming machines, such as the 3D Servo Press, provides the opportunity to implement entirely novel forming processes and to manufacture established machine elements, such as hubs with polygon contour, through the utilisation of forming technology. This publication presents the production of polygon hubs in thin-walled sheets using the additional flexibility provided by multi degree of freedom servo presses. The polygon contour produced by hole-rolling are subjected to further examination to determine whether they meet the required specifications and the properties when used in a shaft-hub connection. In this context, the following criteria were evaluated: geometric dimensional accuracy, mechanical strength against failure under load, and surface quality. The results presented have the potential for future applications to optimise the process chain in the manufacturing of shaft-hub connections with polygon contour and the establishment of an alternative to conventional manufacturing methods like milling and turning.
{"title":"A new process route for the manufacturing of hubs in sheet metal structures by utilising flexible hole-rolling","authors":"Viktor Arne , Daniel Spies , Dirk Alexander Molitor , Fuzhang He , Peter Groche","doi":"10.1016/j.jmatprotec.2024.118666","DOIUrl":"10.1016/j.jmatprotec.2024.118666","url":null,"abstract":"<div><div>The development of novel forming machines, such as the 3D Servo Press, provides the opportunity to implement entirely novel forming processes and to manufacture established machine elements, such as hubs with polygon contour, through the utilisation of forming technology. This publication presents the production of polygon hubs in thin-walled sheets using the additional flexibility provided by multi degree of freedom servo presses. The polygon contour produced by hole-rolling are subjected to further examination to determine whether they meet the required specifications and the properties when used in a shaft-hub connection. In this context, the following criteria were evaluated: geometric dimensional accuracy, mechanical strength against failure under load, and surface quality. The results presented have the potential for future applications to optimise the process chain in the manufacturing of shaft-hub connections with polygon contour and the establishment of an alternative to conventional manufacturing methods like milling and turning.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118666"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169456","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118706
Ning Cui , Tianqi Zhao , Zhiguo Wang , Yuhui Zhao , Yaojie Chao , Hai Lin , Desheng Li , Jibin Zhao
Over the years, porosity defects have been one of the significant factors limiting the development of aluminum alloys during the joining process. This paper employs the process of laser metal deposition welding (LMDW) to join Al-Mg-Sc-Zr alloys with high Mg content. Through the micromorphology of pores, elemental distribution, and finite element analysis (FEA), the mechanisms of formation, growth, and spillage of pore defects in aluminum alloys containing low-melting-point elements are explored. This study not only delves into the mechanism of low-melting-point element-induced porosity and enriches the principle of porosity formation, but also explores the influence of heat transfer paths and flow fields on the porosity enrichment during the butt-welding process, which provides a reference direction for future research. The study examines the effects of different process parameters and layers on the distribution and size of pores, revealing that pore-rich areas are concentrated along the fusion lines and the interlayer fusion lines. Furthermore, the three-dimensional model is constructed via finite element analysis to simulate the distribution of Mg and the flow field within the melt pool. Finally, ultrasonic vibration is introduced to mitigate porosity defects. Through controlled experiments, the optimal ultrasonic vibration current parameters are identified that minimize Mg loss and alleviate pore accumulation along the fusion lines and interlayer fusion lines. Compared with no ultrasonic vibration, the porosity at the melt pool center ameliorated by 20 %, the porosity near the fusion line decreased by 22 %, and the tensile strength increased by 41.9 %.
