Journal of Materials Processing Technology最新文献_第6页

Numerical and experimental study on spatter formation mechanisms and suppression method during ultra-high power laser-arc hybrid welding 超高功率激光-电弧复合焊接溅射形成机理及抑制方法的数值与实验研究

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-13 DOI: 10.1016/j.jmatprotec.2025.119151

Yan Li , Shaoning Geng , Yilin Wang , Chu Han , Shaoyun Song , Bangyan Xu

Ultra-high power laser-arc hybrid welding (UH-LAHW, laser power ≥20 kW) provides an effective method for joining thick-walled components. However, under ultra-high power laser irradiation, intense keyhole-molten pool fluctuations lead to spatter formation, which remains a critical challenge hindering the industrial application of UH-LAHW. This study systematically investigates spatter formation and suppression mechanisms in UH-LAHW through combined experimental and simulation approaches. The intrinsic relationships among keyhole wall protrusion dynamics, molten pool oscillations, and spatter formation were analyzed. Results indicate that front keyhole wall (FKW) protrusions exhibit two distinct motion modes under laser irradiation: “melt-evaporation-displacement” and “melt-evaporation-evaporation”. The former is identified as the dominant mechanism driving rapid upward movement of liquid columns and spatter formation. Regulating the laser-to-arc energy ratio threshold (E_L:A= 2.2:1–1.8:1) can reduce FKW protrusion volume, expand the keyhole opening, and decrease liquid column ejection height. This process culminated in the effective suppression of spatter at the optimal welding condition (E_L:A = 2.0:1). This study presents an effective approach for spatter suppression and provides a theoretical foundation and data support for industrial application of UH-LAHW technology.

超高功率激光-电弧复合焊接（UH-LAHW，激光功率≥20 kW）为厚壁构件的焊接提供了一种有效的方法。然而，在超高功率激光照射下，强烈的锁孔-熔池波动导致飞溅形成，这仍然是阻碍UH-LAHW工业应用的关键挑战。本研究采用实验和模拟相结合的方法，系统地研究了UH-LAHW中飞溅的形成和抑制机制。分析了锁孔壁突出动力学、熔池振荡和飞溅形成之间的内在关系。结果表明：激光照射下，前锁孔壁突出物呈现“熔融-蒸发-位移”和“熔融-蒸发-蒸发”两种不同的运动模式。前者被认为是驱动液柱快速向上运动和飞溅形成的主要机制。调节激光-电弧能量比阈值（EL:A= 2.2:1-1.8:1）可以减小FKW突出体积，扩大锁孔开度，降低液柱喷射高度。该过程最终在最佳焊接条件下（EL:A = 2.0:1）有效地抑制了飞溅。该研究提出了有效的飞溅抑制方法，为UH-LAHW技术的工业应用提供了理论基础和数据支持。

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引用次数: 0

High-power laser-arc hybrid additive manufacturing of aluminum alloys: Resolving the conflict between forming precision and keyhole-induced porosity via beam oscillation 大功率激光-电弧复合增材制造铝合金：利用光束振荡解决成形精度与锁孔诱导孔隙率之间的冲突

