International Journal of Machine Tools & Manufacture最新文献

{"title":"A high efficiency pre-dissolution electrochemical polishing method for improving surface uniformity in additively manufactured alloys","authors":"Jierui Mu ,&nbsp;Qiang Lu ,&nbsp;Zijue Tang ,&nbsp;Yi Wu ,&nbsp;Haowei Wang ,&nbsp;Hongze Wang","doi":"10.1016/j.ijmachtools.2025.104297","DOIUrl":"10.1016/j.ijmachtools.2025.104297","url":null,"abstract":"<div><div>Electrochemical polishing (ECP) offers significant advantages in reducing surface roughness of complex additively manufactured (AMed) components. However, conventional one-step ECP methods hinder further removal of near-surface defects, such as inherent adhesive powders and step effects, owing to the simultaneous dissolution and smoothing processes. Additionally, the topological conformity between the formed high-resistance oxide layer and the metal matrix limits the polishing effectiveness, producing undesirable surface inconsistency and poor dimensional accuracy. In this study, we introduce a pre-dissolution step prior to the conventional ECP process, namely pre-dissolution ECP. This approach is based on the electrochemical dissolution behavior of adhesive powders and the melt pool (MP) structure to transform the irregular, rough as-built surface into a pre-dissolved MP morphology with a uniform current density distribution, aiming to optimize the subsequent ECP process. By combining <em>in situ</em> X-ray synchrotron radiation observation with comparative quantitative analysis of samples before and after mechanical polishing, precise dissolution parameters were determined to achieve a polished surface with uniformly distributed height differences. For AMed Al alloys with high Si content, when the percentage change rate of dissolved areas of the cross-sectional profile in the pre-dissolution step is 0.060 ± 0.003 %/min, different adhesive powder regions exhibit consistent height differences on the pre-dissolved surface. During the subsequent polishing step, compared to direct ECP (∼5.3 μm), the isotropic etching-based smoothing effect in NaOH solution further reduces surface roughness of the pre-dissolved surface to ∼1.5 μm, and the corresponding standard deviation of height difference is reduced by 80.7 %. Moreover, the use of low voltage and the one-time removal of surface cluster layers ensures improved roundness tolerance (85.7 %) and capillary action (304.4 %) for AMed heat pipes with internal channels (Φ1.4 mm) after polishing. This pre-dissolution strategy mitigates the complexity and randomness of as-built surface features, facilitating better ECP performance. It can also be integrated with advanced ECP technologies, thereby expanding the application potential of AMed structures, including but not limited to internal channels.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"209 ","pages":"Article 104297"},"PeriodicalIF":14.0,"publicationDate":"2025-05-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144138301","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel computational approach using receptance coupling substructure analysis for prediction of tool tip dynamics in industrial machining applications","authors":"Jesus David Chaux,&nbsp;Patxi X. Aristimuño Osoro,&nbsp;Pedro J. Arrazola","doi":"10.1016/j.ijmachtools.2025.104296","DOIUrl":"10.1016/j.ijmachtools.2025.104296","url":null,"abstract":"","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"209 ","pages":"Article 104296"},"PeriodicalIF":14.0,"publicationDate":"2025-05-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144137745","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Inducing electrochemical discharges on insulating surfaces for damage-free electrochemical jet machining of glass","authors":"Genglin Zhu ,&nbsp;Hexin Li ,&nbsp;Wenjun Lu ,&nbsp;Sanjun Liu ,&nbsp;Weidong Liu ,&nbsp;Yonghua Zhao","doi":"10.1016/j.ijmachtools.2025.104293","DOIUrl":"10.1016/j.ijmachtools.2025.104293","url":null,"abstract":"<div><div>A key limitation of electrochemical jet machining (EJM) is its inability to process insulating materials. While electrochemical discharge machining (ECDM) can handle such materials, its contact-based nature often causes thermal damage. Additionally, the challenge of initiating electrochemical discharges on the insulating workpiece, rather than on the tool electrode, remains unresolved. This study presents a new mechanism for directly inducing electrochemical discharges on insulating surfaces through the controlled interplay of electro- and hydrodynamic fields. For the first time, we demonstrate damage-free machining of insulating materials using an electrolyte jet, in a new process termed jet-electrochemical discharge machining (Jet-ECDM). This is achieved by generating electrochemical discharges at the jet-impingement zone on the insulating workpiece surface, with the gas evolved at the nozzle electrode acting as a dielectric. The spatiotemporal dynamics of discharges, including location, frequency, and intensity, are analyzed and shown to critically influence machining results. High-speed imaging visualizes the gas bubble behaviors, while simulation reveals how discharges are focused onto a localized machining area through concentrated electric fields and gas distribution. Key process parameters, including voltage, working gap, and electrolyte flow rate, are identified for effective process control. Thermocouple measurements show a discharge-induced average temperature rise of ∼160 °C at the machining site. Unlike conventional ECDM, Jet-ECDM's non-contact approach avoids thermal damage, enabling stress-free, purely chemical material removal. This is validated by machining microfeatures in quartz glass, achieving superior surface finishes (∼Ra 50 nm) and a damage-free subsurface. This research extends the material applicability of EJM to insulating materials and introduces a novel method for stress-free machining of glass and ceramics using electrochemical discharges.