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Optimizing L-DED repair of arc-shaped grooves via defocus control: Thermodynamic modeling and aspect ratio-defocus distance matching mechanism 圆弧形沟槽离焦控制优化L-DED修复:热力学建模与纵横比-离焦距离匹配机制
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119147
Xianzhi Jin , Lei Wang , Zelin Zhang , Yuyao Guo , Xuhui Xia
Laser Directed Energy Deposition (L-DED) has been widely employed in the repair of core components such as rolls, turbine blades, and bearings. However, when L-DED is directly applied to defect areas, geometric irregularities on the surface can lead to random and uneven distribution of laser energy, resulting in fluctuations in repair layer hardness, poor adhesion, and even secondary failures. Pre-machining suitably arc-shaped grooves in the defect areas and matching them with appropriate defocus parameters can regulate the laser energy distribution, serving as a key technical approach to enhance the stability of repair layer hardness and bonding quality. This study innovatively couples laser propagation, powder flow, and groove structure to establish a thermal-fluid-solid coupling model applicable to curved surfaces, quantifying the effects of positive/negative defocus modes on the powder flow field and heat transfer process in the molten pool. Furthermore, it reveals the influence mechanism of negative defocus on the temperature evolution of the molten pool in arc grooves and the deposition quality, establishing a quantitative matching relationship between arc grooves with different width-to-height ratio (D) and defocus distance (H). The results indicate that when the D = 2, the optimal H is −30 mm; when D = 2.5, it is −65 mm; and when D = 3 and 4, it is −85 mm. Through multi-physics simulations and experimental validation, it is demonstrated that the matching relationship between the D and the H of the arc groove can achieve a defect-free bonding interface after repair and stabilize the microhardness at 480–520 HV. This study provides a theoretical basis and process guidance for the L-DED repair of curved components, promoting the advancement of L-DED technology from planar/simple groove repairs to complex curved surface repairs.
激光定向能沉积技术(L-DED)已广泛应用于轧辊、涡轮叶片和轴承等核心部件的修复。然而,当L-DED直接应用于缺陷区域时,表面的几何不规则性会导致激光能量的随机和不均匀分布,导致修复层硬度波动,附着力差,甚至二次失效。在缺陷区域预加工合适的弧形凹槽,并与之匹配合适的离焦参数,可以调节激光能量分布,是提高修复层硬度稳定性和粘接质量的关键技术途径。本研究创新性地将激光传播、粉末流动和凹槽结构耦合在一起,建立了适用于曲面的热流固耦合模型,量化了正/负离焦模式对熔池中粉末流场和换热过程的影响。揭示了负离焦对电弧槽内熔池温度演变及沉积质量的影响机理,建立了不同宽高比(D)的电弧槽与离焦距离(H)之间的定量匹配关系。结果表明:当D = 2时,最佳H为−30 mm;当D = 2.5时,为- 65 mm;当D = 3和4时,为- 85 mm。通过多物理场模拟和实验验证,证明了电弧槽D与H的匹配关系可以实现修复后的无缺陷粘接界面,并将显微硬度稳定在480 ~ 520 HV。本研究为曲面零件的L-DED修复提供了理论依据和工艺指导,促进了L-DED技术从平面/简单凹槽修复向复杂曲面修复的发展。
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引用次数: 0
Guidance for authors on contributions the JMPT considers out of scope 对JMPT认为超出范围的贡献的作者的指导
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-23 DOI: 10.1016/j.jmatprotec.2025.119161
Dragos Axinte
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引用次数: 0
Metallurgical origin of dual-cracking mechanism in resistance spot welds of dissimilar aluminum alloys 异种铝合金电阻点焊双裂纹机制的冶金成因
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-17 DOI: 10.1016/j.jmatprotec.2025.119154
Yu-Xue Zhang , Hai-Long Jia , De-Ping Jiang , Yi-Hang Yang , Wei Liu , Xiao-Li Zhou , Min Zha , Wei He , Pin-Kui Ma