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119146

Heziqi Liu , Lianyong Xu , Kangda Hao , Yongdian Han , Lei Zhao , Wenjing Ren

In laser-arc hybrid additive manufacturing (LAHAM), the high-power laser required for precise forming often leads to unstable keyhole behavior and severe keyhole-induced porosity, which compromise mechanical properties. In this study, laser beam oscillation was employed to address this contradiction. It was found that laser beam oscillation could distribute the laser energy over a larger area, reducing the average power density below the critical threshold for keyhole formation. Under high-power laser processing (laser power of 3 kW), optimizing the oscillation parameters decreased the keyhole-induced porosity from 16.3 % under the non-oscillating condition to 0.3 %, and restored the elongation from 2.2 % to 17.4 %. Moreover, the high-power laser with beam oscillation preserved the precision-forming benefits. The highly ionized plasma generated by the laser provided a low-resistance channel for the arc current, which attracted and compressed the arc. The resulting electromagnetic forces guided the droplets along a more controlled transfer path, and together with the stabilized molten pool behavior, enabled superior forming accuracy. Compared with the low-power (laser power of 1 kW) samples, the surface roughness was reduced by 68.2 %, and the material utilization increased by 29.4 %. In addition, the high-power oscillating laser promoted molten flow to disrupt dendrites, facilitated rapid crystallization, and reduced local temperature gradients, thereby breaking the directional growth of columnar grains. The resulting refined, random-oriented multimodal grain structure significantly reduced mechanical anisotropy. This work provides a feasible technical pathway and a valuable reference for achieving high-quality additive manufacturing of aluminum and other challenging materials.

在激光-电弧混合增材制造（LAHAM）中，精确成形所需的高功率激光通常会导致锁孔行为不稳定和严重的锁孔诱导孔隙率，从而影响机械性能。在本研究中，激光束振荡被用来解决这一矛盾。研究发现，激光束振荡可以使激光能量分布在更大的区域，使平均功率密度降低到形成锁孔的临界阈值以下。在高功率激光加工（激光功率为3 kW）条件下，优化振荡参数后，锁孔诱导孔隙率从非振荡条件下的16.3 %降低到0.3 %，延伸率从2.2 %恢复到17.4 %。同时，高功率激光在光束振荡下保持了高精度成形的优势。激光产生的高电离等离子体为电弧电流提供了低阻通道，吸引并压缩了电弧。由此产生的电磁力引导液滴沿着更受控制的传递路径，并与稳定的熔池行为一起，实现了卓越的成形精度。与低功率（激光功率为1 kW）样品相比，表面粗糙度降低了68.2% %，材料利用率提高了29.4% %。此外，高功率振荡激光促进熔融流动破坏枝晶，促进快速结晶，降低局部温度梯度，从而破坏柱状晶粒的定向生长。由此产生的精细化、随机定向的多模态晶粒结构显著降低了力学各向异性。为实现铝等具有挑战性材料的高质量增材制造提供了可行的技术途径和有价值的参考。

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引用次数: 0

Optimizing L-DED repair of arc-shaped grooves via defocus control: Thermodynamic modeling and aspect ratio-defocus distance matching mechanism 圆弧形沟槽离焦控制优化L-DED修复：热力学建模与纵横比-离焦距离匹配机制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119147

Xianzhi Jin , Lei Wang , Zelin Zhang , Yuyao Guo , Xuhui Xia

Laser Directed Energy Deposition (L-DED) has been widely employed in the repair of core components such as rolls, turbine blades, and bearings. However, when L-DED is directly applied to defect areas, geometric irregularities on the surface can lead to random and uneven distribution of laser energy, resulting in fluctuations in repair layer hardness, poor adhesion, and even secondary failures. Pre-machining suitably arc-shaped grooves in the defect areas and matching them with appropriate defocus parameters can regulate the laser energy distribution, serving as a key technical approach to enhance the stability of repair layer hardness and bonding quality. This study innovatively couples laser propagation, powder flow, and groove structure to establish a thermal-fluid-solid coupling model applicable to curved surfaces, quantifying the effects of positive/negative defocus modes on the powder flow field and heat transfer process in the molten pool. Furthermore, it reveals the influence mechanism of negative defocus on the temperature evolution of the molten pool in arc grooves and the deposition quality, establishing a quantitative matching relationship between arc grooves with different width-to-height ratio (D) and defocus distance (H). The results indicate that when the D = 2, the optimal H is −30 mm; when D = 2.5, it is −65 mm; and when D = 3 and 4, it is −85 mm. Through multi-physics simulations and experimental validation, it is demonstrated that the matching relationship between the D and the H of the arc groove can achieve a defect-free bonding interface after repair and stabilize the microhardness at 480–520 HV. This study provides a theoretical basis and process guidance for the L-DED repair of curved components, promoting the advancement of L-DED technology from planar/simple groove repairs to complex curved surface repairs.

