Journal of Materials Processing Technology最新文献_第7页

Refill friction stir spot welding of high-strength aluminium alloys: Linking hook formation and calculated heat input to microstructure and mechanical properties 高强度铝合金的再填充搅拌摩擦点焊：连接钩的形成和计算的热量输入对微观结构和机械性能的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-09 DOI: 10.1016/j.jmatprotec.2025.119180

Sebastian Fritsche , Jonathan Draper , Ricardo Henrique Buzolin , Ryan Maxwell , Athanasios Toumpis , Alexander Galloway , Sergio T. Amancio-Filho

Refill Friction Stir Spot Welding is a promising technique for joining lightweight aluminium alloys such as AA7075-T6. However, hook defects—microstructural discontinuities at the weld interface—can significantly compromise joint integrity. Additionally, variations in heat input during welding influence microstructure evolution and mechanical properties. This study investigates the influence of process parameters and the hook defect on the quasi-static performance of AA7075-T6 RFSSW joints. Joints with various parameter combinations were analysed using optical microscopy, electron backscatter diffraction, tensile lap shear testing, and microhardness mapping, alongside thermocouple measurements of process temperatures. A semi-quantitative heat input model was developed to provide new insights into thermal characteristics and their effects on microstructural evolution. The obtained results show a decrease in ultimate lap shear force for high upward or downward-directed hooks. A welding time of 4 s and rotational speed of 2200 rpm resulted in optimal joint performance, achieving an ultimate lap shear force of 12.2 kN and sufficient heat input to prevent refill defects. Extended welding durations led to overheating and additional defects in the stir zone, while low welding time or rotational speed significantly influenced welding temperatures, heat input, and microstructural characteristics at the shoulder plunge path periphery. The findings emphasise the critical role of dynamic recrystallisation in the resulting microstructures and their impact on mechanical performance. Fatigue strength of the optimised joints exceeds RFSSW joints reported in the literature, underscoring the effectiveness of the selected process parameters in enhancing joint durability. Furthermore, the established semi-quantitative heat input model links energy partitioning to defect formation and microhardness of the joints. This provides new insights into the RFSSW process and enables knowledge transfer to other RFSSW applications.

再填充搅拌摩擦点焊是一种很有前途的连接轻质铝合金（如AA7075-T6）的技术。然而，钩状缺陷——焊接界面的微观组织不连续——会严重损害接头的完整性。此外，焊接过程中热量输入的变化会影响微观组织的演变和力学性能。研究了工艺参数和挂钩缺陷对AA7075-T6 RFSSW接头准静态性能的影响。使用光学显微镜、电子背散射衍射、拉伸搭接剪切测试和显微硬度图以及热电偶测量工艺温度对不同参数组合的接头进行了分析。建立了半定量的热输入模型，为热特性及其对微观组织演化的影响提供了新的见解。结果表明，高向上或向下导向的吊钩的极限搭接剪力减小。焊接时间为4 s，转速为2200 rpm，接头性能最佳，最终接合力为12.2 kN，热量输入充足，可防止再填充缺陷。延长的焊接时间会导致搅拌区过热和额外的缺陷，而较低的焊接时间或转速会显著影响焊接温度、热输入和肩部插入路径周边的显微组织特征。研究结果强调了动态再结晶在产生的微观结构及其对机械性能的影响中的关键作用。优化后的接头的疲劳强度超过了文献报道的RFSSW接头，强调了所选工艺参数在提高接头耐久性方面的有效性。建立的半定量热输入模型将能量分配与缺陷形成和接头显微硬度联系起来。这为RFSSW流程提供了新的见解，并使知识能够转移到其他RFSSW应用程序中。

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引用次数: 0

Regulation of PBF-LB/M melt pool oscillation behavior via beam shaping: A study based on time-frequency characteristics of coaxial radiation signals 光束整形对PBF-LB/M熔池振荡行为的调节：基于同轴辐射信号时频特性的研究

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-09 DOI: 10.1016/j.jmatprotec.2025.119181

Tao Zhu , Xiangjun Xiang , Qiang Gong , Jiaxing Wen , Lai Wei , Tian Huang , Hongkai Jin , Changqiu Chen , Huabin He , Kaihua Sun , Xianfeng Shen , Shuke Huang

