Journal of Materials Processing Technology最新文献_第9页

Electrohydrodynamic embedded printing of low-viscosity ink: Printability and ink rheology

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-03 DOI: 10.1016/j.jmatprotec.2025.118753

Shihao Tan , Hao Yi , Zenan Niu , Di Wu , Huajun Cao

Electrohydrodynamic (EHD) embedded printing technology offers notable advantages in non-contact printing of low-viscosity inks, including one-step manufacturing, liquid encapsulation, and higher print resolution. By incorporating a liquid substrate, this technology stabilizes the printing process, enhances overall print quality, and mitigates issues such as the coffee ring effect. Despite these benefits, printability challenges remain, primarily due to interference from residual charges and the complex solute migration influenced by ink rheology. To address these, this study employed pulse signal modulation, successfully neutralizing residual charges and enhancing printing process stability. Additionally, key EHD printing parameters—pressure, printing height, and voltage—were optimized to further improve reliability and printability. The study also delved into the impact of ink rheology on printed structure morphology and, consequently, on the embedded morphology. Specifically, it analyzed how variations in rheological properties of low-viscosity inks influenced the printed structure, which in turn affected the final embedded morphology. A comprehensive mapping of these influences was developed, revealing correlations between printed structure morphology and embedded morphology. This work provides a comprehensive process guide that helps optimize printability and ink rheology in EHD embedded printing, thereby enhancing its potential for one-step manufacturing of flexible electronics and expanding its potential applications to high-precision embedded printing of other functional materials.

{"title":"Electrohydrodynamic embedded printing of low-viscosity ink: Printability and ink rheology","authors":"Shihao Tan , Hao Yi , Zenan Niu , Di Wu , Huajun Cao","doi":"10.1016/j.jmatprotec.2025.118753","DOIUrl":"10.1016/j.jmatprotec.2025.118753","url":null,"abstract":"<div><div>Electrohydrodynamic (EHD) embedded printing technology offers notable advantages in non-contact printing of low-viscosity inks, including one-step manufacturing, liquid encapsulation, and higher print resolution. By incorporating a liquid substrate, this technology stabilizes the printing process, enhances overall print quality, and mitigates issues such as the coffee ring effect. Despite these benefits, printability challenges remain, primarily due to interference from residual charges and the complex solute migration influenced by ink rheology. To address these, this study employed pulse signal modulation, successfully neutralizing residual charges and enhancing printing process stability. Additionally, key EHD printing parameters—pressure, printing height, and voltage—were optimized to further improve reliability and printability. The study also delved into the impact of ink rheology on printed structure morphology and, consequently, on the embedded morphology. Specifically, it analyzed how variations in rheological properties of low-viscosity inks influenced the printed structure, which in turn affected the final embedded morphology. A comprehensive mapping of these influences was developed, revealing correlations between printed structure morphology and embedded morphology. This work provides a comprehensive process guide that helps optimize printability and ink rheology in EHD embedded printing, thereby enhancing its potential for one-step manufacturing of flexible electronics and expanding its potential applications to high-precision embedded printing of other functional materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118753"},"PeriodicalIF":6.7,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175407","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}

引用次数: 0

Multi-material laser powder bed fusion additive manufacturing of architecturally designed dual-phase heterostructures using heterogeneous high-entropy alloys

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118708

Guoqing Huang , Bo Li , Hanlin He , Fuzhen Xuan

Since the concept of high-entropy alloys (HEAs) was introduced, the development of HEAs with synergistic strength and toughness has posed a significant challenge to researchers. Traditional approaches based on random biphasic solid-solution designs often suffer from high variability and poor controllability. In this study, a novel method for multi-material laser powder bed fusion (MM-LPBF) with staggered printing was developed. Using AlCuCoCrFeNi-HEA and MnCoCrFeNi-HEA powders as starting materials, three heterogeneous bi-metallic structures were fabricated. These include staggered multi-layer planar, staggered multi-layer rotating grating, and staggered multi-layer checkerboard structures. The printed bi-metallic structures exhibit a dual-phase heterogeneous composition, consisting of fine body-centered cubic (BCC) crystals and coarse columnar face-centered cubic (FCC) crystals. The interfaces between the dual phases are firmly bonded by transitional “dual-phase intercalation”. Experimental evaluations demonstrate that these structures possess enhanced interfacial strengthening and crack suppression, particularly the staggered multilayer checkerboard structure, which exhibits remarkable impact resistance and energy absorption across multiple reinforcement mechanisms. This study provides valuable insights for the field of metal-based multi-material additive manufacturing, offering new perspectives and potential applications for the future design and fabrication of diverse materials.