{"title":"Porosity evolution mechanisms, influencing factors, and ultrasonic-assisted regulation in joining high Mg-content aluminum alloys","authors":"Ning Cui , Tianqi Zhao , Zhiguo Wang , Yuhui Zhao , Yaojie Chao , Hai Lin , Desheng Li , Jibin Zhao","doi":"10.1016/j.jmatprotec.2024.118706","DOIUrl":"10.1016/j.jmatprotec.2024.118706","url":null,"abstract":"<div><div>Over the years, porosity defects have been one of the significant factors limiting the development of aluminum alloys during the joining process. This paper employs the process of laser metal deposition welding (LMDW) to join Al-Mg-Sc-Zr alloys with high Mg content. Through the micromorphology of pores, elemental distribution, and finite element analysis (FEA), the mechanisms of formation, growth, and spillage of pore defects in aluminum alloys containing low-melting-point elements are explored. This study not only delves into the mechanism of low-melting-point element-induced porosity and enriches the principle of porosity formation, but also explores the influence of heat transfer paths and flow fields on the porosity enrichment during the butt-welding process, which provides a reference direction for future research. The study examines the effects of different process parameters and layers on the distribution and size of pores, revealing that pore-rich areas are concentrated along the fusion lines and the interlayer fusion lines. Furthermore, the three-dimensional model is constructed via finite element analysis to simulate the distribution of Mg and the flow field within the melt pool. Finally, ultrasonic vibration is introduced to mitigate porosity defects. Through controlled experiments, the optimal ultrasonic vibration current parameters are identified that minimize Mg loss and alleviate pore accumulation along the fusion lines and interlayer fusion lines. Compared with no ultrasonic vibration, the porosity at the melt pool center ameliorated by 20 %, the porosity near the fusion line decreased by 22 %, and the tensile strength increased by 41.9 %.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118706"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168497","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118698
Ying Zhi , Dong Wang , Yao Jiang , Xianlei Hu , Tao Sun , Xianghua Liu
This research presents a novel method for preparing tailor rolled blanks of aluminum alloy (Al-TRB) by synergizing variable gauge rolling with heat treatment, achieving a remarkable property differentiation between thin and thick zones and enhanced strength-plasticity. After variable gauge rolling, there is a notable increase in both tensile and yield strengths across the zones, attributed to deformation strengthening, though elongation decreases. The process induces a pronounced property difference, with a tensile strength difference of 72 MPa, a yield strength difference of 100 MPa, and an elongation difference of 12.4 % between thin and thick zones. This property gradient is a fundamental advancement, offering a strategic advantage in automotive component manufacturing by allowing the properties of different parts on the same component to be matched according to their specific operational demands. Subsequent re-aging and bake-hardening treatments further enhance the strength-plasticity, elevating the tensile strengths of the thin and thick zones to 407 MPa and 329 MPa, respectively, while improving elongations to 13.4 % and 20.7 %. The strength increment is attributed to precipitation strengthening, while the elongation increment is due to dislocation recovery during re-aging and bake-hardening. The fundamental advancement of this research lies in the tailored property differentiation of Al-TRB, which not only surpasses the mechanical properties of conventional 6000-series Al-TRB but also provides a strategic advantage in automotive component manufacturing. This innovation enables the maximization of load-carrying potential by matching the properties of different parts on the same component according to specific operational demands, thereby enhancing overall vehicle performance and safety.
{"title":"Achieving property differentiation and enhanced strength-plasticity in tailor rolled blank of aluminum alloy by variable gauge rolling and heat treatment","authors":"Ying Zhi , Dong Wang , Yao Jiang , Xianlei Hu , Tao Sun , Xianghua Liu","doi":"10.1016/j.jmatprotec.2024.118698","DOIUrl":"10.1016/j.jmatprotec.2024.118698","url":null,"abstract":"<div><div>This research presents a novel method for preparing tailor rolled blanks of aluminum alloy (Al-TRB) by synergizing variable gauge rolling with heat treatment, achieving a remarkable property differentiation between thin and thick zones and enhanced strength-plasticity. After variable gauge rolling, there is a notable increase in both tensile and yield strengths across the zones, attributed to deformation strengthening, though elongation decreases. The process induces a pronounced property difference, with a tensile strength difference of 72 MPa, a yield strength difference of 100 MPa, and an elongation difference of 12.4 % between thin and thick zones. This property gradient is a fundamental advancement, offering a strategic advantage in automotive component manufacturing by allowing the properties of different parts on the same component to be matched according to their specific operational demands. Subsequent re-aging and bake-hardening treatments further enhance the strength-plasticity, elevating the tensile strengths of the thin and thick zones to 407 MPa and 329 MPa, respectively, while improving elongations to 13.4 % and 20.7 %. The strength increment is attributed to precipitation strengthening, while the elongation increment is due to dislocation recovery during re-aging and bake-hardening. The fundamental advancement of this research lies in the tailored property differentiation of Al-TRB, which not only surpasses the mechanical properties of conventional 6000-series Al-TRB but also provides a strategic advantage in automotive component manufacturing. This innovation enables the maximization of load-carrying potential by matching the properties of different parts on the same component according to specific operational demands, thereby enhancing overall vehicle performance and safety.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118698"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169452","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118703