This study investigates the fundamental mechanisms of solidification cracking in resistance spot welding (RSW) of dissimilar Al–Si/AA5182 alloys with unequal thicknesses. Two distinct cracking behaviors were identified. Unlike previous reports in which cracks predominantly occurred in the partially melted zone, this work reveals that Type I cracks form at the interface between the columnar grain zone (CGZ) and the equiaxed grain zone (EGZ). The asynchronous solidification of these two zones produces a solid-fraction disparity, concentrating thermal shrinkage stress. Simultaneously, the segregation of β-Al₃(Fe,Mn)Si₂ and Mg₂Si particles and the presence of low-melting eutectic films hinder liquid feeding, promoting intergranular cracking. By contrast, Type II cracks develop in the EGZ center under excessive heat input due to severe volumetric shrinkage and the blockage of interdendritic feeding channels, which rupture the remaining eutectic liquid films and generate internal hot cracks. Based on these findings, a dual-cracking mechanism is proposed to describe how thermal–metallurgical nonuniformity and feeding constraints govern crack initiation and propagation. This mechanistic framework provides a broader understanding of solidification cracking under asymmetric solidification conditions, extending beyond the specific Al–Si/Al–Mg system. The insights establish a scientific basis for defect suppression and process optimization in resistance spot welding and other rapid-solidification processes of lightweight alloys.
研究了不同厚度Al-Si /AA5182合金电阻点焊中凝固开裂的基本机理。确定了两种不同的开裂行为。与以往的报告中裂纹主要发生在部分熔化区不同,这项工作揭示了I型裂纹形成于柱状晶区(CGZ)和等轴晶区(EGZ)之间的界面。这两个区域的非同步凝固产生了固相分数差异,集中了热收缩应力。同时,β-Al₃(Fe,Mn)Si₂和Mg₂Si颗粒的偏析以及低熔共晶膜的存在阻碍了液体的进料,促进了晶间开裂。相比之下,在过多的热输入下,由于严重的体积收缩和枝晶间进料通道的堵塞,在EGZ中心形成II型裂纹,使剩余的共晶液膜破裂,产生内部热裂纹。基于这些发现,提出了双裂纹机制来描述热-金相不均匀性和进料约束如何影响裂纹的萌生和扩展。这一机制框架为不对称凝固条件下的凝固开裂提供了更广泛的理解,超出了特定的Al-Si / Al-Mg体系。这为电阻点焊等轻量化合金快速凝固工艺的缺陷抑制和工艺优化提供了科学依据。
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引用次数: 0
Effect of local crystallographic texture on near-surface residual stress variation in machined titanium 局部晶体织构对加工钛近表面残余应力变化的影响
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-14 DOI: 10.1016/j.jmatprotec.2025.119153
Akshay Mundayadan Chandroth , Nikhil Prabhu , Martin Diehl , Marc Seefeldt , Joris Everaerts
Machining of metals causes near-surface plastic deformation, inducing residual stresses that can significantly impact a component's performance. Since most metals are polycrystals these stresses are multiscale in nature. Most studies on machining-induced residual stresses focus on the macroscale, even though microscale stresses, which are more challenging to measure, can deviate significantly from the macroscale average. In this study, microscale residual stresses in annealed Ti-6Al-4V subjected to abrasive wheel cutting are quantified experimentally for the first time. Titanium is of particular interest for this study due to its strong crystallographic anisotropy and the presence of clusters of grains with similar orientation known as microtextured regions (MTRs). Via Focused Ion Beam - Digital Image Correlation ring-core measurements, it is shown that microscale residual stresses are present in the range of ±200 MPa prior to cutting. After cutting, in-plane near-surface residual stresses are found to be more compressive to depths of approximately 20 μm. Cutting also induces out-of-plane near-surface residual stresses, with large dispersion in both tension and compression. The sign of out-of-plane residual stresses is found to correlate with the MTR’s average elastic modulus. Crystal plasticity simulations confirm that elastic anisotropy affects residual stress development due to elastic recovery. Furthermore, lower compressive stress levels during loading combined with a higher elastic recovery promotes the formation of detrimental tensile residual stress in grains, particularly in those oriented for easy basal slip. Overall, this study illustrates the importance of investigating microscale residual stress variation in polycrystalline metals after machining, particularly for highly anisotropic metals.
