Pub Date : 2025-11-07DOI: 10.1016/j.jmatprotec.2025.119143
Fangxian Zhang , Chuanqiang Peng , Tao Zhu , Xinliang Xie , Liping Zhou , Yang Li , Qi Chao , Guohua Fan
Controlling the solidification behavior of Ni-based superalloys to achieve tailored crystallographic textures or single-crystal structures is essential for producing high-performance components for extreme-temperature applications. Additive manufacturing, particularly laser powder bed fusion (LPBF), offers unique capabilities for microstructural design. In this study, we present an overlapping-based strategy to produce single-crystal-like textures along arbitrary three-dimensional orientations in the non-weldable IN738LC superalloy via LPBF. By tuning melt pool geometry and overlapping rates- through adjustments in hatch space and layer thickness-we successfully engineered three distinct textures without altering scan strategy: < 001 > ∥building direction (BD), < 311 > ∥BD, and < 110 > ∥BD. The mechanisms driving texture development, including epitaxial growth and subsequent competitive grain selection, are analyzed using computational fluid dynamics simulations of the thermal field and temperature gradient distributions. This work provides a new pathway for fabricating single-crystal-like Ni-based superalloy components using LPBF, advancing the integration of texture control into additive manufacturing.
{"title":"Tailoring single-crystal-like textures in a non-weldable Ni-based superalloy by controlling overlap behavior in laser powder bed fusion","authors":"Fangxian Zhang , Chuanqiang Peng , Tao Zhu , Xinliang Xie , Liping Zhou , Yang Li , Qi Chao , Guohua Fan","doi":"10.1016/j.jmatprotec.2025.119143","DOIUrl":"10.1016/j.jmatprotec.2025.119143","url":null,"abstract":"<div><div>Controlling the solidification behavior of Ni-based superalloys to achieve tailored crystallographic textures or single-crystal structures is essential for producing high-performance components for extreme-temperature applications. Additive manufacturing, particularly laser powder bed fusion (LPBF), offers unique capabilities for microstructural design. In this study, we present an overlapping-based strategy to produce single-crystal-like textures along arbitrary three-dimensional orientations in the non-weldable IN738LC superalloy via LPBF. By tuning melt pool geometry and overlapping rates- through adjustments in hatch space and layer thickness-we successfully engineered three distinct textures without altering scan strategy: < 001 > ∥building direction (BD), < 311 > ∥BD, and < 110 > ∥BD. The mechanisms driving texture development, including epitaxial growth and subsequent competitive grain selection, are analyzed using computational fluid dynamics simulations of the thermal field and temperature gradient distributions. This work provides a new pathway for fabricating single-crystal-like Ni-based superalloy components using LPBF, advancing the integration of texture control into additive manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119143"},"PeriodicalIF":7.5,"publicationDate":"2025-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145527657","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 : 2025-11-07DOI: 10.1016/j.jmatprotec.2025.119142
Siyuan Zhang , Yanwen Sun , Zeyi Liu , Meijia Sun , Tianyu Zhang , Xiaoming Liu , Wangzhong Mu , Tie Liu , Qiang Wang
The agglomeration of inclusions in continuous casting blooms destroys the continuity and compactness of the steel matrix, which seriously restricts the fatigue life and corrosion resistance of the steel. A novel traceability method for the distribution of inclusions was introduced to reveal the evolution of inclusion agglomeration. This method demonstrated the position evolution of inclusions when they passed through different planes by assigning colors for inclusions. In this study, a mathematical model coupled with electromagnetic field, flow, heat transfer, solidification, and non-metallic inclusion movement was developed to study the agglomeration behavior of inclusions under dual-mode electromagnetic field control modes (edge-to-center flow mode and the coupled mode of center-to-edge flow and edge-to-center flow). Numerical simulation revealed that the coupled mode significantly enhanced inclusion distribution uniformity in the solidified shell, with a 63.7 % reduction of the number in the localized agglomeration zone compared to the edge-to-center flow mode. Experimental measurements demonstrated a 46.7 % decrease in inclusion number density near the quarter position of the loose side under coupled mode compared to edge-to-center flow mode. Under coupled mode, the flow of molten steel at the center and the edge of the mold with the opposite directions helped to disperse the inclusions and promote the uniform distribution of inclusions in the cross-section. This study provides a new strategy to suppress inclusion agglomeration in continuous casting blooms by electromagnetic metallurgy technology.