激光定向能沉积技术（L-DED）已广泛应用于轧辊、涡轮叶片和轴承等核心部件的修复。然而，当L-DED直接应用于缺陷区域时，表面的几何不规则性会导致激光能量的随机和不均匀分布，导致修复层硬度波动，附着力差，甚至二次失效。在缺陷区域预加工合适的弧形凹槽，并与之匹配合适的离焦参数，可以调节激光能量分布，是提高修复层硬度稳定性和粘接质量的关键技术途径。本研究创新性地将激光传播、粉末流动和凹槽结构耦合在一起，建立了适用于曲面的热流固耦合模型，量化了正/负离焦模式对熔池中粉末流场和换热过程的影响。揭示了负离焦对电弧槽内熔池温度演变及沉积质量的影响机理，建立了不同宽高比(D)的电弧槽与离焦距离(H)之间的定量匹配关系。结果表明：当D = 2时，最佳H为−30 mm；当D = 2.5时，为- 65 mm；当D = 3和4时，为- 85 mm。通过多物理场模拟和实验验证，证明了电弧槽D与H的匹配关系可以实现修复后的无缺陷粘接界面，并将显微硬度稳定在480 ~ 520 HV。本研究为曲面零件的L-DED修复提供了理论依据和工艺指导，促进了L-DED技术从平面/简单凹槽修复向复杂曲面修复的发展。

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引用次数: 0

Effects of laser energy uniformization via static beam shaping on ablation behavior and mechanism of SiCf/SiC composites 静态光束整形激光能量均匀化对SiCf/SiC复合材料烧蚀行为及机理的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119149

Xintong Cai, Xin Qin, Jinbo Niu, Renke Kang, Zhigang Dong, Yan Bao, Guangyi Ma, Fangyong Niu

Laser assisted machining (LAM) is an effective method to solve difficult machining problem of Ceramic Matrix Composites (CMC), which includes laser pretreatment and subsequent mechanical machining. However, the commonly used Gaussian beam in pretreatment causes uneven evolution of material removal, thereby affecting machining process. To achieve a uniform machining effect, static beam shaping was used to study influence of energy uniformization on interaction between laser and SiC_f/SiC in this paper, and ablation mechanism of circular Gaussian and rectangular uniform laser and growth mechanism of new SiC were explored. Under laser irradiation, CMC exists in two states: oxidation-modified and ablative-removal. In oxidation-modified state, there is transition zone with increased width at oxide layer edge under Gaussian laser, and subsurface crack propagation area is arc-shaped. Uniform laser generates oxide layer with relatively narrower edge transition zone and with uniform width, reducing crack region width and maintaining consistent distribution depth. In ablative-removal state, Gaussian laser forms semi-circular ablation grooves, recast layers and heat affected zones, and generates longitudinal extending cracks. Uniform laser forms flat-bottomed characteristic area. Cracks are suppressed and damage layer depth is reduced by 51.9 %. Under two beams, new 3C-SiC with face-centered cubic (FCC) structure and semi-coherent interface is generated in Si-rich phase. SiC is subjected to along heat dissipation and coarsen into columnar crystals. Uniform thermal expansion constraint forms SiC twin crystal under uniform laser. Therefore, uniform ablation effects of CMC can be obtained through beam shaping, and the results are expected to be applied in laser pretreatment of LAM.