金属加工引起近表面塑性变形,产生残余应力,这可以显著影响部件的性能。由于大多数金属是多晶体,所以应力在本质上是多尺度的。大多数关于加工残余应力的研究都集中在宏观尺度上,尽管微观尺度的应力可能与宏观尺度的平均值有很大的偏离,而微观尺度的应力测量更具挑战性。本研究首次对Ti-6Al-4V退火后砂轮切削的微尺度残余应力进行了实验量化。由于钛具有很强的晶体各向异性,并且存在具有类似取向的晶粒簇,称为微织构区(MTRs),因此对这项研究特别感兴趣。通过聚焦离子束-数字图像相关环芯测量,表明切割前存在±200 MPa范围内的微尺度残余应力。切削后,在约20 μm深度处,面内近表面残余应力更具压缩性。切削也会引起面外近表面残余应力,在拉伸和压缩中都有很大的分散。发现面外残余应力的符号与MTR的平均弹性模量相关。晶体塑性模拟证实了弹性各向异性影响弹性恢复引起的残余应力发展。此外,加载过程中较低的压应力水平与较高的弹性恢复相结合,促进了颗粒中有害的拉伸残余应力的形成,特别是那些易于基底滑移的颗粒。总的来说,这项研究说明了研究多晶金属加工后微尺度残余应力变化的重要性,特别是对于高度各向异性的金属。
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引用次数: 0
Photocatalytic-assisted electrochemical drilling for passivation suppression in high-volume-fraction SiCp/Al composites 高体积分数SiCp/Al复合材料的光催化辅助电化学钻孔钝化抑制
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-07 DOI: 10.1016/j.jmatprotec.2025.119140
Jing Zhou , Long Cheng , Lijie Jiang , Xiaoka Wang , Feng Wang , Xiaoming Kang
High-volume-fraction silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al) are widely used in integrated circuit applications due to their superior thermal and mechanical properties. However, the heterogeneous materials lead to localized passivation during electrochemical drilling, resulting in uneven dissolution and poor hole-profile accuracy. This study introduces a photocatalytic-assisted electrochemical drilling (PAECD) method for suppressing passivation, enhancing dissolution uniformity, and promoting the drilling process. Comprehensive investigations were conducted, including surface characterization analysis, polarization analysis and dissolution behavior assessment of this approach. The PAECD experiments were conducted under different voltages and feeding displacements, followed by through-hole drilling experiments to evaluate the applicability of the method in advanced machining of SiCp/Al composites. Experimental results reveal that photocatalyst addition enables more homogeneous dissolution by reducing oxide formation, suppressing passivation, and lowering the dissolution barrier. The PAECD process achieves a higher material removal rate and depth-to-diameter ratio. Consequently, the entrance overcut is minimized, the electrochemical reactions are effectively synchronized with the feeding motion, and the tool wear is significantly reduced. Furthermore, residual SiC particles at hole entrances are markedly diminished, local passivation is effectively suppressed, and vertical electrolyte circulation is enhanced. Compared with conventional electrochemical drilling, the PAECD process achieves a 27.63 % reduction in side clearance and an 8.33 % reduction in taper angle, yielding a smoother profile and more precise hole profiles of high-volume-fraction SiCp/Al composites.