{"title":"Multi-material laser powder bed fusion additive manufacturing of architecturally designed dual-phase heterostructures using heterogeneous high-entropy alloys","authors":"Guoqing Huang , Bo Li , Hanlin He , Fuzhen Xuan","doi":"10.1016/j.jmatprotec.2024.118708","DOIUrl":"10.1016/j.jmatprotec.2024.118708","url":null,"abstract":"<div><div>Since the concept of high-entropy alloys (HEAs) was introduced, the development of HEAs with synergistic strength and toughness has posed a significant challenge to researchers. Traditional approaches based on random biphasic solid-solution designs often suffer from high variability and poor controllability. In this study, a novel method for multi-material laser powder bed fusion (MM-LPBF) with staggered printing was developed. Using AlCuCoCrFeNi-HEA and MnCoCrFeNi-HEA powders as starting materials, three heterogeneous bi-metallic structures were fabricated. These include staggered multi-layer planar, staggered multi-layer rotating grating, and staggered multi-layer checkerboard structures. The printed bi-metallic structures exhibit a dual-phase heterogeneous composition, consisting of fine body-centered cubic (BCC) crystals and coarse columnar face-centered cubic (FCC) crystals. The interfaces between the dual phases are firmly bonded by transitional “dual-phase intercalation”. Experimental evaluations demonstrate that these structures possess enhanced interfacial strengthening and crack suppression, particularly the staggered multilayer checkerboard structure, which exhibits remarkable impact resistance and energy absorption across multiple reinforcement mechanisms. This study provides valuable insights for the field of metal-based multi-material additive manufacturing, offering new perspectives and potential applications for the future design and fabrication of diverse materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118708"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168495","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}

引用次数: 0

Faster surface finishing with shape adaptive grinding plus ceria

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118704

Ashwani Pratap , Kathryn Copson , Anthony Beaucamp

Shape adaptive grinding (SAG) is a well-established approach to obtain optical smooth quality on hard ceramic and metallic surfaces. However, the process has been limited to low material removal rate (MRR) when already smooth surfaces are processed using SAG pads. In this work, shape adaptive grinding plus ceria (SAG+) is put forward as an effective approach to increase the MRR, whereby ceria is used as polishing slurry and enables softening of glass/glass-ceramic surfaces through chemical reaction and enhances subsequent material removal through mechanical action of the SAG pad. A macroscopic material removal model is established for SAG+ process on BK7 glass where the effect of ceria on the surface hardness correlates well with the material removal rate. Experiments were performed on BK7 glass with different grades of resin bonded diamond SAG tools to benchmark performance against the standard SAG process. It was observed that the material removal rate increased by 3.5–10 times for SAG+ when all other conditions remain the same. It was also determined that removal rate increases most drastically when the abrasive grit of SAG pad and ceria slurry are of comparable size. Lapped Zerodur™ samples were also processed to check the applicability in pre-polishing of rough glass-ceramic surfaces. A reduction of almost 50 % could be obtained in processing time when using the SAG+ process.

