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Online pre-perception of forming state based on real-time measurement in spinning of thin-walled shell component 基于实时测量的薄壁壳件旋压成形状态在线预感知
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-26 DOI: 10.1016/j.jmatprotec.2024.118676
Xinggang Yan, Pengfei Gao, Mei Zhan, Xinshun Li, Han Zhang
Die-less spinning is an advance incremental forming process widely used for the manufacturing of thin-walled shell components. During the spinning, workpiece shape and forming state both change continuously, and the influence of process parameters on the forming results is also time-varying, which make it difficult to control the forming quality. To this end, this work develops a real-time measurement system and an online pre-perception method to provide technical support for dynamic control of the spinning process. Specifically, the real-time measurement system is constructed firstly by placing two laser profilers bilaterally at two sides of the workpiece. Based on the measuring data of two laser profilers, the profile data of workpiece cross-section is obtained by coordinate transformation, data denoising and correcting the error caused by inclined workpiece surface. Then, an algorithm is proposed to identify the critical geometric parameters (flange width, roller action radius, wall thickness and flange fluctuation degree) of workpiece shape from the profile data. In contrast to the measurement results by a three-coordinate measuring machine, the developed system presents a real-time measurement error less than 4 %. Moreover, an online pre-perception method of wall thickness and wrinkling defect is developed based on the real-time measured workpiece shape parameters. The online pre-perception of wall thickness and wrinkling defect presents high accuracy with the relative error less than 2.1 %. The above results indicate both the workpiece dimensions and spinning state can be well real-time measured and online pre-perceived, which can provide important foundation for the study of time-varying influence and dynamic control of the spinning process.
无模旋压是一种先进的增量成形工艺,广泛应用于薄壁壳件的制造。在旋压过程中,工件形状和成形状态都是连续变化的,工艺参数对成形结果的影响也是时变的,给成形质量的控制带来了困难。为此,本工作开发了实时测量系统和在线预感知方法,为纺纱过程的动态控制提供技术支持。具体而言,首先在工件两侧两侧放置两个激光轮廓仪,构建实时测量系统。以两台激光轮廓机的测量数据为基础,通过坐标变换、数据去噪和工件表面倾斜误差校正,得到工件截面轮廓数据。然后,提出了一种从型材数据中识别工件形状关键几何参数(凸缘宽度、滚轮作用半径、壁厚和凸缘起伏度)的算法。与三坐标测量机的测量结果相比,该系统的实时测量误差小于4 %。在此基础上,提出了一种基于实时测量工件形状参数的壁厚和起皱缺陷在线预感知方法。对壁厚和起皱缺陷的在线预感知精度较高,相对误差小于2.1 %。上述结果表明,工件尺寸和旋压状态都可以很好地实时测量和在线预感知,为研究旋压过程的时变影响和动态控制提供了重要的基础。
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引用次数: 0
An efficient high-quality cutting method for thick SiCf/SiC ceramic matrix composites using UV laser multiline layered scanning with focus increment optimization 利用紫外激光多线分层扫描和焦点增量优化,实现厚 SiCf/SiC 陶瓷基复合材料的高效优质切割方法
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-26 DOI: 10.1016/j.jmatprotec.2024.118674
Zhiwei Xu , Yuanyuan Jiang , Jinxuan Bai , Linmao Qian
Laser-layered scanning techniques have achieved considerable success in cutting and drilling applications. However, their effectiveness in processing SiCf/SiC ceramic matrix composites—critical materials for next-generation aerospace thermal components—remains less than optimal. This study addresses the challenge of enhancing the quality and efficiency of cutting thick samples by being the first to highlight the crucial influence of focus increment adjustments in the laser-layered scanning process. Specifically, it examines the relationship between the predetermined laser focus drop per layer and the actual ablation depth achieved. Systematic analysis explores the impact of focus increment adjustments on both the macroscopic structural alterations during cutting and the microstructural characteristics of the cut surfaces. The findings demonstrate that the UV nanosecond laser multi-line layered scanning technique is particularly effective for processing thick SiCf/SiC samples, achieving a surface area of 5 × 5 mm² (Sa 366.92 nm) in just 117.58 s. By optimising the focus increment, a high and stable material removal rate is maintained throughout the process, reducing surface oxidation, minimising the formation of a recast layer, and reducing fibre interface debonding. Additionally, the study reveals the mechanism behind the formation of surface taper and presents a method to achieve a taper-free surface by adjusting the laser incidence angle. These findings provide valuable insights for the rapid and high-quality machining of matrix composites, offering significant improvements over existing methods.