Melt pool instability remains a critical barrier to the reliability of Powder Bed Fusion by Laser Beam Melting (PBF-LB/M). While beam shaping is a promising regulatory strategy, the underlying dynamic mechanisms governing its stabilizing effect are not yet fully resolved. By integrating in-situ radiation monitoring with multiphysics simulations on HR-2 austenitic stainless steel, this work systematically elucidates the intrinsic mechanism through which a flat-top beam mitigate melt pool oscillation. The research reveals that the uniform energy distribution of the flat-top beam fundamentally suppresses the steep temperature gradients within the melt pool and the consequent Marangoni convection, thereby significantly enhancing hydrodynamic stability. This stability was validated across multiple dimensions. Within a wide processing window (power 170–450 W, speed 500–1200 mm/s), the use of a flat-top beam, compared to a Gaussian beam, reduced the peak melt pool temperature by an average of 500°C and decreased the maximum fluid velocity by approximately 50 %. Crucially, this profound stabilization of the internal thermo-fluid dynamics is directly reflected in the time-frequency analysis of the real-time photodiode signal, which captures the thermal radiation emitted from the melt pool. The flat-top beam effectively filters out high-frequency (>1 kHz) spectral energy by over 80 %, transforming the melt pool dynamics from a stochastic, high-frequency oscillatory state driven by intense convection to a predictable, low-frequency dominant regime. Ultimately, this study establishes and verifies a cascading physical mechanism: energy homogenization leads to the mitigation of temperature gradients and peak temperatures, which in turn suppresses Marangoni flow velocity and results in a transition of melt pool oscillations from high-frequency, erratic fluctuations to low-frequency, periodic ones. This work provides a critical theoretical basis and a frequency-domain diagnostic tool for leveraging beam shaping to achieve high-stability PBF-LB/M additive manufacturing.

熔池不稳定性是影响激光熔化粉末床熔合可靠性的一个重要因素。虽然束整形是一种很有前途的调节策略，但控制其稳定效果的潜在动力机制尚未完全解决。通过将现场辐射监测与HR-2奥氏体不锈钢的多物理场模拟相结合，系统地阐明了平顶梁缓解熔池振荡的内在机制。研究表明，平顶梁的均匀能量分布从根本上抑制了熔池内陡峭的温度梯度和由此产生的Marangoni对流，从而显著提高了流体动力稳定性。这种稳定性在多个维度上得到了验证。在宽处理窗口内（功率170-450 W，速度500 - 1200 mm/s），与高斯光束相比，使用平顶光束可将熔池峰值温度平均降低500°C，并将最大流体速度降低约50% %。至关重要的是，这种内部热流体动力学的深度稳定直接反映在实时光电二极管信号的时频分析中，该信号捕获了熔池发出的热辐射。平顶光束有效地滤除高频（>1 kHz）频谱能量，滤除率超过80% %，将熔池动力学从由强烈对流驱动的随机高频振荡状态转变为可预测的低频主导状态。最终，本研究建立并验证了一个级联物理机制：能量均一化导致温度梯度和峰值温度降低，进而抑制马兰戈尼流速度，导致熔池振荡从高频、不稳定波动转变为低频、周期性波动。这项工作为利用光束整形实现高稳定性PBF-LB/M增材制造提供了关键的理论基础和频域诊断工具。

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引用次数: 0

Heterogeneity-induced ductile–brittle transition behavior in negative rake angle cutting of Al/SiCp composites Al/SiCp复合材料负前角切削中非均质诱导的韧脆转变行为

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-06 DOI: 10.1016/j.jmatprotec.2025.119177

Wei Sun , Zhenlong Cheng , Yaohui Wang , Dehui Liu , Peiyao Sheng , Kui Liu , Junyun Chen , Penghui Li