Zhenghao Wei , Zhiyu Wang , Huiqiang Liang , Junqiang Li , Jiongchong Fang , Wenjun Lu , Jiawen Zhang , Haifeng Gao , Zhongdu He , Yu Guo , Xu Sui , Guosong Zeng
Introducing an external energy field to force the oxidation of SiC is considered as an effective way to address the current challenge of chemical mechanical polishing (CMP) for SiC fabrication. In this study, we firstly compared several reported oxidation methods that have been used in different CMP-based techniques for SiC substrate, and demonstrated that the electrochemical (EC) and photoelectrochemical (PEC) anodic oxidations had significant advancement of the oxidation efficiency. Further comparison between EC and PEC revealed that PEC produced more uniform and smoother oxide layers in similar oxidation rates, while applied voltage and light intensity played a composing role in controlling the outcome. The quasi-in situ (photo)electrochemical atomic force microscopy analysis on the nanoindentation introduced artificial defects unraveled that, holes were prone to gather around the defective regions and resulted in faster oxidation rate, while the PEC can suppress such selective oxidation. These results suggest that the introduction of light has the potential to address the long-standing challenge of poor surface quality in electrochemical mechanical polishing (ECMP), not only for SiC but for various different semiconductor materials, and provide practical guidance for the industry to enhance PECMP performance on SiC and other hard and chemical inert semiconductor materials through optimizing oxidation processes.
{"title":"Effect of UV-illumination on electrochemical anodic oxidation of SiC","authors":"Zhenghao Wei , Zhiyu Wang , Huiqiang Liang , Junqiang Li , Jiongchong Fang , Wenjun Lu , Jiawen Zhang , Haifeng Gao , Zhongdu He , Yu Guo , Xu Sui , Guosong Zeng","doi":"10.1016/j.jmatprotec.2024.118703","DOIUrl":"10.1016/j.jmatprotec.2024.118703","url":null,"abstract":"<div><div>Introducing an external energy field to force the oxidation of SiC is considered as an effective way to address the current challenge of chemical mechanical polishing (CMP) for SiC fabrication. In this study, we firstly compared several reported oxidation methods that have been used in different CMP-based techniques for SiC substrate, and demonstrated that the electrochemical (EC) and photoelectrochemical (PEC) anodic oxidations had significant advancement of the oxidation efficiency. Further comparison between EC and PEC revealed that PEC produced more uniform and smoother oxide layers in similar oxidation rates, while applied voltage and light intensity played a composing role in controlling the outcome. The quasi-in situ (photo)electrochemical atomic force microscopy analysis on the nanoindentation introduced artificial defects unraveled that, holes were prone to gather around the defective regions and resulted in faster oxidation rate, while the PEC can suppress such selective oxidation. These results suggest that the introduction of light has the potential to address the long-standing challenge of poor surface quality in electrochemical mechanical polishing (ECMP), not only for SiC but for various different semiconductor materials, and provide practical guidance for the industry to enhance PECMP performance on SiC and other hard and chemical inert semiconductor materials through optimizing oxidation processes.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118703"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168925","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}
Subgrain formation and its coupling with the α phase significantly improve the strength and toughness of titanium alloys. To elucidate the effect of temperature changes on the formation mechanism of nano-subgrains in Ti-6V-5Al-5Mo-5Cr-3Nb-2Zr-0.2Si alloy, multi-directional forging was conducted at various temperatures, and finally quantified the contribution of subgrains and phase evolution to mechanical properties. The results revealed that the equiaxed α phase precipitates at the β grain boundary. As the temperature rises, the aspect ratio of the α phase increases, while its content decreases. The formation mechanism of nano-subgrains during multi-directional forging at 690 ℃ involves dislocation accumulation and the separation of torsional bands within the β grains. When the temperature increases, the deformation resistance decreases, eliminating the need for crystal torsion to reduce this resistance. Subsequently, high-density dislocations form dislocation walls, which delineate the boundaries of fine nano-subgrains. This random orientation of subgrains significantly enhances both the strength and toughness of the titanium alloy forged at 770 ℃. Therefore, the tensile strength and fracture toughness of the alloy reach peak values of 1084.8 MPa and 54.18 MPa·m1/2, respectively. Microstructural analysis of the cracks reveals that the nano-subgrains effectively hinder their rapid propagation. Due to the coupled strengthening effect of subgrains and α phases, the tensile strength and fracture toughness of the titanium alloy forged at 770 ℃ are increased by 26 % and 40 % respectively compared with the as-cast alloy.