激光辅助加工是解决陶瓷基复合材料加工难题的有效方法，包括激光预处理和后续机械加工。然而，预处理中常用的高斯光束导致材料去除演化不均匀，从而影响加工过程。为了获得均匀的加工效果，本文采用静态光束整形的方法研究了能量均匀化对激光与SiCf/SiC相互作用的影响，探讨了圆形高斯和矩形均匀激光的烧蚀机理和新型SiC的生长机理。在激光照射下，CMC以氧化改性和烧蚀去除两种状态存在。在氧化修饰态下，高斯激光作用下氧化层边缘存在宽度增大的过渡区，亚表面裂纹扩展区呈弧形；均匀激光产生的氧化层边缘过渡区相对较窄，宽度均匀，减小了裂纹区域宽度，保持了一致的分布深度。在烧蚀去除状态下，高斯激光形成半圆形烧蚀槽、重铸层和热影响区，并产生纵向延伸裂纹。均匀激光形成平底特征区。裂纹得到抑制，损伤层深度减少51.9 %。在两束作用下，富si相生成了具有面心立方（FCC）结构和半相干界面的新型3C-SiC。碳化硅受到沿热耗散和粗化成柱状晶体。均匀激光下均匀热膨胀约束形成碳化硅双晶。因此，通过光束整形可以获得CMC均匀的烧蚀效果，其结果有望应用于LAM的激光预处理。

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引用次数: 0

Magnetic-assisted laser shock peening of WE43 magnesium alloys with real-time imaging of plasma dynamics and acoustic emission monitoring WE43镁合金磁辅助激光冲击强化等离子体动力学实时成像及声发射监测

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119148

Hongbiao Hu , Zongshen Wang , Zhenshan Guo , Yongling Wu , Hongyu Zheng

Laser shock peening (LSP) is an effective technique for enhancing the mechanical performance of magnesium alloys, however, its efficiency is often constrained by low laser energy coupling and the inherently low plasticity of the material. This study proposes a novel magnetic-assisted LSP (MLSP) strategy that incorporates static magnetic fields and real-time monitoring, including acoustic emission (AE) detection and intensified charge-coupled device (ICCD) plasma imaging. Numerical simulations of magnetic field intensity and plasma dynamics are conducted to clarify the MLSP process mechanism. The synergistic effects of plasma intensification and magnetoplastic dislocation unpinning enhance shock wave intensity and deepen the residual stress layer through the coupling of mechanical force, magnetic field, and material. The results show that applying a 0.8 T magnetic field markedly improves plasma confinement and energy density, reducing the longitudinal propagation distance to 3.7 mm—57.5 % shorter than without the magnetic field. Compared with the conventional LSP process, the MLSP process increases yield strength by 8.3 % and tensile strength by 6.5 % while maintaining excellent ductility. At the same time, MLSP markedly improves the compressive residual stress (CRS), achieving a peak value of −194.1 MPa (a 14.0 % increase), extends the CRS-affected layer depth to 776.3 μm (a 10.1 % increase), and raises surface hardness by 23.3 %. In addition, MLSP induces pronounced microstructural evolution, including surface grain refinement to 34.5 μm—a 14.4 % reduction compared with LSP samples—together with increased dislocation entanglement and a higher density of nano-precipitates.

激光冲击强化是提高镁合金力学性能的一种有效技术，但其效率往往受到低激光能量耦合和材料本身低塑性的限制。本研究提出了一种新的磁辅助LSP （MLSP）策略，该策略结合了静态磁场和实时监测，包括声发射（AE）检测和强化电荷耦合器件（ICCD）等离子成像。通过磁场强度和等离子体动力学的数值模拟，阐明了MLSP过程的机理。等离子体强化和磁塑性位错解钉的协同效应通过机械力、磁场和材料的耦合增强了激波强度，加深了残余应力层。结果表明，施加0.8 T磁场显著改善等离子体约束和能量密度，使纵向传播距离比无磁场时缩短3.7 mm-57.5 %。与传统LSP工艺相比，MLSP工艺在保持良好延展性的同时，屈服强度提高了8.3 %，拉伸强度提高了6.5 %。同时，MLSP显著提高了材料的压缩残余应力（CRS），峰值达到- 194.1 MPa（增加14.0 %），CRS影响层深度扩展到776.3 μm（增加10.1 %），表面硬度提高23.3% %。此外，MLSP诱导了明显的微观结构演变，包括表面晶粒细化到34.5 μm，与LSP样品相比降低了14.4 %，同时位错纠缠增加，纳米沉淀密度更高。