激光分层扫描技术在切割和钻孔应用中取得了巨大成功。然而,它们在加工 SiCf/SiC 陶瓷基复合材料(下一代航空航天热部件的关键材料)方面的效果仍未达到最佳。本研究首次强调了激光分层扫描过程中焦点增量调整的关键影响,从而解决了提高厚样品切割质量和效率的难题。具体来说,它研究了每层预定激光焦点下降与实际达到的烧蚀深度之间的关系。系统分析探讨了焦点增量调整对切割过程中宏观结构变化和切割表面微观结构特征的影响。研究结果表明,紫外纳秒激光多线分层扫描技术对处理厚的 SiCf/SiC 样品特别有效,只需 117.58 秒就能获得 5 × 5 mm² 的表面积(Sa 366.92 nm)。通过优化焦点增量,在整个加工过程中保持了较高且稳定的材料去除率,减少了表面氧化,最大限度地减少了重铸层的形成,并降低了纤维界面脱粘。此外,研究还揭示了表面锥度形成的机理,并提出了一种通过调整激光入射角实现无锥度表面的方法。这些发现为基体复合材料的快速和高质量加工提供了宝贵的见解,与现有方法相比有了显著的改进。
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引用次数: 0
Influence of Cu/Ni coating on microstructure and mechanical properties in steel/aluminum single-sided resistance spot welding joint 铜/镍涂层对钢/铝单面电阻点焊接头微观结构和机械性能的影响
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-25 DOI: 10.1016/j.jmatprotec.2024.118675
Gang Wang, Kang Zhou, Baokai Ren, Wenxiao Yu
Due to significant differences in physical and chemical properties between aluminum and steel, directly joining them using traditional resistance spot welding (RSW) process often cannot achieve satisfactory high-quality joints. In this work, some key factors influencing the quality of steel/aluminum welded joints were analyzed and a method based on fracture mechanism analysis was proposed aiming to improve the strength of steel/aluminum joints. The proposed method utilized a copper/nickel bimetallic coating on the steel surfaces, which was joined with aluminum alloy through single-sided RSW. This approach effectively addressed severe deformation of aluminum alloy and reduced stress cracks caused by residual stress in joints. Furthermore, the influence of coating on the microstructure and mechanical properties of steel/aluminum interface was further investigated. Experimental results showed the coating participated in interfacial metallurgical reactions, mainly forming intermetallic compounds (IMCs) such as Ni‍‍-Al, Fe-Cu, Cu-Al, and Fe-Ni, which mixed with Fe-Al compounds. Additionally, the coating refined the IMC grain size, resulting in smaller grains compared to Fe2Al5, the primary IMC in uncoated joints. Moreover, the coating reduced IMC layer thickness to within 2.0‍ μm at the weld center, and increased thinner IMC layer thickness by 0.4 μm at the weld periphery. This implied that the coating inhibited the mutual diffusion of Fe and Al atoms, preventing the formation of Fe-Al compounds and promoting a more uniform IMC layer thickness. Microhardness and tensile tests indicated that the coating reduced the hardness gradient of steel/aluminum interface, and increased IMC layer toughness and strength, improving the overall mechanical properties of the joints. The coated steel/aluminum joints with button fracture achieved a peak load of 6.7 kN and an average tensile-shear strength of 127.5 MPa, representing a 49.3 % increase in strength compared to uncoated steel/aluminum joints. This work will provide theoretical insights for steel/aluminum RSW and promote academic and practical engineering applications.