{"title":"Formation behavior of subcrystals and its strengthening and toughening mechanism by coupling with α phase in titanium alloys during forging at various temperatures","authors":"Shichen Sun , Hongze Fang , Jiaqi Hao , Baohui Zhu , Xianfei Ding , Ruirun Chen","doi":"10.1016/j.jmatprotec.2024.118705","DOIUrl":"10.1016/j.jmatprotec.2024.118705","url":null,"abstract":"<div><div>Subgrain formation and its coupling with the α phase significantly improve the strength and toughness of titanium alloys. To elucidate the effect of temperature changes on the formation mechanism of nano-subgrains in Ti-6V-5Al-5Mo-5Cr-3Nb-2Zr-0.2Si alloy, multi-directional forging was conducted at various temperatures, and finally quantified the contribution of subgrains and phase evolution to mechanical properties. The results revealed that the equiaxed α phase precipitates at the β grain boundary. As the temperature rises, the aspect ratio of the α phase increases, while its content decreases. The formation mechanism of nano-subgrains during multi-directional forging at 690 ℃ involves dislocation accumulation and the separation of torsional bands within the β grains. When the temperature increases, the deformation resistance decreases, eliminating the need for crystal torsion to reduce this resistance. Subsequently, high-density dislocations form dislocation walls, which delineate the boundaries of fine nano-subgrains. This random orientation of subgrains significantly enhances both the strength and toughness of the titanium alloy forged at 770 ℃. Therefore, the tensile strength and fracture toughness of the alloy reach peak values of 1084.8 MPa and 54.18 MPa·m<sup>1/2</sup>, respectively. Microstructural analysis of the cracks reveals that the nano-subgrains effectively hinder their rapid propagation. Due to the coupled strengthening effect of subgrains and α phases, the tensile strength and fracture toughness of the titanium alloy forged at 770 ℃ are increased by 26 % and 40 % respectively compared with the as-cast alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118705"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168983","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118700
Shubham Verma , ChuanSong Wu , Lalit Thakur , Najib Ahmad Muhammad , Shengli Li
Heat generation during friction stir welding (FSW) significantly impacts heat-treatable aluminium alloy grain microstructure and precipitation behavior. Therefore, it is crucial to employ cooling techniques to reduce the excessive heat in the welding zone. Here, a new biodegradable nanofluid (comprising sunflower oil and copper oxide) process cooling was utilized to reduce the excess heat during the FSW of AA6082 alloy. Compressed air was mixed with the nanofluid, creating a mist spray known as minimum quantity lubrication (n-MQL), which was then sprayed onto the surface during FSW (i.e., n-MQL-FSW). A detailed comparative analysis of microstructure evolution and tensile behavior was performed on the FSW joints under normal and biodegradable process cooling conditions. A significant reduction in temperature was observed during n-MQL-FSW, and it also reduces asymmetrical heat transfer during welding. Additionally, the promotion of nucleation rate and growth of equiaxed grain occurs in the nugget zone (NZ), which dominates the continuous dynamic recrystallization (CDRX) during n-MQL-FSW. Moreover, the bulging frequency of high-angle grain boundaries (HAGBs) in NZ was also enhanced compared to FSW. The average grain size results of 25.81 ± 3.69 µm in the NZ were found for FSW observed in the shoulder-affected zone and then decreased to 21.36 ± 1.14 μm for n-MQL-FSW at the same position. Furthermore, the fraction of substructure in NZ was reduced, while the fraction of recrystallization was increased during the n-MQL-FSW. The tensile strength was ∼ 81 %, and ∼ 64 % of the BM was observed for n-MQL-FSW and FSW, respectively. The elongation percentage did not show any significant changes during both processes. This study reveals an efficient approach to reducing excess heat input during the FSW process to manufacture high-performance components.