{"title":"Multi-field coupling traceability method for non-metallic inclusion agglomeration in continuous casting under dual-mode electromagnetic control","authors":"Siyuan Zhang , Yanwen Sun , Zeyi Liu , Meijia Sun , Tianyu Zhang , Xiaoming Liu , Wangzhong Mu , Tie Liu , Qiang Wang","doi":"10.1016/j.jmatprotec.2025.119142","DOIUrl":"10.1016/j.jmatprotec.2025.119142","url":null,"abstract":"<div><div>The agglomeration of inclusions in continuous casting blooms destroys the continuity and compactness of the steel matrix, which seriously restricts the fatigue life and corrosion resistance of the steel. A novel traceability method for the distribution of inclusions was introduced to reveal the evolution of inclusion agglomeration. This method demonstrated the position evolution of inclusions when they passed through different planes by assigning colors for inclusions. In this study, a mathematical model coupled with electromagnetic field, flow, heat transfer, solidification, and non-metallic inclusion movement was developed to study the agglomeration behavior of inclusions under dual-mode electromagnetic field control modes (edge-to-center flow mode and the coupled mode of center-to-edge flow and edge-to-center flow). Numerical simulation revealed that the coupled mode significantly enhanced inclusion distribution uniformity in the solidified shell, with a 63.7 % reduction of the number in the localized agglomeration zone compared to the edge-to-center flow mode. Experimental measurements demonstrated a 46.7 % decrease in inclusion number density near the quarter position of the loose side under coupled mode compared to edge-to-center flow mode. Under coupled mode, the flow of molten steel at the center and the edge of the mold with the opposite directions helped to disperse the inclusions and promote the uniform distribution of inclusions in the cross-section. This study provides a new strategy to suppress inclusion agglomeration in continuous casting blooms by electromagnetic metallurgy technology.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119142"},"PeriodicalIF":7.5,"publicationDate":"2025-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145527602","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 : 2025-11-07DOI: 10.1016/j.jmatprotec.2025.119139
Wenlong Li , Fan Jiang , Bin Xu , Jiankang Song , Haowen Suo , Wei Cheng , Xinqiang Ma , Zhenzhen Zhang , Di Yang , Shujun Chen
Variable polarity plasma arc welding (VPPAW) is a high-energy-density keyhole welding technique with considerable potential for the efficient and defect-free joining of thick aluminum alloy. However, the extended digging depth in thick workpieces intensifies the complexity of the welding process, as torch travel at different digging depths, even under optimized parameter, results in distinct variations in weld quality. In this study, a transparent observation system was established by butt-jointing a thick aluminum alloy plate with a quartz glass sheet, enabling direct visualization of the dynamic behaviors of the keyhole and weld pool during the digging stage. A deep learning-based image processing approach utilizing the SegFormer architecture was developed to extract these dynamic features. The findings reveal that the weld pool depth evolution is a highly dynamic multi-phase process, progressing through three alternating cycles of rapid growth and quasi-steady behavior, ultimately reaching a blasting-type penetration. The mechanism involves the establishment of thermal-force equilibrium when the molten metal reaches a critical thickness, halting the digging process. Arc-induced oscillations break this equilibrium, triggering molten metal outflow and keyhole deepening, which reflects the transient and non-equilibrium characteristics of energy transfer in plasma-metal coupling. Molten metal droplet cluster represents a distinctive phenomenon during the digging stage, arising from the continuous outflow of molten metal from the interior of keyhole. The externally observable weld pool and droplet cluster areas effectively indicate the internal digging stage, offering characteristic features to guide torch travel and ensure weld quality. Observations under varying welding parameters demonstrate that the dynamic, multi-phase digging process persists, confirming its governance by transient, non-equilibrium energy transfer mechanisms. The timing of droplet cluster detachment serves as a crucial indicator for assessing the suitability of welding parameter. This work provides a solid foundation for intelligent control in advanced VPPAW of thick aluminum alloy.