由于铝和钢在物理和化学性质上存在显著差异,使用传统的电阻点焊(RSW)工艺直接连接铝和钢往往无法获得令人满意的高质量焊点。本研究分析了影响钢/铝焊接接头质量的一些关键因素,并提出了一种基于断裂机理分析的方法,旨在提高钢/铝接头的强度。所提出的方法利用钢表面的铜/镍双金属涂层,通过单面 RSW 与铝合金连接。这种方法有效地解决了铝合金的严重变形问题,并减少了接头中残余应力引起的应力裂纹。此外,还进一步研究了涂层对钢/铝界面微观结构和机械性能的影响。实验结果表明,涂层参与了界面冶金反应,主要形成了金属间化合物(IMC),如 Ni‍‍-Al、Fe-Cu、Cu-Al 和 Fe-Ni,并与 Fe-Al 化合物混合。此外,涂层还细化了 IMC 晶粒大小,与未涂层接头中的主要 IMC Fe2Al5 相比,IMC 晶粒更小。此外,涂层还将焊缝中心的 IMC 层厚度减小到 2.0‍ μm 以内,并将焊缝外围较薄的 IMC 层厚度增加了 0.4 μm。这意味着涂层抑制了铁原子和铝原子的相互扩散,阻止了铁铝化合物的形成,并使 IMC 层厚度更加均匀。显微硬度和拉伸试验表明,涂层减少了钢/铝界面的硬度梯度,提高了 IMC 层的韧性和强度,改善了接头的整体机械性能。与未涂层的钢/铝接头相比,带钮扣断裂涂层的钢/铝接头达到了 6.7 kN 的峰值载荷和 127.5 MPa 的平均拉伸剪切强度,强度提高了 49.3%。这项工作将为钢/铝 RSW 提供理论依据,并促进学术和实际工程应用。
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引用次数: 0
Multimodal experimental and numerical evaluation of Residual Stress in AA6082-T6 Friction Stir Welding pipe girths AA6082-T6搅拌摩擦焊管径残余应力的多模态试验与数值计算
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-23 DOI: 10.1016/j.jmatprotec.2024.118665
Alessandro Tognan , Noel Sheshi , Emanuele Vaglio , Vladimir Luzin , Daniel Hattingh , Enrico Salvati
Although Residual Stress (RS) induced by Friction Stir Welding (FSW) has been widely investigated for planar weldments, the same attention has not been paid as far as the curved variant is concerned. To comprehensively address this gap, the present paper studies the RS in three AA6082-T6 FSW pipes (37.5 mm outer diameter × 3 mm thickness) manufactured with varying feed speeds, i.e. 50, 75, 100 mm/min. RS evaluations were cross-validated by two independent experimental methods, i.e. Neutron Diffraction and Contour Method. A novel multi-physics Finite Element (FE) model was implemented and calibrated using the previously obtained experimental outcomes to shed light on the key physical mechanism responsible for the arising of RS. The analysis unveiled M-like hoop RS patterns akin to flat FSW butt-welds but having lower magnitudes ranging from −20 MPa to 65 MPa, most likely due to the different thermal histories. The axial RS oscillates between -20 MPa and 20 MPa, whereas the radial component turned out to negligible. The FE model also demonstrated how feed speed, plunge force, and external clamping conditions alter RS magnitude while identifying 75 mm/min as the optimal speed that minimises the peak hoop RS to 40 MPa.