{"title":"Investigating the influence of biodegradable nanofluid process cooling on dynamic recrystallization and grain microstructure in friction stir welding of AA6082 alloy","authors":"Shubham Verma , ChuanSong Wu , Lalit Thakur , Najib Ahmad Muhammad , Shengli Li","doi":"10.1016/j.jmatprotec.2024.118700","DOIUrl":"10.1016/j.jmatprotec.2024.118700","url":null,"abstract":"<div><div>Heat generation during friction stir welding (FSW) significantly impacts heat-treatable aluminium alloy grain microstructure and precipitation behavior. Therefore, it is crucial to employ cooling techniques to reduce the excessive heat in the welding zone. Here, a new biodegradable nanofluid (comprising sunflower oil and copper oxide) process cooling was utilized to reduce the excess heat during the FSW of AA6082 alloy. Compressed air was mixed with the nanofluid, creating a mist spray known as minimum quantity lubrication (n-MQL), which was then sprayed onto the surface during FSW (i.e., n-MQL-FSW). A detailed comparative analysis of microstructure evolution and tensile behavior was performed on the FSW joints under normal and biodegradable process cooling conditions. A significant reduction in temperature was observed during n-MQL-FSW, and it also reduces asymmetrical heat transfer during welding. Additionally, the promotion of nucleation rate and growth of equiaxed grain occurs in the nugget zone (NZ), which dominates the continuous dynamic recrystallization (CDRX) during n-MQL-FSW. Moreover, the bulging frequency of high-angle grain boundaries (HAGBs) in NZ was also enhanced compared to FSW. The average grain size results of 25.81 ± 3.69 µm in the NZ were found for FSW observed in the shoulder-affected zone and then decreased to 21.36 ± 1.14 μm for n-MQL-FSW at the same position. Furthermore, the fraction of substructure in NZ was reduced, while the fraction of recrystallization was increased during the n-MQL-FSW. The tensile strength was ∼ 81 %, and ∼ 64 % of the BM was observed for n-MQL-FSW and FSW, respectively. The elongation percentage did not show any significant changes during both processes. This study reveals an efficient approach to reducing excess heat input during the FSW process to manufacture high-performance components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118700"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169381","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118692
Zhidong Chang, Wenxuan Peng, Hui Long
Incremental sheet forming (ISF), as a flexible sheet metal forming method, has attracted wide-spreading attention, however the dissatisfied surface quality has limited its adoption for potential industrial applications. There are insufficient studies in assessing the friction condition in ISF and it also lacks accurate methods for determining the coefficient of friction (CoF). Further investigations are required to understand fundamental mechanisms of the effect of friction condition on surface quality in ISF. In this study, it is found that the surface quality of sheet metal parts is considerably improved by rotational-vibration assisted ISF (RV-ISF) process under high-amplitude vibration. The improvement is considered to be attained by several underpinning mechanisms: the friction reduction under vibration, improvement of lubrication condition and increased surface micro-hardness. To investigate these mechanisms, two methods are proposed to evaluate the friction condition at the contact interface between the tool and sheet in ISF. The first method is a new calibration model for an accurate calculation of the CoF in ISF by excluding the effect of the horizontal forming force of the ISF tool. The second method is a novel analytical model in predicting the reduction of CoF under vibration in the RV-ISF. The friction prediction model is validated through experimental results when employing various rotational-vibration tools in processing three different materials. The results show that the forming procedure of “down-milling” is better than “up-milling” for improving the surface quality in RV-ISF. The vibration amplitude has the greatest effect on friction reduction, while other variables including non-vibrating frictional force, contact rigidity coefficient and tool radius also show significant effects on friction reduction. This study presents a significant advancement of friction research in ISF by developing two new friction models, offering new insights and effective methods to improve surface quality and accurately calculate the CoF under vibration effect.