高体积分数碳化硅颗粒增强铝基复合材料(SiCp/Al)因其优异的热学和力学性能而广泛应用于集成电路领域。然而,非均相材料在电化学钻孔过程中会导致局部钝化,导致溶解不均匀,孔轮廓精度较差。本研究介绍了一种光催化辅助电化学钻孔(PAECD)方法,以抑制钝化,提高溶解均匀性,促进钻孔过程。对该方法进行了表面表征分析、极化分析和溶解行为评价。在不同电压和进给位移下进行了PAECD实验,然后进行了通孔钻孔实验,以评估该方法在SiCp/Al复合材料高级加工中的适用性。实验结果表明,光催化剂的加入通过减少氧化物的形成、抑制钝化和降低溶解势垒使溶解更加均匀。PAECD工艺实现了更高的材料去除率和深径比。因此,最大限度地减少了进口过切,电化学反应有效地与进给运动同步,并显着降低了刀具磨损。同时,显著减少了孔入口处的残余SiC颗粒,有效抑制了局部钝化,增强了垂直电解质循环。与传统的电化学钻井相比,PAECD工艺的侧隙减小了27.63 %,锥度减小了8.33 %,从而获得了更光滑、更精确的高体积分数SiCp/Al复合材料孔廓。
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引用次数: 0
Tailoring single-crystal-like textures in a non-weldable Ni-based superalloy by controlling overlap behavior in laser powder bed fusion 通过控制激光粉末床熔合过程中的重叠行为,在不可焊接镍基高温合金中裁剪单晶状织构
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-07 DOI: 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.
控制镍基高温合金的凝固行为,以实现定制的晶体结构或单晶结构,对于生产用于极端温度应用的高性能部件至关重要。增材制造,特别是激光粉末床熔融(LPBF),为微结构设计提供了独特的能力。在这项研究中,我们提出了一种基于重叠的策略,通过LPBF在不可焊接的IN738LC高温合金中沿任意三维方向产生单晶状织构。通过调整熔池几何和重叠率——通过调整孵化空间和层厚度是成功设计三种不同的纹理在不改变扫描策略:& lt; 001年  祝辞 ∥建筑方向(BD) & lt; 311年  祝辞 ∥BD, & lt; 110年  祝辞 ∥BD。利用热场和温度梯度分布的计算流体动力学模拟分析了驱动织构发展的机制,包括外延生长和随后的竞争性晶粒选择。本研究为利用LPBF制备类单晶镍基高温合金部件提供了新的途径,推进了织构控制与增材制造的集成。
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引用次数: 0
Numerical and experimental study on spatter formation mechanisms and suppression method during ultra-high power laser-arc hybrid welding 超高功率激光-电弧复合焊接溅射形成机理及抑制方法的数值与实验研究
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-13 DOI: 10.1016/j.jmatprotec.2025.119151
Yan Li , Shaoning Geng , Yilin Wang , Chu Han , Shaoyun Song , Bangyan Xu
Ultra-high power laser-arc hybrid welding (UH-LAHW, laser power ≥20 kW) provides an effective method for joining thick-walled components. However, under ultra-high power laser irradiation, intense keyhole-molten pool fluctuations lead to spatter formation, which remains a critical challenge hindering the industrial application of UH-LAHW. This study systematically investigates spatter formation and suppression mechanisms in UH-LAHW through combined experimental and simulation approaches. The intrinsic relationships among keyhole wall protrusion dynamics, molten pool oscillations, and spatter formation were analyzed. Results indicate that front keyhole wall (FKW) protrusions exhibit two distinct motion modes under laser irradiation: “melt-evaporation-displacement” and “melt-evaporation-evaporation”. The former is identified as the dominant mechanism driving rapid upward movement of liquid columns and spatter formation. Regulating the laser-to-arc energy ratio threshold (EL:A= 2.2:1–1.8:1) can reduce FKW protrusion volume, expand the keyhole opening, and decrease liquid column ejection height. This process culminated in the effective suppression of spatter at the optimal welding condition (EL:A = 2.0:1). This study presents an effective approach for spatter suppression and provides a theoretical foundation and data support for industrial application of UH-LAHW technology.