{"title":"Faster surface finishing with shape adaptive grinding plus ceria","authors":"Ashwani Pratap , Kathryn Copson , Anthony Beaucamp","doi":"10.1016/j.jmatprotec.2024.118704","DOIUrl":"10.1016/j.jmatprotec.2024.118704","url":null,"abstract":"<div><div>Shape adaptive grinding (SAG) is a well-established approach to obtain optical smooth quality on hard ceramic and metallic surfaces. However, the process has been limited to low material removal rate (MRR) when already smooth surfaces are processed using SAG pads. In this work, shape adaptive grinding plus ceria (SAG+) is put forward as an effective approach to increase the MRR, whereby ceria is used as polishing slurry and enables softening of glass/glass-ceramic surfaces through chemical reaction and enhances subsequent material removal through mechanical action of the SAG pad. A macroscopic material removal model is established for SAG+ process on BK7 glass where the effect of ceria on the surface hardness correlates well with the material removal rate. Experiments were performed on BK7 glass with different grades of resin bonded diamond SAG tools to benchmark performance against the standard SAG process. It was observed that the material removal rate increased by 3.5–10 times for SAG+ when all other conditions remain the same. It was also determined that removal rate increases most drastically when the abrasive grit of SAG pad and ceria slurry are of comparable size. Lapped Zerodur™ samples were also processed to check the applicability in pre-polishing of rough glass-ceramic surfaces. A reduction of almost 50 % could be obtained in processing time when using the SAG+ process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118704"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168493","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Curvature, microstructure, and mechanical property of an asymmetric aluminium profile produced by sideways extrusion with variable speed

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118699

Jiaxin Lv , Xiaochen Lu , Junquan Yu , Zhusheng Shi , Jianguo Lin

Sideways extrusion is an advanced technology for one-step production of curved profiles eliminating the need for subsequent bending processes. Its effectiveness in controlling the bending curvature of symmetric products has been well established in prior research. However, there is no report on the effect of asymmetric product shape on bending curvature and still lacking quantitative analysis of welding quality and microstructure of the extrudate for the sideways extrusion, limiting its application scope. In this study, an asymmetric Z-shape aluminium profile was manufactured using sideways extrusion at different speeds and the corresponding numerical simulation was conducted to analyse the extrudate shape, welding quality, microstructural and mechanical properties. The bending mechanism of extrudate, resulting from the non-uniform metal flow during extrusion, was identified. The curvature radius was found to depend on the average exit velocity and the velocity gradient along the transverse direction both of which increase with increasing extrusion speed. Improvements in welding quality and increased recrystallisation fraction during extrusion were quantitatively predicted using developed subroutines and these predications aligned well with the results from post-extrusion examination. In addition, tensile test results differed for profile sections extruded at different speeds, which were attributed to the combined effect of welding quality, work hardening, recovery and continuous dynamic recrystallisation.

{"title":"Curvature, microstructure, and mechanical property of an asymmetric aluminium profile produced by sideways extrusion with variable speed","authors":"Jiaxin Lv , Xiaochen Lu , Junquan Yu , Zhusheng Shi , Jianguo Lin","doi":"10.1016/j.jmatprotec.2024.118699","DOIUrl":"10.1016/j.jmatprotec.2024.118699","url":null,"abstract":"<div><div>Sideways extrusion is an advanced technology for one-step production of curved profiles eliminating the need for subsequent bending processes. Its effectiveness in controlling the bending curvature of symmetric products has been well established in prior research. However, there is no report on the effect of asymmetric product shape on bending curvature and still lacking quantitative analysis of welding quality and microstructure of the extrudate for the sideways extrusion, limiting its application scope. In this study, an asymmetric Z-shape aluminium profile was manufactured using sideways extrusion at different speeds and the corresponding numerical simulation was conducted to analyse the extrudate shape, welding quality, microstructural and mechanical properties. The bending mechanism of extrudate, resulting from the non-uniform metal flow during extrusion, was identified. The curvature radius was found to depend on the average exit velocity and the velocity gradient along the transverse direction both of which increase with increasing extrusion speed. Improvements in welding quality and increased recrystallisation fraction during extrusion were quantitatively predicted using developed subroutines and these predications aligned well with the results from post-extrusion examination. In addition, tensile test results differed for profile sections extruded at different speeds, which were attributed to the combined effect of welding quality, work hardening, recovery and continuous dynamic recrystallisation.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118699"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A novel strengthening method using Al3Ti for oscillation laser-MIG hybrid welded joints of Al-Zn-Mg-Cu alloy

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118695

Zhuoming Tan , Xiaohui Zhou , Bin Wang , Weining Qi , Peng Li , Fuyun Liu , Zhao Zhang , Tao Yu , Caiwang Tan