{"title":"Towards understanding the surface friction in rotational-vibration assisted incremental sheet forming","authors":"Zhidong Chang, Wenxuan Peng, Hui Long","doi":"10.1016/j.jmatprotec.2024.118692","DOIUrl":"10.1016/j.jmatprotec.2024.118692","url":null,"abstract":"<div><div>Incremental sheet forming (ISF), as a flexible sheet metal forming method, has attracted wide-spreading attention, however the dissatisfied surface quality has limited its adoption for potential industrial applications. There are insufficient studies in assessing the friction condition in ISF and it also lacks accurate methods for determining the coefficient of friction (CoF). Further investigations are required to understand fundamental mechanisms of the effect of friction condition on surface quality in ISF. In this study, it is found that the surface quality of sheet metal parts is considerably improved by rotational-vibration assisted ISF (RV-ISF) process under high-amplitude vibration. The improvement is considered to be attained by several underpinning mechanisms: the friction reduction under vibration, improvement of lubrication condition and increased surface micro-hardness. To investigate these mechanisms, two methods are proposed to evaluate the friction condition at the contact interface between the tool and sheet in ISF. The first method is a new calibration model for an accurate calculation of the CoF in ISF by excluding the effect of the horizontal forming force of the ISF tool. The second method is a novel analytical model in predicting the reduction of CoF under vibration in the RV-ISF. The friction prediction model is validated through experimental results when employing various rotational-vibration tools in processing three different materials. The results show that the forming procedure of “down-milling” is better than “up-milling” for improving the surface quality in RV-ISF. The vibration amplitude has the greatest effect on friction reduction, while other variables including non-vibrating frictional force, contact rigidity coefficient and tool radius also show significant effects on friction reduction. This study presents a significant advancement of friction research in ISF by developing two new friction models, offering new insights and effective methods to improve surface quality and accurately calculate the CoF under vibration effect.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118692"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169455","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118693
Yuanping Yu , Xiuzhen Zhang , Cong Wang , Jiaqi Hu , Dengshan Zhou , Chao Yang , Deliang Zhang
Solid-state recycling that is devoid of metal melting process represents an energy-effective, environment-friendly and materials-saving way in producing sustainable aluminum (Al) materials from its scraps, and thereby is a promising solution in recycling of Al-based chips. On the recycling of Al-based chips by solid-state route, however, one major concern comes from the presence of prior chip boundaries which are expected to negatively influence the mechanical properties of recycled materials. In the current study, we examined prior chip boundaries in a solid-state recycled AA6063 Al alloy fabricated by extrusion of its machining chips, and found that samples taken from the edge and central regions of the extruded, artificially-aged rod exhibit drastically different oxide-decorated prior chip boundaries. The observed variations in oxide-decorated prior chip boundaries between the two locations are intimately linked to the shear strain encountered during the extrusion process. Adjacent to the edge region, a higher shear strain facilitates the fine dispersion of smaller oxides along the prior chip boundaries that are aligned with the extrusion direction. Conversely, in the central region, a reduced shear strain results in the coarse distribution of larger oxides fragments within the prior chip boundaries. As a result, the samples derived from the edge and central regions display essentially different grain structures, strain hardening effects, and fracture behaviors. Our results demonstrate deformation-controlled oxide-decorated prior chip boundaries in chip-based Al alloys, and their principal influence on recycled materials’ microstructures and tensile properties.