虽然搅拌摩擦焊在平面焊件中的残余应力问题已经得到了广泛的研究,但对于曲面焊件的残余应力问题却没有得到足够的重视。为了全面解决这一差距,本文研究了三种AA6082-T6 FSW管(外径37.5 mm ×厚度3mm)在不同进给速度(即50、75和100 mm/min)下制造的RS。RS评价采用中子衍射法和轮廓法两种独立的实验方法进行交叉验证。利用之前获得的实验结果,建立并校准了一种新的多物理场有限元(FE)模型,以阐明产生RS的关键物理机制。分析结果揭示了类似于FSW平对接焊缝的m形箍RS模式,但其强度较低,范围在- 20 MPa至65 MPa之间,很可能是由于不同的热历史。轴向RS在-20 MPa和20 MPa之间振荡,而径向分量则可以忽略不计。有限元模型还展示了进给速度、插入力和外部夹紧条件如何改变RS值,并确定75 mm/min为将箍箍峰值RS降至40 MPa的最佳速度。
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引用次数: 0
Single-crystal structure formation in laser directed energy deposited Inconel 718 through process parameter optimization and substrate orientation tuning 通过工艺参数优化和基底取向调整在激光定向能沉积 Inconel 718 中形成单晶结构
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-22 DOI: 10.1016/j.jmatprotec.2024.118673
Zuo Li , Xin Lin , Shang Sui , Xuan Zhao , Bo Yao , Chongliang Zhong , Andres Gasser , Hua Tan
A transverse grain boundary perpendicular to the applied loading direction is normally considered a main reason for the deterioration of the mechanical properties of nickel-based superalloys at high temperatures. Therefore, reducing or even eliminating these types of grain boundaries can effectively delay failure and improve high-temperature mechanical properties. In this study, the feasibility of process parameter optimization and substrate rotation was explored for fabricating single-crystal Inconel 718 specimens during laser directed energy deposition (LDED). The study determined that optimizing the process parameters was dependent on the ability to enlarge the [001] region at the bottom of the melt pool as much as possible. Simultaneously, ensuring that the remelting depth exceeded the stray grain region height at the top of the melt pool was necessary. Therefore, that the stray grains can be fully erased during the subsequent deposition process. Accordingly, an Inconel 718 single-walled specimen (height: 20 mm) with a full single-crystal structure was successfully fabricated using LDED for the first time. However, this approach remains insufficient for fabricating a block with a single-crystal structure, as SGs appear readily in the overlapping regions. Substrate rotation was further considered, where ensuring that one side of the melt pool was in the [001]-grain region was critical. Although the other side of the melt pool featured SGs, they were eliminated through the following overlapping process, as the SG region in the current melt pool corresponded to the [001]-grain region in the next melt pool. Through these two approaches, a small-format single-crystal block with dimensions of 27 × 8.3 × 1.3 mm (length × width × height) was successfully fabricated. Because the Inconel 718 superalloy is not specifically designed for single-crystal structure generation, a large-format block with a single-crystal structure still cannot be fabricated using these approaches. Nevertheless, the findings remain insightful because they demonstrate a wider range of variable microstructures achievable with additive manufacturing processes than with traditional forming processes such as casting or forging and may provide more opportunities for improving the mechanical properties. In addition, the preparation of a small-format single-crystal structure has significant applications in repairing damaged components such as aeroengine blades.