Al-Zn-Mg-Cu alloys are extensively utilized in lightweight structural applications, with Al-Mg wires commonly employed to mitigate solidification cracking during fusion welding. However, the suboptimal properties of welded joints have remained a persistent challenge, particularly when paired with low-strength wires. Currently, the strength of fusion welded joints in Al-Zn-Mg-Cu alloys typically achieves about 60% of the base material (BM). This study employed an oscillation laser-MIG hybrid welding technique incorporating a titanium interlayer, and the influence of Al₃Ti on microstructural features and mechanical properties was analyzed. Results demonstrated that the mechanical performance of welded joints was significantly enhanced by the presence of Al₃Ti. Numerical simulations indicated that oscillation laser-induced stirring improved melt fluidity in the molten pool, leading to the formation and uniform distribution of Al₃Ti throughout the weld. Al₃Ti particles as nucleation substrates, facilitating grain refinement. A strengthening mechanism for Al₃Ti applicable to fusion welded joints in Al-Zn-Mg-Cu alloys was proposed, incorporating grain boundary strengthening and particle strengthening. The tensile strength and elongation of the welded joints increased to 401.74 MPa (71% of BM) and 7.27%, respectively. This work demonstrated an innovative processing and an unconventional reinforcement phase which provided guidance for fusion welding of high-strength aluminum alloys in practical applications.

{"title":"A novel strengthening method using Al3Ti for oscillation laser-MIG hybrid welded joints of Al-Zn-Mg-Cu alloy","authors":"Zhuoming Tan , Xiaohui Zhou , Bin Wang , Weining Qi , Peng Li , Fuyun Liu , Zhao Zhang , Tao Yu , Caiwang Tan","doi":"10.1016/j.jmatprotec.2024.118695","DOIUrl":"10.1016/j.jmatprotec.2024.118695","url":null,"abstract":"<div><div>Al-Zn-Mg-Cu alloys are extensively utilized in lightweight structural applications, with Al-Mg wires commonly employed to mitigate solidification cracking during fusion welding. However, the suboptimal properties of welded joints have remained a persistent challenge, particularly when paired with low-strength wires. Currently, the strength of fusion welded joints in Al-Zn-Mg-Cu alloys typically achieves about 60% of the base material (BM). This study employed an oscillation laser-MIG hybrid welding technique incorporating a titanium interlayer, and the influence of Al<sub>3</sub>Ti on microstructural features and mechanical properties was analyzed. Results demonstrated that the mechanical performance of welded joints was significantly enhanced by the presence of Al<sub>3</sub>Ti. Numerical simulations indicated that oscillation laser-induced stirring improved melt fluidity in the molten pool, leading to the formation and uniform distribution of Al<sub>3</sub>Ti throughout the weld. Al<sub>3</sub>Ti particles as nucleation substrates, facilitating grain refinement. A strengthening mechanism for Al<sub>3</sub>Ti applicable to fusion welded joints in Al-Zn-Mg-Cu alloys was proposed, incorporating grain boundary strengthening and particle strengthening. The tensile strength and elongation of the welded joints increased to 401.74 MPa (71% of BM) and 7.27%, respectively. This work demonstrated an innovative processing and an unconventional reinforcement phase which provided guidance for fusion welding of high-strength aluminum alloys in practical applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118695"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169450","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}

引用次数: 0

Efficient manufacture of TiNi/Ti2Ni intermetallic composites with a unique brick-and-mortar structure in a single hot rolling process

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118697

Jun Zha , Guoqing Zu , Zhiping Xiong , Weiwei Zhu , Liying Wang , Ying Han , Xu Ran , Xingwang Cheng

Seashells have a typical brick-and-mortar structure (BMS) composed of tiny mineral particles and organic matter. Such BMS has inspired the development of advanced composite materials with high strength and toughness, yet it is challenging to implement in metallic systems. This study employs the foil-to-foil method combined with hot-press sintering to fabricate layered TiNi/Ti₂Ni intermetallic composite material(ICM). The layered ICM is further subjected to hot rolling with varying deformation, successfully producing ICM with a unique brick-and-mortar structure. The BMS-ICM has an ultra-high content of Ti₂Ni reinforcement phase. The olive-shaped brittle phase of Ti₂Ni is evenly distributed within the TiNi mortar as bricks, with a volume fraction of the Ti₂Ni phase as high as 79 %. The compressive strength of 60 % BMS-ICM perpendicular to the loading direction of the laminate reaches 1963.50 MPa, accompanied by a fracture strain of 24.5 %. Additionally, the unique Ti₂Ni brick and TiNi mortar structure provides multiple toughening mechanisms for BMS-ICM. Compared to conventional materials, BMS-ICM demonstrates significant advantages in crack propagation resistance, thus holding great potential for applications in the military and aerospace fields.