The inherent heterogeneity of Al/SiCp composites caused by the limited synergetic deformation capacity between the soft Al matrix and the hard SiC particles alter the conventional ductile–brittle transition (DBT) behavior of SiC. The conventional DBT theory was originally developed for homogeneous materials. However, its applicability to Al/SiCp composites is significantly limited. Therefore, a deeper understanding of the unique DBT behavior induced by inherent heterogeneity is essential for achieving ductile-regime machining of Al/SiCp composites. This study systematically investigated the heterogeneity-induced DBT behavior of Al/SiCp composites and explored the effect of negative rake angle cutting on this behavior through plunge-cut experiments and molecular dynamics (MD) simulations. The experimental results indicate that the SiC particles at the heterogeneous interface (hetero-interface) experienced a sudden transition to a state with complete brittle-regime removal, bypassing the traditional DBT stage. However, the machined surface of SiC particles located away from the interface still underwent a normal DBT process. The MD simulations show that the abrupt brittle transition is attributed to the sustained crack propagation at the hetero-interface caused by an insufficient support for the SiC particles by the Al matrix. Both experimental and simulation results revealed that negative rake angle cutting enhanced the plastic deformation ability of the interfacial SiC particles, as evidenced by the high dislocation densities. Consequently, compared to that at a 0° tool rake angle, the brittle-regime removal at the hetero-interface was significantly postponed when the tool rake angle was negative, which was conducive to mitigating the interfacial edge collapse of SiC. Finally, a novel critical DBT distance is proposed to quantify the initiated location at the hetero-induced brittle removal of SiC particles, serving as an evaluation parameter for the magnitude of interfacial edge collapses. From this perspective, the particle-removal behavior of Al/SiCp composites cannot be solely determined using the traditional DBT depth; a comprehensive consideration of the critical DBT distance dominated by the interfacial heterogeneity is also required to achieve ductile-regime machining.

软Al基体与硬SiC颗粒之间有限的协同变形能力导致Al/SiCp复合材料固有的非均质性改变了SiC传统的韧脆转变行为。传统的DBT理论最初是针对均匀材料发展起来的。然而，其在Al/SiCp复合材料中的适用性明显受到限制。因此，更深入地了解由固有非均质性引起的独特DBT行为对于实现Al/SiCp复合材料的延性加工至关重要。本研究系统地研究了Al/SiCp复合材料的非均质诱导DBT行为，并通过冲切实验和分子动力学（MD）模拟探讨了负前角切割对该行为的影响。实验结果表明，在非均相界面处的SiC颗粒跳过传统的DBT阶段，突然过渡到脆性完全去除的状态。然而，远离界面的SiC颗粒的加工表面仍然经历了正常的DBT过程。MD模拟结果表明，突变脆性转变是由Al基体对SiC颗粒的支撑不足引起的异质界面处持续裂纹扩展引起的。实验和模拟结果均表明，负前角切削增强了界面SiC颗粒的塑性变形能力，表现为位错密度高。因此，与刀具前倾角为0°时相比，当刀具前倾角为负时，异质界面处脆性状态的去除明显推迟，有利于减轻SiC的界面边缘坍塌。最后，提出了一种新的临界DBT距离，用于量化SiC颗粒异质脆性去除的起始位置，作为界面边缘坍塌程度的评估参数。从这个角度来看，Al/SiCp复合材料的颗粒去除行为不能仅仅用传统的DBT深度来确定；为了实现延性加工，还需要综合考虑由界面非均质性主导的临界DBT距离。

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引用次数: 0

Effect of bypass cold wire spatial position on process stability and elemental transfer in submerged arc welding for in situ alloying 旁通冷丝空间位置对原位合金化埋弧焊工艺稳定性和元素传递的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-10 DOI: 10.1016/j.jmatprotec.2025.119179

Zekun Yang , Zhanli Yang , Dakui Fei , Yanxu Wang , Guofu Wang , Guangnan Zhao , Xin Yuan , Bing Lu , Ziran Wang , Kai Xu