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引用次数: 0

Atomistic insights into ultrafast phase transitions driving nanoparticle formation in femtosecond laser–irradiated nickel-based superalloys 飞秒激光辐照镍基高温合金中驱动纳米颗粒形成的超快相变的原子观察

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-10 DOI: 10.1016/j.jmatprotec.2025.119145

Zhicheng Chen , Jingya Sun , Gen Lin , Ziqi Ding , Yang Ding , Lan Jiang

Femtosecond laser machining of specialty alloys has evolved into a high-precision, low-damage technology with extensive applications in micro- and nano-scale fabrication. However, the lack of atomic-scale underlying mechanisms significantly hinders the efficiency of process optimization. This study investigated the electron dynamics and ultrafast phase transitions of nickel-based superalloys at the atomic level using pump–probe microscopy and molecular dynamics coupled with the two-temperature model (MD-TTM). Within the first 2 ps, electron excitation and scattering increased the transient differential reflectivity (TR). Beyond this timescale, the onset of mechanical relaxation and phase transitions in lattice system decreased the TR. Spatiotemporal analysis of TR micrographs identified thresholds for spallation and phase explosion and confirmed the coexistence of these two-phase transition mechanisms. The experimental observations were further demonstrated by atomic-scale insights from MD-TTM simulations, which capture the evolution of electron–lattice energy transfer, lattice density variations and, material ejection dynamics. Based on the identified mechanisms, the morphology of both the ejected materials and the processed surface can be tuned by precisely adjusting the laser fluence. This study offers fundamental insights into the complex ultrafast processes governing femtosecond laser–alloy interactions and establishes a theoretical foundation for material ejection and surface morphology regulation, enabling high-precision micro/nanostructure fabrication.

飞秒激光加工特种合金已发展成为一种高精度、低损伤的加工技术，在微纳米加工中有着广泛的应用。然而，缺乏原子尺度的潜在机制严重阻碍了工艺优化的效率。本研究利用泵探针显微镜和分子动力学结合双温模型（MD-TTM）在原子水平上研究了镍基高温合金的电子动力学和超快相变。在前2 ps内，电子激发和散射增加了瞬态微分反射率（TR）。在此时间尺度之外，晶格系统中机械松弛和相变的开始降低了TR。TR显微图的时空分析确定了碎裂和相爆炸的阈值，并证实了这两种相变机制的共存。MD-TTM模拟的原子尺度见解进一步证明了实验观察结果，该模拟捕获了电子-晶格能量转移、晶格密度变化和物质弹射动力学的演变。在确定机理的基础上，可以通过精确调节激光辐照量来调整射出材料和加工表面的形貌。该研究为控制飞秒激光与合金相互作用的复杂超快过程提供了基本见解，并为材料喷射和表面形貌调节奠定了理论基础，从而实现高精度微/纳米结构的制造。

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引用次数: 0

Chemomechanical synergy in cobalt polishing: Non-destructive removal via atomic force microscopy at atomic levels 钴抛光中的化学机械协同作用：通过原子力显微镜在原子水平上的非破坏性去除

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-07 DOI: 10.1016/j.jmatprotec.2025.119144