{"title":"Efficient manufacture of TiNi/Ti2Ni intermetallic composites with a unique brick-and-mortar structure in a single hot rolling process","authors":"Jun Zha , Guoqing Zu , Zhiping Xiong , Weiwei Zhu , Liying Wang , Ying Han , Xu Ran , Xingwang Cheng","doi":"10.1016/j.jmatprotec.2024.118697","DOIUrl":"10.1016/j.jmatprotec.2024.118697","url":null,"abstract":"<div><div>Seashells have a typical brick-and-mortar structure (BMS) composed of tiny mineral particles and organic matter. Such BMS has inspired the development of advanced composite materials with high strength and toughness, yet it is challenging to implement in metallic systems. This study employs the foil-to-foil method combined with hot-press sintering to fabricate layered TiNi/Ti₂Ni intermetallic composite material(ICM). The layered ICM is further subjected to hot rolling with varying deformation, successfully producing ICM with a unique brick-and-mortar structure. The BMS-ICM has an ultra-high content of Ti<sub>2</sub>Ni reinforcement phase. The olive-shaped brittle phase of Ti<sub>2</sub>Ni is evenly distributed within the TiNi mortar as bricks, with a volume fraction of the Ti<sub>2</sub>Ni phase as high as 79 %. The compressive strength of 60 % BMS-ICM perpendicular to the loading direction of the laminate reaches 1963.50 MPa, accompanied by a fracture strain of 24.5 %. Additionally, the unique Ti₂Ni brick and TiNi mortar structure provides multiple toughening mechanisms for BMS-ICM. Compared to conventional materials, BMS-ICM demonstrates significant advantages in crack propagation resistance, thus holding great potential for applications in the military and aerospace fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118697"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169453","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A new process route for the manufacturing of hubs in sheet metal structures by utilising flexible hole-rolling

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118666

Viktor Arne , Daniel Spies , Dirk Alexander Molitor , Fuzhang He , Peter Groche

The development of novel forming machines, such as the 3D Servo Press, provides the opportunity to implement entirely novel forming processes and to manufacture established machine elements, such as hubs with polygon contour, through the utilisation of forming technology. This publication presents the production of polygon hubs in thin-walled sheets using the additional flexibility provided by multi degree of freedom servo presses. The polygon contour produced by hole-rolling are subjected to further examination to determine whether they meet the required specifications and the properties when used in a shaft-hub connection. In this context, the following criteria were evaluated: geometric dimensional accuracy, mechanical strength against failure under load, and surface quality. The results presented have the potential for future applications to optimise the process chain in the manufacturing of shaft-hub connections with polygon contour and the establishment of an alternative to conventional manufacturing methods like milling and turning.

{"title":"A new process route for the manufacturing of hubs in sheet metal structures by utilising flexible hole-rolling","authors":"Viktor Arne , Daniel Spies , Dirk Alexander Molitor , Fuzhang He , Peter Groche","doi":"10.1016/j.jmatprotec.2024.118666","DOIUrl":"10.1016/j.jmatprotec.2024.118666","url":null,"abstract":"<div><div>The development of novel forming machines, such as the 3D Servo Press, provides the opportunity to implement entirely novel forming processes and to manufacture established machine elements, such as hubs with polygon contour, through the utilisation of forming technology. This publication presents the production of polygon hubs in thin-walled sheets using the additional flexibility provided by multi degree of freedom servo presses. The polygon contour produced by hole-rolling are subjected to further examination to determine whether they meet the required specifications and the properties when used in a shaft-hub connection. In this context, the following criteria were evaluated: geometric dimensional accuracy, mechanical strength against failure under load, and surface quality. The results presented have the potential for future applications to optimise the process chain in the manufacturing of shaft-hub connections with polygon contour and the establishment of an alternative to conventional manufacturing methods like milling and turning.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118666"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169456","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Porosity evolution mechanisms, influencing factors, and ultrasonic-assisted regulation in joining high Mg-content aluminum alloys