Achieving flexible and cost-effective in-situ alloying within multi-wire submerged arc welding (multi-wire SAW) represents a core challenge for manufacturing high-performance pipeline steels. This study systematically investigates how the spatial position of the alloying source (a bypass cold wire) relative to the energy source (the multi-arc system) governs the physical metallurgy during the welding process. The results reveal that the cold wire feeding position has a decisive influence on both process stability and metallurgical behavior. In this confined-arc process, the highest elemental recovery was counter-intuitively obtained in the most energy-intensive region—the coupled arc zone. However, this high-recovery process window was accompanied by severe arc instability (the average coefficient of variation for the main wire current increased from 4.20 % to 7.08 %, increasing by nearly 70 %), leading to significant chemical segregation and microstructural degradation. To explain this anomalous phenomenon and resolve the aforementioned conflict, this work proposes the "Arc Cavity Confined Reaction" model. This model, for the first time, scientifically demonstrates from the dual mechanisms of physical confinement and chemical protection how the flux-formed cavity transforms conventional arc burn-off" into a controlled "evaporation-confinement- recondensation" cycle, thereby amending the applicability of classical loss theories in confined-arc processes. Based on this theoretical framework, the "molten pool stabilization zone" behind the arcs was ultimately identified as the optimal process window to decouple elemental recovery from process stability, under which condition the weld metal's low-temperature impact toughness (-10°C) reached 165.7 J. This work fundamentally advances the understanding of elemental mass transfer in confined-arc environments, providing a new theoretical framework and critical process guidelines for all advanced materials processing technologies that rely on slag protection.

在多丝埋弧焊（multi-wire埋弧焊）中实现灵活且经济的原位合金化是制造高性能管道钢的核心挑战。本研究系统地研究了合金源（旁路冷丝）相对于能量源（多弧系统）的空间位置对焊接过程中物理冶金的影响。结果表明，冷送丝位置对工艺稳定性和冶金性能都有决定性的影响。在这种封闭电弧过程中，与直觉相反，在能量最密集的区域-耦合电弧区域获得了最高的元素回收率。然而，这个高回收率的过程窗口伴随着严重的电弧不稳定性（主线电流的平均变异系数从4.20 %增加到7.08 %，增加了近70 %），导致显著的化学偏析和微观结构退化。为了解释这一异常现象并解决上述矛盾，本文提出了“弧腔限制反应”模型。该模型首次从物理约束和化学保护的双重机制科学论证了熔剂形成的空腔如何将传统的电弧燃尽转变为受控的“蒸发-约束-再凝聚”循环，从而修正了经典损耗理论在电弧约束过程中的适用性。基于该理论框架，最终确定弧后的“熔池稳定区”是将元素恢复与工艺稳定性分离的最佳工艺窗口，在此条件下，焊缝金属的低温冲击韧性（-10°C）达到165.7 J。这项工作从根本上推进了对限弧环境中元素传质的理解，为所有依赖于渣保护的先进材料加工技术提供了新的理论框架和关键工艺指导。

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引用次数: 0

Laser-induced cold metal transfer arc deflection under sidewall constraints: A novel strategy for enhanced sidewall fusion in thick-plate ultra-narrow-gap welding 侧壁约束下激光诱导冷金属转移电弧偏转：一种增强厚板超窄间隙焊接侧壁熔合的新策略

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-31 DOI: 10.1016/j.jmatprotec.2025.119194

Xiangchen Fan , Guoliang Qin , Guodong Liang , Huijun Xu , Xueyang Guo

In laser-arc hybrid welding, there is a strong coupling effect between the laser and the arc, which is also known as the laser-induced effect. In our studies, the changes of the cold metal transfer (CMT) arc shape were realized by the laser-induced effect, and the influences of different parameters on this effect were systematically investigated. Our experimental results indicate that wire feeding speed significantly influences welding stability, while laser-arc distance in Y-direction is the key parameter for achieving arc lateral deflection and obtaining induced welds. Within an appropriate laser-arc distance range, the arc can be laser-induced to deflect laterally to one side. So, the deflection phenomenon of the CMT arc can be used in an ultra-narrow-gap (≤ 8 mm) welding process. In this scenario, the CMT arc can deflect towards the sidewall without bending or rotating the welding wire. The laser-induced effect allows the CMT arc to heat the sidewall in conjunction with the laser, thereby achieving sufficient sidewall penetration. High-quality induced welds with sufficient sidewall penetration are obtained within the laser-induced range. Meanwhile, the sidewall space constraints within the narrow-gap grooves enhance the laser-induced range, thereby improving the applicability of this technology. Finally, this technology achieved a 30 mm thick ultra-narrow-gap weld with sufficient sidewall penetration, good formability, and low heat damage. These studies support the research and development of the laser-CMT hybrid ultra-narrow-gap welding process of thick plates in industrial applications.