垂直于加载方向的横向晶界通常被认为是镍基超合金在高温下机械性能下降的主要原因。因此,减少甚至消除这类晶界可有效延缓失效并改善高温机械性能。本研究探讨了在激光定向能沉积(LDED)过程中制作单晶 Inconel 718 试样的工艺参数优化和基底旋转的可行性。研究发现,工艺参数的优化取决于尽可能扩大熔池底部 [001] 区域的能力。同时,必须确保重熔深度超过熔池顶部杂散晶粒区域的高度。因此,杂散晶粒可在随后的沉积过程中被完全清除。因此,利用 LDED 首次成功制造出了具有完整单晶结构的 Inconel 718 单壁试样(高度:20 毫米)。然而,这种方法仍不足以制造出具有单晶结构的块体,因为在重叠区域很容易出现 SG。我们进一步考虑了基底旋转的问题,其中确保熔池的一侧位于[001]晶粒区域至关重要。虽然熔池的另一侧出现了 SG,但由于当前熔池中的 SG 区域与下一个熔池中的 [001] 晶粒区域相对应,因此通过接下来的重叠过程消除了 SG。通过这两种方法,成功制造出了尺寸为 27 × 8.3 × 1.3 毫米(长 × 宽 × 高)的小规格单晶块。由于 Inconel 718 超耐热合金并非专为生成单晶结构而设计,因此使用这些方法仍无法制造出具有单晶结构的大规格晶块。尽管如此,这些研究结果仍然很有见地,因为与铸造或锻造等传统成型工艺相比,它们证明了增材制造工艺可实现的可变微观结构范围更广,并为改善机械性能提供了更多机会。此外,制备小尺寸单晶结构在修复航空发动机叶片等受损部件方面也有重要应用。
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引用次数: 0
Splashing effects and mechanism in water jet-guided laser processing of Cf/SiC composites 水射流引导激光加工 Cf/SiC 复合材料过程中的飞溅效应及其机理
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-19 DOI: 10.1016/j.jmatprotec.2024.118671
Binying Bao , Guangyi Zhang , Zhongan Chen , Yang Chao , Wenwu Zhang
Water jet-guided laser (WJGL) processing of ceramic matrix composites offers smooth cutting surfaces and minimizes defects such as delamination, burrs, and recast layers. However, the processing ability of WJGL is limited by the stability of the water jet. Splashing is a critical factor that affects water jet stability. This study investigates the splashing morphology and its impact mechanism during WJGL processing of continuous carbon fiber reinforced silicon carbide (Cf/SiC) composites. High-speed cameras were used to capture splashing morphologies and laser transmission states during drilling and grooving. The results indicate that the splashing morphology was significantly affected by the water jet speed and the micro-hole/groove depth, resulting in behaviors such as water accumulation, droplets falling, rebound droplets, splash impact, water film, and mist, which distorted or even broke the water jet. The laser escaped in the distorted water jet, leading to a reduction in material removal rate. The splashing at the water jet speed of 160 m/s resulted in a 61.1 % reduction in material removal rate during drilling compared to 40 m/s. In addition, a method of placing a porous water-absorbing material on the workpiece surface was proposed, which effectively improved the material removal rate. This paper presents a theoretical basis for comprehending and addressing splashing in WJGL processing.
水射流引导激光(WJGL)加工陶瓷基复合材料可提供光滑的切割表面,并最大限度地减少分层、毛刺和重铸层等缺陷。然而,WJGL 的加工能力受到水射流稳定性的限制。飞溅是影响水射流稳定性的一个关键因素。本研究调查了连续碳纤维增强碳化硅(Cf/SiC)复合材料在 WJGL 加工过程中的飞溅形态及其影响机制。在钻孔和开槽过程中,使用高速相机捕捉飞溅形态和激光传输状态。结果表明,水花形态受水射流速度和微孔/槽深度的影响很大,会出现积水、水滴下落、水滴反弹、水花冲击、水膜和水雾等行为,使水射流变形甚至断裂。激光在扭曲的水射流中逃逸,导致材料去除率降低。与 40 米/秒的水射流速度相比,160 米/秒的水射流速度下的飞溅导致钻孔过程中的材料去除率降低了 61.1%。此外,还提出了一种在工件表面放置多孔吸水材料的方法,有效提高了材料去除率。本文为理解和解决 WJGL 加工中的飞溅问题提供了理论依据。
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引用次数: 0
Achieving enhanced high-temperature strength in Ti-48Al-1Fe alloy sheets by direct hot pack-rolling of powder-sintered billets without cogging 通过直接热包轧粉末烧结坯料实现 Ti-48Al-1Fe 合金板材高温强度的增强而不产生钝化
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-19 DOI: 10.1016/j.jmatprotec.2024.118669
Hanlin Wang , Ce Zhang , Xiangyang Liu , Hao Yu , Rui Liu , Jiazhen Zhang , Xin Lu
The TiAl alloy is a novel lightweight high-temperature structural material that exhibits exceptional performance. The brittleness and mechanical properties of the material can be enhanced by improving the microstructure via rolling. The Ti-48Al-1Fe alloy with high density was produced using powder compaction and pressure-less sintering. Subsequently, the TiAl alloy sheet was formed via hot pack rolling. This study examined the sheet formability of PM Ti-48Al-1Fe alloy sheets at various temperatures, as well as the microstructure and mechanical properties at varied levels of rolling deformations. The microstructure of the powder metallurgy (PM) TiAl alloy sheet has a unique duplex structure, consisting of α2/γ lamellar colonies and a composite