{"title":"The influence of deformation-dependent prior chip boundary on microstructure and tensile properties in a solid-state recycled AA6063 aluminum alloy","authors":"Yuanping Yu , Xiuzhen Zhang , Cong Wang , Jiaqi Hu , Dengshan Zhou , Chao Yang , Deliang Zhang","doi":"10.1016/j.jmatprotec.2024.118693","DOIUrl":"10.1016/j.jmatprotec.2024.118693","url":null,"abstract":"<div><div>Solid-state recycling that is devoid of metal melting process represents an energy-effective, environment-friendly and materials-saving way in producing sustainable aluminum (Al) materials from its scraps, and thereby is a promising solution in recycling of Al-based chips. On the recycling of Al-based chips by solid-state route, however, one major concern comes from the presence of prior chip boundaries which are expected to negatively influence the mechanical properties of recycled materials. In the current study, we examined prior chip boundaries in a solid-state recycled AA6063 Al alloy fabricated by extrusion of its machining chips, and found that samples taken from the edge and central regions of the extruded, artificially-aged rod exhibit drastically different oxide-decorated prior chip boundaries. The observed variations in oxide-decorated prior chip boundaries between the two locations are intimately linked to the shear strain encountered during the extrusion process. Adjacent to the edge region, a higher shear strain facilitates the fine dispersion of smaller oxides along the prior chip boundaries that are aligned with the extrusion direction. Conversely, in the central region, a reduced shear strain results in the coarse distribution of larger oxides fragments within the prior chip boundaries. As a result, the samples derived from the edge and central regions display essentially different grain structures, strain hardening effects, and fracture behaviors. Our results demonstrate deformation-controlled oxide-decorated prior chip boundaries in chip-based Al alloys, and their principal influence on recycled materials’ microstructures and tensile properties.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118693"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169457","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}
Pub Date : 2025-02-01DOI: 10.1016/j.jmatprotec.2024.118707
Guanhong Chen , Xiaowei Wang , Xinyu Yang , Xuqiong Yang , Zhen Zhang , Rongqing Dai , Jiayuan Gu , Tianyu Zhang , Guiyi Wu , Jianming Gong
Laser Beam Powder Bed Fusion (PBF-LB) technology has demonstrated the capability to print products with unique properties by precisely controlling texture. However, understanding the mechanisms governing texture evolution and developing efficient control strategies remain significant challenges, particularly in inter-track texture control. This study addresses these gaps by proposing a novel simulation approach that integrates finite element modeling to track temperature changes and phase field modeling to simulate texture evolution. Through simulation, the inter-track remelting mechanism was revealed, fundamentally explaining texture evolution in PBF-LB and providing a new strategy for precise texture control. The results demonstrated that hatch distance, closely linked to the inter-track overlap ratio and texture type, is the most effective parameter for tailoring texture, unlocking new potential for inter-track texture modulation. This study marks the first use of phase field simulation to guide texture control in PBF-LB, offering a transformative understanding of texture evolution mechanisms. By validating the predictive capability and reliability of the developed simulation approach through experiments, this work provides a robust framework for optimizing texture control in additive manufacturing.
{"title":"An integrated simulation approach for directing the texture control of austenitic stainless steel through laser beam powder bed fusion","authors":"Guanhong Chen , Xiaowei Wang , Xinyu Yang , Xuqiong Yang , Zhen Zhang , Rongqing Dai , Jiayuan Gu , Tianyu Zhang , Guiyi Wu , Jianming Gong","doi":"10.1016/j.jmatprotec.2024.118707","DOIUrl":"10.1016/j.jmatprotec.2024.118707","url":null,"abstract":"<div><div>Laser Beam Powder Bed Fusion (PBF-LB) technology has demonstrated the capability to print products with unique properties by precisely controlling texture. However, understanding the mechanisms governing texture evolution and developing efficient control strategies remain significant challenges, particularly in inter-track texture control. This study addresses these gaps by proposing a novel simulation approach that integrates finite element modeling to track temperature changes and phase field modeling to simulate texture evolution. Through simulation, the inter-track remelting mechanism was revealed, fundamentally explaining texture evolution in PBF-LB and providing a new strategy for precise texture control. The results demonstrated that hatch distance, closely linked to the inter-track overlap ratio and texture type, is the most effective parameter for tailoring texture, unlocking new potential for inter-track texture modulation. This study marks the first use of phase field simulation to guide texture control in PBF-LB, offering a transformative understanding of texture evolution mechanisms. By validating the predictive capability and reliability of the developed simulation approach through experiments, this work provides a robust framework for optimizing texture control in additive manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118707"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168492","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}
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