在激光-电弧复合焊接中，激光与电弧之间存在着强烈的耦合效应，这种耦合效应也被称为激光诱导效应。本研究利用激光诱导效应实现了冷金属转移（CMT）电弧形状的变化，并系统地研究了不同参数对这种影响的影响。实验结果表明，送丝速度对焊接稳定性有显著影响，而y方向激光电弧距离是实现电弧横向偏转和获得感应焊缝的关键参数。在适当的激光电弧距离范围内，激光诱导电弧侧向偏转到一侧。因此，CMT电弧的偏转现象可用于超窄间隙（≤8 mm）焊接工艺。在这种情况下，CMT电弧可以在不弯曲或旋转焊丝的情况下向侧壁偏转。激光诱导效应允许CMT电弧与激光一起加热侧壁，从而实现充分的侧壁穿透。在激光诱导范围内，获得了具有足够侧壁穿透性的高质量诱导焊缝。同时，窄间隙凹槽内的侧壁空间约束增强了激光诱导范围，从而提高了该技术的适用性。最后，该技术实现了30 mm厚的超窄间隙焊缝，具有足够的侧壁穿透性、良好的成形性和低热损伤。这些研究为厚板激光- cmt复合超窄间隙焊接工艺的研究和开发提供了工业应用基础。

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引用次数: 0

A powder-bed in-situ modification strategy for surface quality enhancement in laser powder bed fusion: A case study on oxide ceramics 提高激光粉末床熔合表面质量的粉末床原位改性策略——以氧化陶瓷为例

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-13 DOI: 10.1016/j.jmatprotec.2025.119184

Yuji Li , Jin Huang , Zhenghua Liu , Delong Shi , Beining Li , Weiwei He , Fanbo Meng

In the Laser Powder Bed Fusion (LPBF) forming process of oxide ceramics, Due to the inherently loose structure of the powder bed and the poor thermal conductivity of oxide ceramics, issues such as intense melt pool spattering and uneven melting/solidification frequently arise. To address this challenge, this study proposes an in-situ modulation and modification strategy for the powder bed. Thermal and kinetic models were established to analyze the melting process of the modified powder bed, and multi-scale validation was conducted in conjunction with experimental work.The modified powder bed demonstrates significant suppression of melt pool spattering behavior.Compared with the unmodified control samples, the modified components exhibited reductions in surface roughness values Ra and Rz by 88.6 % and 28.6 %, respectively. In-depth mechanistic analysis revealed that the auxiliary materials infiltrated the interparticle gaps by capillary forces, and sol gelation substantially enhanced the interparticle bonding strength. This phenomenon effectively restrained the particle spattering dynamics under recoil pressure. Concurrently, the incomplete combustion of benzyl alcohol generated an in situ nanoscale carbon layer on the powder bed surface, reducing the melt-pool temperature gradients. This phenomenon weakens the Marangoni convection intensity driven by the surface tension gradients, thereby extending the time window for melt spreading and leveling. The in-situ powder bed modulation and modification strategy provides a new theoretical basis for improving the forming quality and microstructural optimization of oxide ceramic components fabricated by LPBF. Importantly, this strategy offers a novel process pathway for addressing melt pool instability and defect control in LPBF of various material systems.

在氧化物陶瓷的激光粉末床熔合成形过程中，由于粉末床本身的松散结构和氧化物陶瓷的导热性差，经常出现熔池飞溅剧烈和熔化/凝固不均匀等问题。为了解决这一挑战，本研究提出了一种粉末床的原位调制和改造策略。建立了热学和动力学模型，分析了改性粉末床的熔化过程，并结合实验工作进行了多尺度验证。改性粉末床对熔池溅射行为有明显的抑制作用。与未改性的对照样品相比，改性组分的表面粗糙度值Ra和Rz分别降低了88.6% %和28.6% %。深入的机理分析表明，辅助材料通过毛细力渗透颗粒间隙，溶胶凝胶作用大大增强了颗粒间的结合强度。这种现象有效地抑制了粒子在反冲压力下的溅射动力学。同时，苯甲醇的不完全燃烧在粉末床表面形成纳米级碳层，减小了熔池温度梯度。这一现象减弱了由表面张力梯度驱动的Marangoni对流强度，从而延长了熔体扩散和流平的时间窗。粉末床原位调制和改性策略为提高LPBF制备的氧化陶瓷元件的成形质量和优化微结构提供了新的理论依据。重要的是，该策略为解决各种材料体系的LPBF熔池不稳定性和缺陷控制提供了一种新的工艺途径。