超高功率激光-电弧复合焊接(UH-LAHW,激光功率≥20 kW)为厚壁构件的焊接提供了一种有效的方法。然而,在超高功率激光照射下,强烈的锁孔-熔池波动导致飞溅形成,这仍然是阻碍UH-LAHW工业应用的关键挑战。本研究采用实验和模拟相结合的方法,系统地研究了UH-LAHW中飞溅的形成和抑制机制。分析了锁孔壁突出动力学、熔池振荡和飞溅形成之间的内在关系。结果表明:激光照射下,前锁孔壁突出物呈现“熔融-蒸发-位移”和“熔融-蒸发-蒸发”两种不同的运动模式。前者被认为是驱动液柱快速向上运动和飞溅形成的主要机制。调节激光-电弧能量比阈值(EL:A= 2.2:1-1.8:1)可以减小FKW突出体积,扩大锁孔开度,降低液柱喷射高度。该过程最终在最佳焊接条件下(EL:A = 2.0:1)有效地抑制了飞溅。该研究提出了有效的飞溅抑制方法,为UH-LAHW技术的工业应用提供了理论基础和数据支持。
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引用次数: 0
Effects of laser energy uniformization via static beam shaping on ablation behavior and mechanism of SiCf/SiC composites 静态光束整形激光能量均匀化对SiCf/SiC复合材料烧蚀行为及机理的影响
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-11 DOI: 10.1016/j.jmatprotec.2025.119149
Xintong Cai, Xin Qin, Jinbo Niu, Renke Kang, Zhigang Dong, Yan Bao, Guangyi Ma, Fangyong Niu
Laser assisted machining (LAM) is an effective method to solve difficult machining problem of Ceramic Matrix Composites (CMC), which includes laser pretreatment and subsequent mechanical machining. However, the commonly used Gaussian beam in pretreatment causes uneven evolution of material removal, thereby affecting machining process. To achieve a uniform machining effect, static beam shaping was used to study influence of energy uniformization on interaction between laser and SiCf/SiC in this paper, and ablation mechanism of circular Gaussian and rectangular uniform laser and growth mechanism of new SiC were explored. Under laser irradiation, CMC exists in two states: oxidation-modified and ablative-removal. In oxidation-modified state, there is transition zone with increased width at oxide layer edge under Gaussian laser, and subsurface crack propagation area is arc-shaped. Uniform laser generates oxide layer with relatively narrower edge transition zone and with uniform width, reducing crack region width and maintaining consistent distribution depth. In ablative-removal state, Gaussian laser forms semi-circular ablation grooves, recast layers and heat affected zones, and generates longitudinal extending cracks. Uniform laser forms flat-bottomed characteristic area. Cracks are suppressed and damage layer depth is reduced by 51.9 %. Under two beams, new 3C-SiC with face-centered cubic (FCC) structure and semi-coherent interface is generated in Si-rich phase. SiC is subjected to along heat dissipation and coarsen into columnar crystals. Uniform thermal expansion constraint forms SiC twin crystal under uniform laser. Therefore, uniform ablation effects of CMC can be obtained through beam shaping, and the results are expected to be applied in laser pretreatment of LAM.
激光辅助加工是解决陶瓷基复合材料加工难题的有效方法,包括激光预处理和后续机械加工。然而,预处理中常用的高斯光束导致材料去除演化不均匀,从而影响加工过程。为了获得均匀的加工效果,本文采用静态光束整形的方法研究了能量均匀化对激光与SiCf/SiC相互作用的影响,探讨了圆形高斯和矩形均匀激光的烧蚀机理和新型SiC的生长机理。在激光照射下,CMC以氧化改性和烧蚀去除两种状态存在。在氧化修饰态下,高斯激光作用下氧化层边缘存在宽度增大的过渡区,亚表面裂纹扩展区呈弧形;均匀激光产生的氧化层边缘过渡区相对较窄,宽度均匀,减小了裂纹区域宽度,保持了一致的分布深度。在烧蚀去除状态下,高斯激光形成半圆形烧蚀槽、重铸层和热影响区,并产生纵向延伸裂纹。均匀激光形成平底特征区。裂纹得到抑制,损伤层深度减少51.9 %。在两束作用下,富si相生成了具有面心立方(FCC)结构和半相干界面的新型3C-SiC。碳化硅受到沿热耗散和粗化成柱状晶体。均匀激光下均匀热膨胀约束形成碳化硅双晶。因此,通过光束整形可以获得CMC均匀的烧蚀效果,其结果有望应用于LAM的激光预处理。
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引用次数: 0
An enhanced characteristic time-based heat input model for simulating laser heating in additive manufacturing 一种基于增强特征时间的增材制造激光加热模拟热输入模型
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-03 DOI: 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.