{"title":"Dynamic behaviors of keyhole and weld pool during the digging stage in variable polarity plasma arc welding of thick aluminum alloy","authors":"Wenlong Li , Fan Jiang , Bin Xu , Jiankang Song , Haowen Suo , Wei Cheng , Xinqiang Ma , Zhenzhen Zhang , Di Yang , Shujun Chen","doi":"10.1016/j.jmatprotec.2025.119139","DOIUrl":"10.1016/j.jmatprotec.2025.119139","url":null,"abstract":"<div><div>Variable polarity plasma arc welding (VPPAW) is a high-energy-density keyhole welding technique with considerable potential for the efficient and defect-free joining of thick aluminum alloy. However, the extended digging depth in thick workpieces intensifies the complexity of the welding process, as torch travel at different digging depths, even under optimized parameter, results in distinct variations in weld quality. In this study, a transparent observation system was established by butt-jointing a thick aluminum alloy plate with a quartz glass sheet, enabling direct visualization of the dynamic behaviors of the keyhole and weld pool during the digging stage. A deep learning-based image processing approach utilizing the SegFormer architecture was developed to extract these dynamic features. The findings reveal that the weld pool depth evolution is a highly dynamic multi-phase process, progressing through three alternating cycles of rapid growth and quasi-steady behavior, ultimately reaching a blasting-type penetration. The mechanism involves the establishment of thermal-force equilibrium when the molten metal reaches a critical thickness, halting the digging process. Arc-induced oscillations break this equilibrium, triggering molten metal outflow and keyhole deepening, which reflects the transient and non-equilibrium characteristics of energy transfer in plasma-metal coupling. Molten metal droplet cluster represents a distinctive phenomenon during the digging stage, arising from the continuous outflow of molten metal from the interior of keyhole. The externally observable weld pool and droplet cluster areas effectively indicate the internal digging stage, offering characteristic features to guide torch travel and ensure weld quality. Observations under varying welding parameters demonstrate that the dynamic, multi-phase digging process persists, confirming its governance by transient, non-equilibrium energy transfer mechanisms. The timing of droplet cluster detachment serves as a crucial indicator for assessing the suitability of welding parameter. This work provides a solid foundation for intelligent control in advanced VPPAW of thick aluminum alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119139"},"PeriodicalIF":7.5,"publicationDate":"2025-11-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145464850","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}
This study proposes a laser-assisted direct glass imprinting (LADGI) process. In LADGI, laser irradiation is used to directly heat the microstructures on a mold, and a glass surface is locally heated and softened through thermal conduction, which enables rapid imprinting. However, this process involves rapid heating and cooling, which can induce local tensile stress and increases the risk of thermal fractures in the glass. Therefore, the ability to replicate microstructures while preventing thermal fractures is required. Model experiments with laser spot irradiation and coupled thermal stress analysis were conducted using the finite element method to investigate the temperature conditions required for imprinting and the thermal fracture phenomenon. During LAGDI, imprinting occurred at temperatures above the yield point of the glass. After laser irradiation, thermal fractures initiated in areas of the glass surface near the annealing point because the coefficient of linear expansion of the glass changed rapidly around the annealing point; hence, the volumetric expansion rate at the boundary between the high-temperature region and surrounding low-temperature regions was in a non-equilibrium state. This generated local tensile stress during cooling. This study showed that the relative risk of thermal fractures can be evaluated based on the rate at which the glass volume increased when it was heated above the annealing point. Based on these findings, new indicators and were defined to evaluate the LADGI process conditions. These indicators can be used to quantify the efficiency of the process conditions and guide the optimization of the LADGI process.