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引用次数: 0

Cold manufacturing of metallic glass-based composites by ultrasonic vibrations 金属玻璃基复合材料的超声振动冷加工

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-08 DOI: 10.1016/j.jmatprotec.2025.119178

Luyao Li , Yu Zhang , Jinbiao Huang , Zhe Chen , Xiangyang Yu , Wei Li , Jiasen Sun , Kangyu Lin , Chenchen Yuan , Jiang Ma

The design of materials with desirable and tailorable properties is a long-standing goal within materials science, where composites represent a key strategy. However, a central dilemma in conventional composite manufacturing is that the thermal energy required to form strong interfacial bonds often simultaneously induces detrimental side effects, including interfacial reactions and reinforcement degradation. To resolve this generic conflict, we introduce a versatile "cold manufacturing" strategy utilizing metallic glasses as matrices. By exploiting an athermal ultrasonic vibration mechanism—which induces transient liquid-like behavior in metallic glasses without thermal activation—we achieve seamless interfacial bonding across diverse conductors, insulators, metals, and non-metals via oxide-layer-penetrating diffusion at ambient conditions. Crucially, successful fabrication underwater and in liquid nitrogen definitively demonstrates the technique's purely athermal nature, avoiding any thermal degradation pathways. By tuning metallic glasses binder ratios and additive compositions, we precisely engineer mechanical properties (Vickers hardness: 400–1450 HV) and magnetic response (saturation magnetization: 0–158.6 emu/g), forming robust bonds. This work thus establishes a versatile and fundamentally distinct composite manufacturing platform, opening a generic pathway to multifunctional composites free from the intrinsic limitations of heat.

设计具有理想和可定制性能的材料是材料科学的长期目标，其中复合材料代表了关键策略。然而，传统复合材料制造的一个核心难题是，形成强界面键所需的热能往往同时引起有害的副作用，包括界面反应和增强物降解。为了解决这一普遍的冲突，我们引入了一种通用的“冷制造”策略，利用金属玻璃作为矩阵。通过利用非热超声振动机制（在没有热激活的情况下在金属玻璃中诱导瞬态类液体行为），我们在环境条件下通过氧化层穿透扩散实现了不同导体、绝缘体、金属和非金属之间的无缝界面结合。至关重要的是，在水下和液氮中成功制造证明了该技术的纯粹非热性质，避免了任何热降解途径。通过调整金属玻璃粘结剂比例和添加剂成分，我们精确地设计机械性能（维氏硬度：400-1450 HV）和磁响应（饱和磁化强度：0-158.6 emu/g），形成坚固的键。因此，这项工作建立了一个通用的、从根本上独特的复合材料制造平台，开辟了一条不受热量固有限制的多功能复合材料的通用途径。

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引用次数: 0

Effect of laser energy on surface deformation mechanism of Nickel-based single-crystal superalloy subject to Laser shock peening 激光能量对激光冲击强化镍基单晶高温合金表面变形机理的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-05 DOI: 10.1016/j.jmatprotec.2025.119173

Min Dou , Shouyi Sun , Huitao Chen , Tianyu Yuan , Xinmei Wang , Lei Li

This study investigates the effects of Laser Shock Peening (LSP) on the mechanisms of surface plastic deformation in nickel-based single-crystal (NBSC) superalloys. After LSP at 5–9 J, no grain boundaries are introduced, and the single-crystal (SC) characteristics of the material are still retained. Severe plastic deformation occurs accompanied by the formation of a millimeter-scale work-hardened layer (the hardness could increase by 53.8%). In addition, the periodic structures formed on the surface lead to a maximum increase in surface roughness by approximately 8.1-fold. The deformed surface layer comprises a severe plastic deformation layer (SPDL) and a mild plastic deformation layer (MPDL). Within the SPDL, LSP activates the {111}<110> octahedral slip systems, generating high-density <110>-oriented cross-slip bands and characteristic dislocation configurations such as stacking faults (SFs), dislocation walls (DWs), dislocation tangles (DTs), and dislocation networks, thereby increasing the geometrically necessary dislocation (GND) density. At 10 J, localized remelting zones caused by thermal effects are also involved in the plastic deformation process, resulting in a reduction in the SPDL depth and GND density. Nevertheless, the γ matrix phase exhibits a significantly higher dislocation density than the γ' precipitate phase for all LSP-treated samples. This discovery provides critical mechanistic support and parameter guidance for the engineering applications of LSP in the precise surface modification of SC alloys.