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118706

Ning Cui , Tianqi Zhao , Zhiguo Wang , Yuhui Zhao , Yaojie Chao , Hai Lin , Desheng Li , Jibin Zhao

Over the years, porosity defects have been one of the significant factors limiting the development of aluminum alloys during the joining process. This paper employs the process of laser metal deposition welding (LMDW) to join Al-Mg-Sc-Zr alloys with high Mg content. Through the micromorphology of pores, elemental distribution, and finite element analysis (FEA), the mechanisms of formation, growth, and spillage of pore defects in aluminum alloys containing low-melting-point elements are explored. This study not only delves into the mechanism of low-melting-point element-induced porosity and enriches the principle of porosity formation, but also explores the influence of heat transfer paths and flow fields on the porosity enrichment during the butt-welding process, which provides a reference direction for future research. The study examines the effects of different process parameters and layers on the distribution and size of pores, revealing that pore-rich areas are concentrated along the fusion lines and the interlayer fusion lines. Furthermore, the three-dimensional model is constructed via finite element analysis to simulate the distribution of Mg and the flow field within the melt pool. Finally, ultrasonic vibration is introduced to mitigate porosity defects. Through controlled experiments, the optimal ultrasonic vibration current parameters are identified that minimize Mg loss and alleviate pore accumulation along the fusion lines and interlayer fusion lines. Compared with no ultrasonic vibration, the porosity at the melt pool center ameliorated by 20 %, the porosity near the fusion line decreased by 22 %, and the tensile strength increased by 41.9 %.

{"title":"Porosity evolution mechanisms, influencing factors, and ultrasonic-assisted regulation in joining high Mg-content aluminum alloys","authors":"Ning Cui , Tianqi Zhao , Zhiguo Wang , Yuhui Zhao , Yaojie Chao , Hai Lin , Desheng Li , Jibin Zhao","doi":"10.1016/j.jmatprotec.2024.118706","DOIUrl":"10.1016/j.jmatprotec.2024.118706","url":null,"abstract":"<div><div>Over the years, porosity defects have been one of the significant factors limiting the development of aluminum alloys during the joining process. This paper employs the process of laser metal deposition welding (LMDW) to join Al-Mg-Sc-Zr alloys with high Mg content. Through the micromorphology of pores, elemental distribution, and finite element analysis (FEA), the mechanisms of formation, growth, and spillage of pore defects in aluminum alloys containing low-melting-point elements are explored. This study not only delves into the mechanism of low-melting-point element-induced porosity and enriches the principle of porosity formation, but also explores the influence of heat transfer paths and flow fields on the porosity enrichment during the butt-welding process, which provides a reference direction for future research. The study examines the effects of different process parameters and layers on the distribution and size of pores, revealing that pore-rich areas are concentrated along the fusion lines and the interlayer fusion lines. Furthermore, the three-dimensional model is constructed via finite element analysis to simulate the distribution of Mg and the flow field within the melt pool. Finally, ultrasonic vibration is introduced to mitigate porosity defects. Through controlled experiments, the optimal ultrasonic vibration current parameters are identified that minimize Mg loss and alleviate pore accumulation along the fusion lines and interlayer fusion lines. Compared with no ultrasonic vibration, the porosity at the melt pool center ameliorated by 20 %, the porosity near the fusion line decreased by 22 %, and the tensile strength increased by 41.9 %.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118706"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168497","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Achieving property differentiation and enhanced strength-plasticity in tailor rolled blank of aluminum alloy by variable gauge rolling and heat treatment