{"title":"Thermal fracture phenomenon in laser-assisted direct glass imprinting (LADGI)","authors":"Takehiro Mitsuda , Keisuke Nagato , Masayuki Nakao","doi":"10.1016/j.jmatprotec.2025.119131","DOIUrl":"10.1016/j.jmatprotec.2025.119131","url":null,"abstract":"<div><div>This study proposes a laser-assisted direct glass imprinting (LADGI) process. In LADGI, laser irradiation is used to directly heat the microstructures on a mold, and a glass surface is locally heated and softened through thermal conduction, which enables rapid imprinting. However, this process involves rapid heating and cooling, which can induce local tensile stress and increases the risk of thermal fractures in the glass. Therefore, the ability to replicate microstructures while preventing thermal fractures is required. Model experiments with laser spot irradiation and coupled thermal stress analysis were conducted using the finite element method to investigate the temperature conditions required for imprinting and the thermal fracture phenomenon. During LAGDI, imprinting occurred at temperatures above the yield point of the glass. After laser irradiation, thermal fractures initiated in areas of the glass surface near the annealing point because the coefficient of linear expansion of the glass changed rapidly around the annealing point; hence, the volumetric expansion rate at the boundary between the high-temperature region and surrounding low-temperature regions was in a non-equilibrium state. This generated local tensile stress during cooling. This study showed that the relative risk of thermal fractures can be evaluated based on the rate at which the glass volume increased when it was heated above the annealing point. Based on these findings, new indicators <span><math><msub><mrow><mi>E</mi></mrow><mrow><mi>i</mi></mrow></msub></math></span> and <span><math><msub><mrow><mi>I</mi></mrow><mrow><mi>spot</mi></mrow></msub></math></span> were defined to evaluate the LADGI process conditions. These indicators can be used to quantify the efficiency of the process conditions and guide the optimization of the LADGI process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119131"},"PeriodicalIF":7.5,"publicationDate":"2025-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145527656","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 : 2025-11-04DOI: 10.1016/j.jmatprotec.2025.119130
Zubin Chen , Xiyun Yang , Guorui Jiang , Chuanming Liu , Haixin Li , Wenyao Sun , Xianglin Cui , Faquan Liu , Zhenlin Yang , Lilong Zhu
In this work, ultrasonic micro-forging device was creatively designed and proposed to improve the microstructure and enhance the mechanical property of laser directed energy deposited high-entropy alloy based on the dual regulation effect on molten pool and high temperature deposited layer. Multi-scale characterization and simulation were employed to elucidate the effects of ultrasonic micro-forging on porosity reduction, recrystallization behavior and strengthening mechanisms. Finite element simulation revealed that acoustic streaming facilitated bubble escape from the molten pool and reduced porosity by 84.6 % when synchronous ultrasonic vibration was conducted. Meanwhile, due to the deformation strain induced by ultrasonic impact, apart from the static recrystallization and twinning that occurred during the subsequent laser deposition process, dynamic recrystallization also took place simultaneously within the high-temperature deposited layer under ultrasonic micro-forging, resulting in the formation of interlayer gradient structures and 88.8 % reduction in average grain size. Owing to grain boundary strengthening, dislocation strengthening and twinning strengthening with contribution values of 85.7 MPa, 75.8 MPa and 28.5 MPa, respectively, the ultimate tensile strength and yield strength of alloys were remarkably enhanced while still maintaining good ductility after ultrasonic micro-forging conducted. Related strength values and elongation reached 713.1 MPa, 491.6 MPa, and 35.1 %, respectively. The advancement lies in demonstrating that ultrasonic micro-forging device can be used to realize the dual regulation effect of ultrasonic on liquid molten pool and solid deposited layer synchronously during laser deposition, the acoustic streaming effect of ultrasonic energy field in liquid molten pool promotes the pore inhibition while dynamic recrystallization and static recrystallization can be induced by the plastic deformation of high temperature solid deposited layer via ultrasonic impact. It provides a novel approach to improving the microstructure and mechanical properties of high-entropy alloy as well as other FCC alloys by laser directed energy deposition via the synchronous control of molten pool regulation and thermal deformation of deposited layers.