研究了激光冲击强化（LSP）对镍基单晶高温合金表面塑性变形机理的影响。在5-9 J处LSP后，没有引入晶界，材料的单晶（SC）特性仍然保留。发生严重的塑性变形，形成毫米级的加工硬化层（硬度可提高53.8%）。此外，表面形成的周期性结构导致表面粗糙度最大增加约8.1倍。变形表面层包括剧烈塑性变形层（SPDL）和轻度塑性变形层（MPDL）。在SPDL内，LSP激活{111}<；110>；八面体滑移系统，产生高密度<；110>；定向交叉滑移带和特征位错配置，如层错（SFs）、位错壁（DWs）、位错缠结（DTs）和位错网络，从而增加几何上必需的位错（GND）密度。在10 J时，热效应引起的局部重熔区也参与塑性变形过程，导致SPDL深度和GND密度降低。然而，在所有经过lsp处理的样品中，γ基体相的位错密度明显高于γ′沉淀相。这一发现为LSP在SC合金精密表面改性中的工程应用提供了关键的机理支持和参数指导。

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引用次数: 0

Laser additive manufactured high thermal conductivity Cu-GNPs/AlSi7Mg composite based on powder preparation and remelting strategy 基于粉末制备和重熔策略，激光增材制备了高导热Cu-GNPs/AlSi7Mg复合材料

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-05 DOI: 10.1016/j.jmatprotec.2025.119176

Yuqing Liu , Jiawen Luo , Zhe Feng , Siyu Zhang , Zhiwei Hao , Yijie Peng , Wei Fan , Hua Tan , Fengying Zhang , Xin Lin

Coated-graphene nanoplatelets (GNPs) can effectively reduce graphene agglomeration and enhance the thermal conductivity of aluminum metal matrix composites (AMMCs). Thus, laser additive manufacturing (LAM) of coated-GNPs reinforced AMMCs holds great promise for producing lightweight, high thermal conductivity, and complex thermal management structures. However, current powder preparation processes lead to graphene agglomeration, limiting thermal conductivity improvement. Moreover, laser remelting can potentially enhance metallurgical quality and thermal conductivity. Therefore, this study develops LAM-processed Cu-GNPs/AlSi7Mg composite based on optimized powder preparation and remelting strategy. Under combined ultrasonic oscillation and mechanical stirring, 0.5 wt% and 1.5 wt% Cu-GNPs/AlSi7Mg composites (containing 0.1 wt% and 0.3 wt% GNPs) were prepared using chemical Cu plating. The combined mixing ensured uniform graphene dispersion and improved powder flowability, while remelting further reduced defects and enhanced densification. The Cu-GNPs distributed along the grain boundaries promoted component supercooling, resulting in grain refinement and proportion increase of equiaxial grains. Both Cu-GNPs and remelting raised the proportion of heat-affected zones (HAZ) per unit area, where fractured Al-Si eutectic and precipitated Si resulted in lower thermal resistance. In addition, Cu-GNPs established phonon conduction pathways at boundaries, thereby improving grain boundary heat transfer efficiency. Consequently, at 25°C, the thermal conductivity of 1.5 wt% Cu-GNPs/AlSi7Mg reached 156.4 W/(m·K), representing an increase of 23.9 % over AlSi7Mg. Through the synergistic optimization of dispersion, interfacial bonding strength, and metallurgical quality, the thermal conductivity of LAM-ed AlSi7Mg and other Cu-coated GNPs-reinforced systems is effectively improved. This paper provides critical theoretical and technical foundations for engineering applications of thermal management structures.