Fangjin Xie, Min Zhong, Xiaobing Li, Meirong Yi, Jianfeng Chen, Wenhu Xu

With the advancement of integrated circuit (IC) technology, cobalt (Co) has garnered significant attention as a promising interconnect metal. However, challenges persist in its application to chemical mechanical polishing (CMP). This study investigated the chemomechanical synergy between liquid environments and oxidizers on Co surfaces using atomic force microscopy (AFM). Three environments, including deionized (DI) water, anhydrous ethanol, and air, were employed, along with three common oxidizers (H₂O₂, K₂S₂O₈, and KIO₄). Results demonstrate that DI water substantially enhances the chemomechanical synergistic effect, particularly under high downforce conditions, where both scratch depth and width significantly increase. In contrast, air and anhydrous ethanol environments predominantly rely on mechanical action, yielding weaker material removal. Among the oxidizers, KIO₄ exhibits the strongest oxidative capability. It generates a dense oxide layer that optimizes chemomechanical synergy, improves scratch efficiency, and enables non-destructive material removal. Conversely, H₂O₂ and K₂S₂O₈ inhibit scratch effectiveness due to inhomogeneous oxide layer formation. Multiscale characterization reveals the influence of oxidizers on the chemical composition, microstructural morphology, and distribution characteristics of oxide layers on Co surface. This study provides theoretical foundations for optimizing Co CMP processes.

随着集成电路（IC）技术的进步，钴（Co）作为一种有前途的互连金属受到了广泛的关注。然而，它在化学机械抛光（CMP）中的应用仍然存在挑战。本研究利用原子力显微镜（AFM）研究了液体环境和氧化剂对Co表面的化学-力学协同作用。使用了三种环境，包括去离子水、无水乙醇和空气，以及三种常见的氧化剂（H2O2、K2S2O8和KIO4）。结果表明，DI水显著增强了化学力学协同效应，特别是在高下压力条件下，划痕深度和宽度都显著增加。相比之下，空气和无水乙醇环境主要依靠机械作用，产生较弱的材料去除。其中，KIO4的氧化能力最强。它产生致密的氧化层，优化化学机械协同作用，提高划痕效率，并实现非破坏性材料去除。相反，H2O2和K2S2O8由于形成不均匀的氧化层而抑制了划痕效果。多尺度表征揭示了氧化剂对Co表面氧化层的化学组成、微观结构形态和分布特征的影响。本研究为优化Co CMP工艺提供了理论基础。

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引用次数: 0

Synergistic enhancement of strength-toughness of TiAl/Ti₂AlNb diffusion bonding joint via high-energy electropulsing treatment 高能电脉冲处理对TiAl/Ti₂AlNb扩散连接接头强度-韧性的协同增强

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-07 DOI: 10.1016/j.jmatprotec.2025.119141

Yu Peng , Lei Zhu , Li Feng , Yifan Zhang , Zhengxin Feng , Juntao Zou , Beibei Wei , Kaidi Li , Bin Tang , Jinshan Li

The new-generation turbine structure, using TiAl alloy for blades and Ti₂AlNb alloy for the disk significantly enhances the thrust-to-weight ratio and efficiency of aero-engines. The turbine blades are often attached to the disk using advanced welding technologies. However, brittle intermetallic compounds (IMCs) and residual stresses tend to form after welding, impairing the performance of TiAl/Ti₂AlNb joints. In this study, the high-energy electropulsing treatment (HEEPT) was introduced to optimise the interfacial microstructures and properties, of TiAl/Ti₂AlNb joints, substantially improving the efficiency of post-bonding heat treatment. The observed average tensile strength and elongation of TiAl/Ti₂AlNb joints reached 470.93 MPa and 0.353 %, respectively, after 1 min of HEEPT, representing increases of 41.3 % in tensile strength and 99.4 % in elongation compared with those of the joints formed via diffusion bonding (DB). This enhancement is mainly attributed to the combined effects of the thermal and electron wind effects of HEEPT, which prevent the formation of continuous brittle IMCs of AlNb₂ at the bonding interface. Additionally, the interfacial β₀/B2 phase and equiaxed α₂ phase form a soft and hard combination configuration, producing anisotropic strengthening due to deformation-induced stress. Notably, HEEPT induces the precipitation of nanoscale acicular α₂ from equiaxed α phase. Additionally, HEEPT promotes the uniform arrangement of nanoscale acicular ω from β₀/B2 phase at the bonding interface, thereby achieving a synergistic enhancement of strength and toughness. This efficient HEEPT provides a novel strategy to strengthen other dissimilar weld joints and offers a sustainable alternative to traditional heat treatment.