{"title":"Recrystallization and pore inhibition mechanisms of laser directed energy deposited FCC alloy assisted by synchronous ultrasonic micro-forging","authors":"Zubin Chen , Xiyun Yang , Guorui Jiang , Chuanming Liu , Haixin Li , Wenyao Sun , Xianglin Cui , Faquan Liu , Zhenlin Yang , Lilong Zhu","doi":"10.1016/j.jmatprotec.2025.119130","DOIUrl":"10.1016/j.jmatprotec.2025.119130","url":null,"abstract":"<div><div>In this work, ultrasonic micro-forging device was creatively designed and proposed to improve the microstructure and enhance the mechanical property of laser directed energy deposited high-entropy alloy based on the dual regulation effect on molten pool and high temperature deposited layer. Multi-scale characterization and simulation were employed to elucidate the effects of ultrasonic micro-forging on porosity reduction, recrystallization behavior and strengthening mechanisms. Finite element simulation revealed that acoustic streaming facilitated bubble escape from the molten pool and reduced porosity by 84.6 % when synchronous ultrasonic vibration was conducted. Meanwhile, due to the deformation strain induced by ultrasonic impact, apart from the static recrystallization and twinning that occurred during the subsequent laser deposition process, dynamic recrystallization also took place simultaneously within the high-temperature deposited layer under ultrasonic micro-forging, resulting in the formation of interlayer gradient structures and 88.8 % reduction in average grain size. Owing to grain boundary strengthening, dislocation strengthening and twinning strengthening with contribution values of 85.7 MPa, 75.8 MPa and 28.5 MPa, respectively, the ultimate tensile strength and yield strength of alloys were remarkably enhanced while still maintaining good ductility after ultrasonic micro-forging conducted. Related strength values and elongation reached 713.1 MPa, 491.6 MPa, and 35.1 %, respectively. The advancement lies in demonstrating that ultrasonic micro-forging device can be used to realize the dual regulation effect of ultrasonic on liquid molten pool and solid deposited layer synchronously during laser deposition, the acoustic streaming effect of ultrasonic energy field in liquid molten pool promotes the pore inhibition while dynamic recrystallization and static recrystallization can be induced by the plastic deformation of high temperature solid deposited layer via ultrasonic impact. It provides a novel approach to improving the microstructure and mechanical properties of high-entropy alloy as well as other FCC alloys by laser directed energy deposition via the synchronous control of molten pool regulation and thermal deformation of deposited layers.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119130"},"PeriodicalIF":7.5,"publicationDate":"2025-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145448858","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 : 2025-11-03DOI: 10.1016/j.jmatprotec.2025.119129
Mahsa Heidari , Louis N.S. Chiu , Ming Liu , Aijun Huang , Bernard Rolfe , Wenyi Yan
The Characteristic Time-Based Heat Input (CTI) model is an efficient agglomerated laser approach for simulating a heat source in additive manufacturing, significantly reducing computational costs while maintaining accuracy. In the CTI model, Goldak's moving heat source is applied to laser tracks using a characteristic heating time, based on the ratio of the heat source axis to the scanning speed. However, this characteristic heating time is valid only for material points along the central line of the deposited track, which may lead to applying inaccurate power density distribution at other points within the track. This study enhances the CTI model by reformulating the characteristic heating time through volume averaging the laser exposure time for all points within the semi-elliptical cylinder, achieving more precise temperature predictions while preserving computational efficiency. The improvements of the enhanced CTI (ECTI) model are evaluated through a comparative study with experimental data, the detailed Goldak model, and the original CTI model, focusing on laser-directed energy deposition (DED) of two Ti-6Al-4V components: a thin-wall and a cone. The refined characteristic heating time in the ECTI model demonstrates significant mitigation of temperature history deviation for DED (>7.6 % error reduction). The ECTI model shows close agreement with Goldak for residual stress predictions, validated experimentally using the contour method on the cone, and aligns well with experimental measurements of distortion. Additionally, the computational time for the ECTI model is only 23 % of that for the Goldak model in the thin-wall geometry and 19.3 % in the cone geometry.
{"title":"An enhanced characteristic time-based heat input model for simulating laser heating in additive manufacturing","authors":"Mahsa Heidari , Louis N.S. Chiu , Ming Liu , Aijun Huang , Bernard Rolfe , Wenyi Yan","doi":"10.1016/j.jmatprotec.2025.119129","DOIUrl":"10.1016/j.jmatprotec.2025.119129","url":null,"abstract":"<div><div>The Characteristic Time-Based Heat Input (CTI) model is an efficient agglomerated laser approach for simulating a heat source in additive manufacturing, significantly reducing computational costs while maintaining accuracy. In the CTI model, Goldak's moving heat source is applied to laser tracks using a characteristic heating time, based on the ratio of the heat source axis to the scanning speed. However, this characteristic heating time is valid only for material points along the central line of the deposited track, which may lead to applying inaccurate power density distribution at other points within the track. This study enhances the CTI model by reformulating the characteristic heating time through volume averaging the laser exposure time for all points within the semi-elliptical cylinder, achieving more precise temperature predictions while preserving computational efficiency. The improvements of the enhanced CTI (ECTI) model are evaluated through a comparative study with experimental data, the detailed Goldak model, and the original CTI model, focusing on laser-directed energy deposition (DED) of two Ti-6Al-4V components: a thin-wall and a cone. The refined characteristic heating time in the ECTI model demonstrates significant mitigation of temperature history deviation for DED (>7.6 % error reduction). The ECTI model shows close agreement with Goldak for residual stress predictions, validated experimentally using the contour method on the cone, and aligns well with experimental measurements of distortion. Additionally, the computational time for the ECTI model is only 23 % of that for the Goldak model in the thin-wall geometry and 19.3 % in the cone geometry.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119129"},"PeriodicalIF":7.5,"publicationDate":"2025-11-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145448852","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 : 2025-10-28DOI: 10.1016/j.jmatprotec.2025.119126