基于特征时间的热输入(CTI)模型是一种有效的聚束激光方法,用于模拟增材制造中的热源,在保持精度的同时显着降低了计算成本。在CTI模型中,根据热源轴与扫描速度的比值,利用特征加热时间将Goldak的移动热源应用于激光轨迹。然而,这种特征加热时间仅对沿沉积轨道中心线的材料点有效,这可能导致在轨道内的其他点应用不准确的功率密度分布。本研究通过对半椭圆圆柱体内所有点的激光照射时间进行体积平均,重新制定了特征加热时间,从而增强了CTI模型,在保持计算效率的同时实现了更精确的温度预测。通过与实验数据、详细的Goldak模型和原始CTI模型的比较研究,评估了增强CTI (ECTI)模型的改进,重点研究了两种Ti-6Al-4V组件(薄壁和锥形)的激光定向能沉积(DED)。ECTI模型中改进的特征加热时间表明,DED的温度历史偏差显著降低(误差降低>;7.6 %)。ECTI模型与Goldak的残余应力预测结果非常吻合,该模型在锥体上使用轮廓法进行了实验验证,并与实验测量的变形结果很好地吻合。此外,ECTI模型在薄壁几何条件下的计算时间仅为Goldak模型的23 %,在锥形几何条件下的计算时间仅为19.3 %。
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引用次数: 0
Recrystallization and pore inhibition mechanisms of laser directed energy deposited FCC alloy assisted by synchronous ultrasonic micro-forging 同步超声微锻造辅助下激光定向能沉积FCC合金的再结晶及孔抑制机理
IF 7.5 2区 材料科学 Q1 ENGINEERING, INDUSTRIAL Pub Date : 2026-01-01 Epub Date: 2025-11-04 DOI: 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.
本文创造性地设计并提出了基于熔池和高温沉积层的双重调节作用,改善激光定向能沉积高熵合金的微观组织,提高其力学性能的超声微锻造装置。采用多尺度表征和模拟的方法研究了超声微锻造对材料孔隙率降低、再结晶行为和强化机理的影响。有限元模拟结果表明,在超声同步振动下,声流有利于气泡从熔池中逃逸,孔隙率降低84.6 %。同时,由于超声冲击引起的变形应变,在后续激光沉积过程中,除了发生静态再结晶和孪晶外,超声微锻压下高温沉积层内还同时发生动态再结晶,导致层间梯度结构的形成,平均晶粒尺寸减小88.8% %。由于晶界强化、位错强化和孪晶强化作用的贡献值分别为85.7 MPa、75.8 MPa和28.5 MPa,超声微锻后合金的极限抗拉强度和屈服强度得到了显著提高,同时仍保持了良好的延性。相关强度值为713.1 MPa,延伸率为491.6 MPa,延伸率为35.1% %。该研究的进展在于证明了在激光沉积过程中,超声波微锻造装置可以同时实现超声波对液体熔池和固体沉积层的双重调节作用;液体熔池中超声能量场的声流效应促进了孔隙抑制作用,而高温固相沉积层在超声冲击下的塑性变形可诱发动态再结晶和静态再结晶。通过同步控制熔池调节和沉积层热变形,为提高高熵合金及其他FCC合金的显微组织和力学性能提供了一条新途径。
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Journal of Materials Processing Technology
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