采用TiAl合金做叶片，Ti2AlNb合金做盘的新一代涡轮结构显著提高了航空发动机的推重比和效率。涡轮叶片通常使用先进的焊接技术连接到磁盘上。然而，焊接后易形成脆性金属间化合物（IMCs）和残余应力，影响TiAl/Ti2AlNb接头的性能。在本研究中，采用高能电脉冲处理（HEEPT）优化TiAl/Ti2AlNb接头的界面组织和性能，大大提高了键后热处理的效率。经1 min HEEPT处理后，TiAl/Ti2AlNb接头的平均抗拉强度和伸长率分别达到470.93 MPa和0.353 %，与扩散连接（DB）形成的接头相比，拉伸强度和伸长率分别提高了41.3 %和99.4 %。这种增强主要是由于HEEPT的热风效应和电子风效应的共同作用，阻止了AlNb 2在键合界面处形成连续的脆性imc。界面β0/B2相与等轴α2相形成软硬结合形态，变形诱发应力作用产生各向异性强化。值得注意的是，HEEPT诱导等轴α相析出纳米针状α2。此外，HEEPT促进了β0/B2相在键合界面上的纳米级针状ω的均匀排列，从而实现了强度和韧性的协同增强。这种高效的HEEPT提供了一种新的策略来加强其他不同的焊接接头，并提供了传统热处理的可持续替代方案。

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引用次数: 0

Heat input regulation for geometric and property control in directed energy deposition with dense scan path strategy 基于密集扫描路径的定向能沉积几何和性能控制的热输入调节

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-07 DOI: 10.1016/j.jmatprotec.2025.119138

Zhiyu Ye , Binghua Lv , Rui Li , Mingzhi Chen , Zhandong Wang , Guifang Sun , En-Hou Han

A fundamental challenge in manufacturing high-performance components using directed energy deposition (DED) is the effective management of heat accumulation when processing complex geometries with a high infill density zigzag scanning strategy. This study reveals an inherent conflict between local and global thermal effects that unresolved by constant power strategies: high power intensifies local melt pool instability at path turning points, whereas low power causes more severe global heat accumulation and sacrifices forming accuracy due to an increased layer count. The study establishes a dual heat-affected zone (HAZ) gradient evolution model at the DED-HIP interface, and reveals the embrittlement risk of the dissolution heat-affected zone (D-HAZ) under high heat input and the softening mechanism of the over-aged HAZ (OA-HAZ). Therefore, this study proposes a power closed-loop control (PCLC) strategy based on real-time melt pool width monitoring to achieve active thermal management. It is revealed that the PCLC technology, by precisely suppressing local overheating in the zigzag scanning path, achieves a synergistic optimization of morphology, accuracy, and microstructure, with significantly enhanced mechanical properties (elongation reached 21.15 %, and tensile strength reached 1189 MPa, achieving 95.8 % that of the substrate). This research provides crucial theoretical guidance and technical support for the additive manufacturing of high-performance components requiring customized microstructures and precise geometric control, such as aero-engine integral blisks.