Yuxin Liu , Dengyong Wang , Shuofang Zhou , Feiji Kong , Shuaidong Chen , Jingyu Zhao , Hongchang Ni
In-wall co-rotating electrochemical machining (ICRECM) is an innovative electrochemical method primarily applied to manufacturing of thin-walled annular components in the aerospace field. However, during the electrochemical forming process, relative motion causes the electrolyte flow channels to gradually become tortuous and irregular. This reduces the forming accuracy of the inner surface grid structure. To address this issue, this paper proposes an open flow field mode with a cathode internal liquid supply and establishes a corresponding flow field simulation model. Through this simulation model, the locality of the flow field mode and the influence of rotational position on the flow field distribution are analyzed and experimentally verified. A processing strategy that periodically reverses the rotation direction is proposed to improve the forming accuracy and symmetry of the inner surface grid. Experimental results show that under this flow field mode and processing strategy, grid structures with a depth of 10 mm can be stably machined, with a grid symmetry deviation within 0.1 mm and a grid wall thickness uniformity within 0.1 mm in most areas. This demonstrates that the open flow field pattern and processing strategy effectively overcome the limitations of closed flow channels and structural factors during the machining process, thereby enhancing the types of structures that ICRECM can process, making it a highly promising technology for the aerospace industry.
{"title":"The precise co-rotating electrochemical machining of inner surface mesh structures using open flow fields","authors":"Yuxin Liu , Dengyong Wang , Shuofang Zhou , Feiji Kong , Shuaidong Chen , Jingyu Zhao , Hongchang Ni","doi":"10.1016/j.jmatprotec.2025.119126","DOIUrl":"10.1016/j.jmatprotec.2025.119126","url":null,"abstract":"<div><div>In-wall co-rotating electrochemical machining (ICRECM) is an innovative electrochemical method primarily applied to manufacturing of thin-walled annular components in the aerospace field. However, during the electrochemical forming process, relative motion causes the electrolyte flow channels to gradually become tortuous and irregular. This reduces the forming accuracy of the inner surface grid structure. To address this issue, this paper proposes an open flow field mode with a cathode internal liquid supply and establishes a corresponding flow field simulation model. Through this simulation model, the locality of the flow field mode and the influence of rotational position on the flow field distribution are analyzed and experimentally verified. A processing strategy that periodically reverses the rotation direction is proposed to improve the forming accuracy and symmetry of the inner surface grid. Experimental results show that under this flow field mode and processing strategy, grid structures with a depth of 10 mm can be stably machined, with a grid symmetry deviation within 0.1 mm and a grid wall thickness uniformity within 0.1 mm in most areas. This demonstrates that the open flow field pattern and processing strategy effectively overcome the limitations of closed flow channels and structural factors during the machining process, thereby enhancing the types of structures that ICRECM can process, making it a highly promising technology for the aerospace industry.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"346 ","pages":"Article 119126"},"PeriodicalIF":7.5,"publicationDate":"2025-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145413610","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 : 2025-10-28DOI: 10.1016/j.jmatprotec.2025.119125
Haotian Li , Lianggang Guo , Heng Li , Yunpeng Xin , Yanwei Wang , Shuai Zhu , Xiangdong Hu
Profiled ring rolling (PRR) is a local-loading forming process for manufacturing profiled rings. Limited understanding of metal flow laws and competitive behaviors during PRR hinders effective metal flow control, challenging precision forming. This study investigates a representative profiled ring with inner and outer grooves (PRIOG), revealing competitive behaviors of metal flow and proposing oriented control strategies to achieve precision forming. First, the cross-section forming mechanism of the PRIOG is analyzed based on deformation modes and metal flow in the active and passive deformation zones (ADZ and PDZ). Uneven axial metal flow, resulting from differing deformation modes between the inner and outer ADZs, critically affects cross-section forming. Outer groove forming is driven by axial flow in the outer ADZ, whereas inner groove forming arises from radial bending of the blank induced by uneven axial flow. Second, competitive behaviors between axial and circumferential metal flow, inner/outer groove forming, and cross-section forming versus diameter growth under varying PRR parameters are clarified. Embedding this knowledge into a neural network model enables the establishment of a precision forming criterion. Based on these, oriented control strategies, including forging design, blank design, roller motion design, and multi-step PRR, are proposed to enhance the competitive advantage of axial metal flow in the outer ADZ, ensuring precision forming. Finally, the application of these strategies to an industrial-scale PRIOG successfully achieved precision forming in production trials. The results provide critical insights into metal flow competition during PRR, offering a theoretical foundation and technical support for the process design.