structure. The rolling deformation process generates spherical recrystallized grains, which effectively reduce stress concentration. The enhanced composite structure is mostly localized at the interfaces between grains, creating a robust obstacle for the movement of dislocations at high temperatures. This results in the desired outcome of reinforcing the mechanical properties of the material at high temperatures through grain boundary strengthening. This study demonstrates that the ultimate tensile strength (UTS) of PM TiAl sheet tensile specimens in the rolling direction at room temperature is 443 MPa with 1 % elongation, whereas at 800 °C, the UTS rises to 548 MPa with 2.5 % elongation. This study proposes a novel process for the efficient production of Ti48Al1Fe sheets with good high-temperature mechanical properties. This technique entails the hot rolling of high-density sintered powder metallurgy billets, offering an innovative approach for the economical and swift production of TiAl alloy sheets during practical manufacturing process.
钛铝合金是一种新型轻质高温结构材料,具有优异的性能。通过轧制改善微观结构可提高材料的脆性和机械性能。利用粉末压制和无压烧结技术生产出了高密度的 Ti-48Al-1Fe 合金。随后,通过热包轧制形成了 TiAl 合金板材。本研究考察了粉末 Ti-48Al-1Fe 合金板材在不同温度下的成形性,以及在不同轧制变形水平下的微观结构和机械性能。粉末冶金(PM)TiAl 合金板材的微观结构具有独特的双相结构,由 α2/γ 层状菌落和复合结构组成。轧制变形过程会产生球形再结晶晶粒,从而有效减少应力集中。增强的复合结构主要集中在晶粒之间的界面上,为位错在高温下的移动提供了强有力的障碍。这就达到了通过晶界强化在高温下增强材料力学性能的预期效果。本研究表明, PM TiAl 板材拉伸试样在室温下沿轧制方向的极限拉伸强度(UTS)为 443 兆帕(伸长率为 1%),而在 800 °C 时,UTS 上升到 548 兆帕(伸长率为 2.5%)。本研究提出了一种高效生产具有良好高温机械性能的 Ti48Al1Fe 板材的新工艺。该技术需要对高密度烧结粉末冶金坯料进行热轧,为在实际生产过程中经济、快速地生产 TiAl 合金板材提供了一种创新方法。
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引用次数: 0
Architecting unusual dual-gradient structures to overcome the strength-ductility trade-off in metallic materials 构建非同寻常的双梯度结构,克服金属材料中的强度-电导率权衡问题
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-19 DOI: 10.1016/j.jmatprotec.2024.118670
Ziru Han , Kaiwen Liu , Lichu Zhou , Feng Fang , Jianqing Jiang , Xuefeng Zhou
It has been a longstanding challenge for metallic materials with homogeneous structures to escape the common strength-ductility trade-off dilemma. In this work, an unusual dual-gradient structure, consisting of both grain size gradient and strain gradient, was introduced into commercial pure titanium wires by mediating torsion strain and annealing parameters to address this issue. Microstructural characteristics of the annealed and tensile samples were systematically characterized by electron backscattered diffraction and transmission electron microscope to unveil the origin and influence of dual-gradient structure. The results show that the strain and grain size distributions can be controlled by tuning torsion strain followed by partial recrystallization annealing. Specifically, when the torsion angles are 40π and 50π, the corresponding annealed samples are characterized with a gradient decline of both grain size and residual strain from the center to the surface, while the samples with a 20π torsion angle exhibit the opposite gradient characteristics. Compared with homogeneously structured pure titanium with a yield strength of 268 MPa, the samples with a 40π torsion angle shows a remarkable yield strength of 379 MPa, which increases by 40 %, while without sacrificing the uniform elongation. This improved strength-ductility synergy can be attributed to the combined effects of fine grain strengthening, dislocation strengthening, and back stress strengthening, endowed by dual-gradient structure. Dynamic strain adjustments throughout the deformation process help to minimize the hardness difference between soft and hard zones in the heterostructures, promoting better deformation coordination between various layers and ultimately inducing a decent ductility of dual-gradient structure. This study not only offers a new insight and guidance to solve the strength-ductility trade-off dilemma, but also provides an attractive method for industries to fabricate dual-gradient structure in a low-cost and simple way.