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118698

Ying Zhi , Dong Wang , Yao Jiang , Xianlei Hu , Tao Sun , Xianghua Liu

This research presents a novel method for preparing tailor rolled blanks of aluminum alloy (Al-TRB) by synergizing variable gauge rolling with heat treatment, achieving a remarkable property differentiation between thin and thick zones and enhanced strength-plasticity. After variable gauge rolling, there is a notable increase in both tensile and yield strengths across the zones, attributed to deformation strengthening, though elongation decreases. The process induces a pronounced property difference, with a tensile strength difference of 72 MPa, a yield strength difference of 100 MPa, and an elongation difference of 12.4 % between thin and thick zones. This property gradient is a fundamental advancement, offering a strategic advantage in automotive component manufacturing by allowing the properties of different parts on the same component to be matched according to their specific operational demands. Subsequent re-aging and bake-hardening treatments further enhance the strength-plasticity, elevating the tensile strengths of the thin and thick zones to 407 MPa and 329 MPa, respectively, while improving elongations to 13.4 % and 20.7 %. The strength increment is attributed to precipitation strengthening, while the elongation increment is due to dislocation recovery during re-aging and bake-hardening. The fundamental advancement of this research lies in the tailored property differentiation of Al-TRB, which not only surpasses the mechanical properties of conventional 6000-series Al-TRB but also provides a strategic advantage in automotive component manufacturing. This innovation enables the maximization of load-carrying potential by matching the properties of different parts on the same component according to specific operational demands, thereby enhancing overall vehicle performance and safety.

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引用次数: 0

Effect of UV-illumination on electrochemical anodic oxidation of SiC

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-02-01 DOI: 10.1016/j.jmatprotec.2024.118703

Zhenghao Wei , Zhiyu Wang , Huiqiang Liang , Junqiang Li , Jiongchong Fang , Wenjun Lu , Jiawen Zhang , Haifeng Gao , Zhongdu He , Yu Guo , Xu Sui , Guosong Zeng

Introducing an external energy field to force the oxidation of SiC is considered as an effective way to address the current challenge of chemical mechanical polishing (CMP) for SiC fabrication. In this study, we firstly compared several reported oxidation methods that have been used in different CMP-based techniques for SiC substrate, and demonstrated that the electrochemical (EC) and photoelectrochemical (PEC) anodic oxidations had significant advancement of the oxidation efficiency. Further comparison between EC and PEC revealed that PEC produced more uniform and smoother oxide layers in similar oxidation rates, while applied voltage and light intensity played a composing role in controlling the outcome. The quasi-in situ (photo)electrochemical atomic force microscopy analysis on the nanoindentation introduced artificial defects unraveled that, holes were prone to gather around the defective regions and resulted in faster oxidation rate, while the PEC can suppress such selective oxidation. These results suggest that the introduction of light has the potential to address the long-standing challenge of poor surface quality in electrochemical mechanical polishing (ECMP), not only for SiC but for various different semiconductor materials, and provide practical guidance for the industry to enhance PECMP performance on SiC and other hard and chemical inert semiconductor materials through optimizing oxidation processes.

{"title":"Effect of UV-illumination on electrochemical anodic oxidation of SiC","authors":"Zhenghao Wei , Zhiyu Wang , Huiqiang Liang , Junqiang Li , Jiongchong Fang , Wenjun Lu , Jiawen Zhang , Haifeng Gao , Zhongdu He , Yu Guo , Xu Sui , Guosong Zeng","doi":"10.1016/j.jmatprotec.2024.118703","DOIUrl":"10.1016/j.jmatprotec.2024.118703","url":null,"abstract":"<div><div>Introducing an external energy field to force the oxidation of SiC is considered as an effective way to address the current challenge of chemical mechanical polishing (CMP) for SiC fabrication. In this study, we firstly compared several reported oxidation methods that have been used in different CMP-based techniques for SiC substrate, and demonstrated that the electrochemical (EC) and photoelectrochemical (PEC) anodic oxidations had significant advancement of the oxidation efficiency. Further comparison between EC and PEC revealed that PEC produced more uniform and smoother oxide layers in similar oxidation rates, while applied voltage and light intensity played a composing role in controlling the outcome. The quasi-in situ (photo)electrochemical atomic force microscopy analysis on the nanoindentation introduced artificial defects unraveled that, holes were prone to gather around the defective regions and resulted in faster oxidation rate, while the PEC can suppress such selective oxidation. These results suggest that the introduction of light has the potential to address the long-standing challenge of poor surface quality in electrochemical mechanical polishing (ECMP), not only for SiC but for various different semiconductor materials, and provide practical guidance for the industry to enhance PECMP performance on SiC and other hard and chemical inert semiconductor materials through optimizing oxidation processes.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118703"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168925","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0