{"title":"Competitive behaviors and oriented control strategies of metal flow in profiled ring rolling","authors":"Haotian Li , Lianggang Guo , Heng Li , Yunpeng Xin , Yanwei Wang , Shuai Zhu , Xiangdong Hu","doi":"10.1016/j.jmatprotec.2025.119125","DOIUrl":"10.1016/j.jmatprotec.2025.119125","url":null,"abstract":"<div><div>Profiled ring rolling (PRR) is a local-loading forming process for manufacturing profiled rings. Limited understanding of metal flow laws and competitive behaviors during PRR hinders effective metal flow control, challenging precision forming. This study investigates a representative profiled ring with inner and outer grooves (PRIOG), revealing competitive behaviors of metal flow and proposing oriented control strategies to achieve precision forming. First, the cross-section forming mechanism of the PRIOG is analyzed based on deformation modes and metal flow in the active and passive deformation zones (ADZ and PDZ). Uneven axial metal flow, resulting from differing deformation modes between the inner and outer ADZs, critically affects cross-section forming. Outer groove forming is driven by axial flow in the outer ADZ, whereas inner groove forming arises from radial bending of the blank induced by uneven axial flow. Second, competitive behaviors between axial and circumferential metal flow, inner/outer groove forming, and cross-section forming versus diameter growth under varying PRR parameters are clarified. Embedding this knowledge into a neural network model enables the establishment of a precision forming criterion. Based on these, oriented control strategies, including forging design, blank design, roller motion design, and multi-step PRR, are proposed to enhance the competitive advantage of axial metal flow in the outer ADZ, ensuring precision forming. Finally, the application of these strategies to an industrial-scale PRIOG successfully achieved precision forming in production trials. The results provide critical insights into metal flow competition during PRR, offering a theoretical foundation and technical support for the process design.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"346 ","pages":"Article 119125"},"PeriodicalIF":7.5,"publicationDate":"2025-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145413065","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 : 2025-10-28DOI: 10.1016/j.jmatprotec.2025.119128
Somin Shin, Hyun Jun Ryu, Seong Jae Kim, Dong Geun Kim, Sanha Kim
In integrated device manufacturing, the demand for ultrafine polished surfaces without defects continues to increase as the device geometries scale down. Residual particles remaining on wafer surfaces after abrasive polishing can lead to considerable yield losses, especially as nanoscale contaminants increasingly act as killer defects in advanced devices. Polyvinyl alcohol (PVA) brushes, characterized by their soft, flexible, and porous nature, are widely adopted after surface polishing to remove such contaminants via direct contact with the substrate. However, when it comes to removing ultrafine particles smaller than a micrometer, conventional brushes exhibit much lower cleaning efficiency, limited by the length scale of their pore structures. To address this challenge, we first study the correlation between brush pore size and particle removal efficiency based on contact mechanics theory. The model suggests that brushes featuring reduced pore sizes possess high density of surface asperities, therefore enhancing the probability of physical contact with the contaminants. Furthermore, the removal force generated by the finer-pored brush is more likely to exceed the detachment threshold of surface particles. To realize the downsized porous PVA brush, we employed sodium chloride particles as the sacrificial material during PVA brush synthesis which allows miniaturized pore sizes down to 12.5 μm. Experiments using particles ranging from tens of nanometers to several micrometers validate the model’s predictions and demonstrate that downsizing brush pores from a hundred micrometers to tens of micrometers significantly improves the removal efficiency, particularly for submicron particles, where the effect of pore scale becomes increasingly dominant. This research contributes to a deeper understanding of physical particle removal mechanisms in brush scrubbing and provides practical insights for designing pore-scale-optimized brushes that enhance cleaning performance, minimize surface defects, and ultimately support yield enhancement in future integrated 3D device manufacturing.
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