长期以来,具有均匀结构的金属材料一直面临着如何摆脱常见的强度-电导率权衡困境的挑战。本研究通过调节扭转应变和退火参数,在商用纯钛金属丝中引入了由晶粒大小梯度和应变梯度组成的非同寻常的双梯度结构,以解决这一问题。通过电子反向散射衍射和透射电子显微镜对退火和拉伸样品的微观结构特征进行了系统表征,以揭示双梯度结构的起源和影响。结果表明,应变和晶粒尺寸分布可以通过调整扭转应变和部分再结晶退火来控制。具体来说,当扭转角为 40π 和 50π 时,相应的退火样品的晶粒大小和残余应变都呈现出从中心向表面梯度下降的特征,而扭转角为 20π 的样品则呈现出相反的梯度特征。与屈服强度为 268 兆帕的均匀结构纯钛相比,扭转角为 40π 的样品的屈服强度高达 379 兆帕,显著提高了 40%,而且没有牺牲均匀伸长率。这种强度-电导率协同作用的改善可归因于双梯度结构赋予的细晶粒强化、位错强化和背应力强化的综合效应。整个变形过程中的动态应变调整有助于最大限度地减小异质结构中软硬区之间的硬度差异,促进各层之间更好的变形协调,最终使双梯度结构具有良好的延展性。这项研究不仅为解决强度-延展性权衡难题提供了新的见解和指导,还为工业界以低成本、简单的方式制造双梯度结构提供了一种极具吸引力的方法。
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引用次数: 0
Reusability of Ti-6Al-4V powder in laser powder bed fusion: Influence on powder morphology, oxygen uptake, and mechanical properties 激光粉末床熔融中 Ti-6Al-4V 粉末的重复使用性:对粉末形态、吸氧量和机械性能的影响
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-19 DOI: 10.1016/j.jmatprotec.2024.118672
Zhongming Zhuo , Ruyi Ji , Lei Wang , Jian Mao
The reusability of Ti-6Al-4V powder in laser powder bed fusion (L-PBF) processes is essential for achieving economic efficiency and maintaining consistent product quality. While powder reuse offers clear cost benefits, it also raises concerns about preserving material quality and consistency across multiple build cycles. This study, therefore, investigates the effects of repeated powder reuse on key parameters, including powder morphology, oxygen uptake, and mechanical properties. The results demonstrate that the repeated reuse of the powder results in a decrease in satellite particles and an increase in particle deformation. Oxygen content progressively increases with each cycle; however, smooth particles maintain relatively stable oxygen levels, whereas rough particles exhibit a more pronounced rise in oxygen content. Mechanical testing shows that as oxygen levels increase, tensile strength improves, yet elongation decreases. This observed increase in strength can be partially attributed to oxygen-induced phase transformations, where localized oxygen enrichment promotes the formation of the face-centered cubic (FCC) β phase, contributing to material strengthening. These findings emphasize the importance of optimizing powder reuse strategies, particularly in controlling oxygen levels, to achieve the optimal balance between strength and ductility in high-quality material properties.