涂层-石墨烯纳米片（GNPs）可以有效地减少石墨烯团聚，提高铝金属基复合材料（ammc）的导热性。因此，激光增材制造（LAM）涂层gnps增强ammc在生产轻量化、高导热性和复杂热管理结构方面具有很大的前景。然而，目前的粉末制备工艺导致石墨烯团聚，限制了导热性的提高。此外，激光重熔可以潜在地提高冶金质量和导热性。因此，本研究基于优化的粉末制备和重熔策略，开发了lam制备的Cu-GNPs/AlSi7Mg复合材料。在超声振荡和机械搅拌的联合作用下，采用化学镀铜法制备了0.5 wt%和1.5 wt%的Cu-GNPs/AlSi7Mg复合材料（含0.1 wt%和0.3 wt% GNPs）。复合混合确保了石墨烯均匀分散，提高了粉末流动性，而重熔进一步减少了缺陷，增强了致密性。沿晶界分布的Cu-GNPs促进组分过冷，导致晶粒细化，等轴晶比例增加。Cu-GNPs和重熔均提高了单位面积热影响区（HAZ）的比例，其中Al-Si共晶断裂和Si析出导致热阻降低。此外，Cu-GNPs在晶界处建立了声子传导通路，从而提高了晶界传热效率。因此，在25°C时，1.5 wt% Cu-GNPs/AlSi7Mg的导热系数达到156.4 W/(m·K)，比AlSi7Mg增加23.9 %。通过分散、界面结合强度和冶金质量的协同优化，有效提高了lamed AlSi7Mg和其他cu包覆gnps增强体系的导热性。本文为热管理结构的工程应用提供了重要的理论和技术基础。

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引用次数: 0

Stress-aware graph neural network for springback prediction considering material variations 考虑材料变化的应力感知图神经网络回弹预测

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-02-01 Epub Date: 2025-12-29 DOI: 10.1016/j.jmatprotec.2025.119189

Hui Wang , Heonyong Lim , Jeong Whan Yoon

Accurate prediction of springback is crucial for quality control in sheet metal forming, especially when available limited data constrains the use of conventional data-driven methods. As the first attempt to apply for Graph Neural Network (GNN) to sheet metal forming process considering material variations, this study newly proposes a graph-based deep learning framework, which leverages Graph Attention Networks to predict nodal coordinates and state variables including stress components, equivalent plastic strain etc. across the part. A two-stage training strategy is introduced to enhance the model’s physical consistency by incorporating stress components as auxiliary targets, while GNN mechanism enables adaptive encoding of material influence on stress distribution. This work advances the fundamental understanding of metal forming by representing the stress–strain–geometry interaction as a spatially connected network, establishing a quantitative link between local mechanical response and global springback behavior. Beyond the case-specific prediction, this study reveals a generic relationship between the spatial evolution of stress–strain fields and the resulting geometric deviation, demonstrating that such physically coupled behavior can be effectively represented through graph topology. This finding provides a generalized framework for modeling deformation–relaxation phenomena in various forming processes. Comparative results show that the proposed framework outperforms a baseline artificial neural network, achieving higher accuracy despite the limited dataset of 256 simulations, and offers strong potential for process optimization and intelligent forming design.

准确的回弹预测对于钣金成形的质量控制至关重要，特别是当可用的有限数据限制了传统数据驱动方法的使用时。作为将图神经网络（GNN）应用于考虑材料变化的钣金成形过程的首次尝试，本研究提出了一种基于图的深度学习框架，该框架利用图注意力网络来预测零件的节点坐标和状态变量，包括应力分量、等效塑性应变等。引入了两阶段训练策略，通过将应力分量作为辅助目标来增强模型的物理一致性，而GNN机制可以自适应编码材料对应力分布的影响。这项工作通过将应力-应变-几何相互作用表示为空间连接网络，在局部机械响应和全局回弹行为之间建立定量联系，从而提高了对金属成形的基本理解。除了个案预测外，本研究还揭示了应力应变场的空间演化与几何偏差之间的一般关系，表明这种物理耦合行为可以通过图拓扑有效地表示。这一发现为模拟各种成形过程中的变形松弛现象提供了一个广义框架。对比结果表明，该框架优于基线人工神经网络，在256个模拟数据有限的情况下仍能获得更高的精度，为工艺优化和智能成形设计提供了强大的潜力。

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引用次数: 0