使用定向能沉积（DED）技术制造高性能部件的一个基本挑战是，在使用高填充密度之字形扫描策略处理复杂几何形状时，如何有效地管理热积累。该研究揭示了局部和全局热效应之间的内在冲突，而恒定功率策略无法解决：高功率加剧了路径转折点的局部熔池不稳定性，而低功率导致更严重的全局热积累，并由于层数增加而牺牲成型精度。建立了d - hip界面双热影响区（HAZ）梯度演化模型，揭示了高热输入下溶出热影响区（D-HAZ）的脆化风险和过时效热影响区（OA-HAZ）的软化机理。因此，本研究提出了一种基于实时熔池宽度监测的功率闭环控制（PCLC）策略，以实现主动热管理。结果表明，PCLC技术通过精确抑制之字形扫描路径中的局部过热，实现了形貌、精度和微观结构的协同优化，力学性能显著提高（伸长率达到21.15 %，抗拉强度达到1189 MPa，达到基体的95.8% %）。该研究为航空发动机整体式叶盘等需要定制微结构和精确几何控制的高性能部件的增材制造提供了重要的理论指导和技术支持。

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引用次数: 0

Photocatalytic-assisted electrochemical drilling for passivation suppression in high-volume-fraction SiCp/Al composites 高体积分数SiCp/Al复合材料的光催化辅助电化学钻孔钝化抑制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-11-07 DOI: 10.1016/j.jmatprotec.2025.119140

Jing Zhou , Long Cheng , Lijie Jiang , Xiaoka Wang , Feng Wang , Xiaoming Kang

High-volume-fraction silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al) are widely used in integrated circuit applications due to their superior thermal and mechanical properties. However, the heterogeneous materials lead to localized passivation during electrochemical drilling, resulting in uneven dissolution and poor hole-profile accuracy. This study introduces a photocatalytic-assisted electrochemical drilling (PAECD) method for suppressing passivation, enhancing dissolution uniformity, and promoting the drilling process. Comprehensive investigations were conducted, including surface characterization analysis, polarization analysis and dissolution behavior assessment of this approach. The PAECD experiments were conducted under different voltages and feeding displacements, followed by through-hole drilling experiments to evaluate the applicability of the method in advanced machining of SiCp/Al composites. Experimental results reveal that photocatalyst addition enables more homogeneous dissolution by reducing oxide formation, suppressing passivation, and lowering the dissolution barrier. The PAECD process achieves a higher material removal rate and depth-to-diameter ratio. Consequently, the entrance overcut is minimized, the electrochemical reactions are effectively synchronized with the feeding motion, and the tool wear is significantly reduced. Furthermore, residual SiC particles at hole entrances are markedly diminished, local passivation is effectively suppressed, and vertical electrolyte circulation is enhanced. Compared with conventional electrochemical drilling, the PAECD process achieves a 27.63 % reduction in side clearance and an 8.33 % reduction in taper angle, yielding a smoother profile and more precise hole profiles of high-volume-fraction SiCp/Al composites.

高体积分数碳化硅颗粒增强铝基复合材料（SiCp/Al）因其优异的热学和力学性能而广泛应用于集成电路领域。然而，非均相材料在电化学钻孔过程中会导致局部钝化，导致溶解不均匀，孔轮廓精度较差。本研究介绍了一种光催化辅助电化学钻孔（PAECD）方法，以抑制钝化，提高溶解均匀性，促进钻孔过程。对该方法进行了表面表征分析、极化分析和溶解行为评价。在不同电压和进给位移下进行了PAECD实验，然后进行了通孔钻孔实验，以评估该方法在SiCp/Al复合材料高级加工中的适用性。实验结果表明，光催化剂的加入通过减少氧化物的形成、抑制钝化和降低溶解势垒使溶解更加均匀。PAECD工艺实现了更高的材料去除率和深径比。因此，最大限度地减少了进口过切，电化学反应有效地与进给运动同步，并显着降低了刀具磨损。同时，显著减少了孔入口处的残余SiC颗粒，有效抑制了局部钝化，增强了垂直电解质循环。与传统的电化学钻井相比，PAECD工艺的侧隙减小了27.63 %，锥度减小了8.33 %，从而获得了更光滑、更精确的高体积分数SiCp/Al复合材料孔廓。

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引用次数: 0