在激光粉末床熔融(L-PBF)工艺中,Ti-6Al-4V 粉末的可重复使用性对于实现经济效益和保持稳定的产品质量至关重要。虽然粉末重复使用具有明显的成本优势,但它也引发了在多个制造周期中保持材料质量和一致性的问题。因此,本研究调查了粉末重复使用对粉末形态、吸氧量和机械性能等关键参数的影响。结果表明,粉末的重复使用会导致卫星颗粒的减少和颗粒变形的增加。氧含量随着每次循环而逐渐增加;然而,光滑的颗粒能保持相对稳定的氧含量,而粗糙的颗粒则表现出更明显的氧含量上升。机械测试表明,随着氧含量的增加,拉伸强度提高,但伸长率降低。观察到的这种强度增加可部分归因于氧引起的相变,即局部氧富集促进了面心立方体(FCC)β 相的形成,从而增强了材料的强度。这些发现强调了优化粉末再利用策略的重要性,特别是在控制氧含量方面,以实现高质量材料性能中强度和延展性之间的最佳平衡。
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引用次数: 0
Effects of ultrasonic shot peening process on the microstructure and mechanical properties of nickel-based superalloys formed by selective laser melting 超声波喷丸强化工艺对选择性激光熔炼形成的镍基超合金微观结构和机械性能的影响
IF 6.7 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2024-11-17 DOI: 10.1016/j.jmatprotec.2024.118667
Lan Chen, Yunze Li, Tianqi Yu, Xinzhou Zhang, Xudong Ren
Selective laser melting (SLM) is an attractive additive manufacturing technique for fabricating high-performance superalloys engineering components. Unfortunately, these as-built parts generally exhibit unsatisfied mechanical properties because of their natural thermal residual stress and non-equilibrium microstructures. Ultrasonic shot peening (USP) can effectively inhibit defect expansion and even close pores, thereby improving the mechanical properties of alloys. In this study, the internal defects, residual stress and microhardness redistribution, tensile properties, as well as microstructural response of the GH3230 alloy treated by different ultrasonic peening time are systematically studied. USP treatment induces a significant carbides fragmentation and synthesizes surface gradient heterogeneous structure, which displays a microstructure gradient in grain size, carbides size and dislocation density from surface to core. Long-time USP treatment induces work softening of GH3230 alloys. The work softening mechanism of the GH3230 alloys after long-time USP treatment is ascribed to the increase of surface temperature and high stored strain energy. Both the microhardness and residual compressive stress in the softened region of GH3230 alloys are reduced. Work softening effect increases the surface plasticity of the GH3230 sample, which induces deeper gradient structure. The various strengthening mechanisms of gradient heterogeneous structures, as well as the multiple effects of hetero deformation induced (HDI) hardening, and densification strengthening are responsible for achieving strength-ductility synergy. The research findings provide new insights based on USP for improving the mechanical properties of heterogeneous superalloys engineering components.
选择性激光熔融(SLM)是一种极具吸引力的增材制造技术,可用于制造高性能超级合金工程部件。遗憾的是,由于其天然的热残余应力和非平衡微结构,这些成品部件通常表现出不尽人意的机械性能。超声波喷丸强化(USP)能有效抑制缺陷扩展,甚至封闭气孔,从而改善合金的机械性能。本研究系统研究了经不同时间超声强化处理的 GH3230 合金的内部缺陷、残余应力和显微硬度的重新分布、拉伸性能以及微观结构响应。USP 处理会导致碳化物明显破碎,并合成表面梯度异质结构,从表面到核心显示出晶粒大小、碳化物大小和位错密度的微观结构梯度。长时间的 USP 处理会引起 GH3230 合金的加工软化。长时间 USP 处理后 GH3230 合金的加工软化机制可归因于表面温度的升高和高存储应变能。GH3230 合金软化区域的显微硬度和残余压应力都降低了。加工软化效应增加了 GH3230 试样的表面塑性,从而诱发了更深的梯度结构。梯度异质结构的各种强化机制以及异质变形诱导(HDI)硬化和致密化强化的多重效应是实现强度-电导率协同作用的原因。研究结果为基于 USP 提高异质超合金工程部件的机械性能提供了新的见解。
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引用次数: 0
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Journal of Materials Processing Technology
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