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"209 ","pages":"Article 104293"},"PeriodicalIF":14.0,"publicationDate":"2025-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144137626","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Ultrafast phase transformation and strengthening mechanisms in alloys induced by femtosecond laser shock: a novel strategy for intermetallic control","authors":"Zhiyuan Liu ,&nbsp;Wenmin Tang ,&nbsp;Feng Pan ,&nbsp;Xueran Deng ,&nbsp;Fei Fan ,&nbsp;Jingjing Yang ,&nbsp;Cheng Lei ,&nbsp;Sheng Liu ,&nbsp;Qiao Xu ,&nbsp;Du Wang","doi":"10.1016/j.ijmachtools.2025.104292","DOIUrl":"10.1016/j.ijmachtools.2025.104292","url":null,"abstract":"<div><div>This study proposes a novel alloy-strengthening strategy enabled by femtosecond laser shock peening (FLSP), which utilizes ultrahigh peak shock pressures exceeding the intrinsic bond rupture strength of metallic bonds to achieve atomic-level microstructural modification. In contrast to conventional nanosecond laser shock peening (NLSP), FLSP induces a distinct strengthening mechanism through the dynamic fragmentation of intermetallic phases and the controllable precipitation of nanoscale strengthening phases. Through integrating a synergistic experimental investigation with molecular dynamics (MD) simulation, we establish a generalized pressure–dependent phase transformation framework, identifying critical thresholds of shock pressure required to initiate atomic bond rupture and subsequent phase evolution. This framework enables precise tuning of energy input to promote the formation of nanoscale strengthening phases while suppressing undesirable microscale precipitates. Compared to NLSP, FLSP demonstrates superior efficacy in microstructure refinement capabilities, enabling synergistic strengthening through grain refinement, dislocation multiplication, and pressure-mediated phase transformation. Notably, the discovered pressure–sensitive phase evolution behavior provides a transferable paradigm for microstructural design and performance optimization across a wide range of metallic systems. This work advances the fundamental understanding of laser–matter interactions under extreme conditions and offers a physics-informed pathway for the design of high-performance structural materials through targeted laser parameter engineering.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"209 ","pages":"Article 104292"},"PeriodicalIF":14.0,"publicationDate":"2025-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144115134","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Suppression of hot cracking in Ni-based single-crystal superalloys fabricated by laser directed energy deposition through thermal cycle regulation","authors":"Yan Zeng,&nbsp;Boyuan Guan,&nbsp;Tianyu Yuan,&nbsp;Huitao Chen,&nbsp;Lei Li","doi":"10.1016/j.ijmachtools.2025.104283","DOIUrl":"10.1016/j.ijmachtools.2025.104283","url":null,"abstract":"<div><div>The fabrication of Ni-based single-crystal (SX) superalloys through laser directed energy deposition (L-DED) is hindered by the high susceptibility of SX structures to hot cracking. Therefore, achieving crack-free SX superalloys during L-DED is crucial for advancing the application of this technology in SX turbine blade repair. Based on solidification shrinkage and solid-bridging theory, this study systematically investigated the formation mechanisms of hot cracks in a multi-pass multi-layer DD6 SX prepared by L-DED through microstructure characterisation and coupled thermal-mechanical simulations. The results demonstrate that the initiation and propagation of hot cracks are governed by the overlapping characteristics at the inter-pass and interlayer regions, which influence the formation of liquid films and localisation of the stress-strain concentration. Furthermore, the results revealed that the formation of stray grains and hot cracking mutually amplified each other. To address these challenges, a novel strategy for hot crack suppression is to optimise the dwell time at the inter-pass and interlayer regions to regulate the dendrite growth and elemental segregation. Consequently, a three-pass five-layer Ni-based single-crystal sample with a width of 2–3 mm was successfully prepared, which was free of cracks. Moreover, the hot crack suppression method was applied to single-pass thin-wall deposition, achieving a single-crystal structure with height exceeding 10 mm and a proportion of over 95 %. The repair quality surpassed the requirements for single-crystal blade repair. This study provides new insights into the thermal-mechanical mechanisms underlying hot cracking and establishes a scientific framework for mitigating the cracks in L-DED DD6 SX, thereby advancing their applicability in high-end component repair.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104283"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143912651","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel suppressing evaporation method for enhancing micro-complex magnesium alloy parts additive manufacturing","authors":"Lin Su ,&nbsp;Xujiang Chao ,&nbsp;Jun Luo,&nbsp;Lei Zhao,&nbsp;Yi Zhou,&nbsp;Lewen Yang,&nbsp;Lehua Qi","doi":"10.1016/j.ijmachtools.2025.104281","DOIUrl":"10.1016/j.ijmachtools.2025.104281","url":null,"abstract":"<div><div>The increasing demand for micro-complex and customizable magnesium (Mg) alloy structures presents significant challenges for additive manufacturing (AM), particularly in controlling porosity and achieving high-dimensional accuracy. These challenges arise from bubble entrapment and explosive events caused by intense Mg evaporation. This study, for the first time, elucidates the fundamental mechanism underlying these defects, identifying spontaneous bubble nucleation and subsequent explosions within the melt pool as the root cause. In metal droplet-based AM (MDBM), experiments demonstrate that larger bubbles destabilize droplets and disrupt deposition trajectories due to intensified energy release, ultimately degrading print quality. To address this issue, a bubble nucleation and growth model, independent of specific Mg alloy AM methods, was developed. Based on this model, a novel strategy was proposed to mitigate Mg evaporation-induced defects. By identifying a critical bubble nucleation temperature, it was established that operating below this threshold completely suppresses bubble nucleation, thereby preventing associated defects. For conditions exceeding this temperature, the bubble growth model enables precise regulation of bubble size through process parameter optimization, effectively minimizing defects and enhancing structural integrity. As a result, the fabricated structures exhibit high dimensional precision and superior mechanical performance, characterized by pore-free microstructures, minimal dimensional deviation, and enhanced mechanical properties. This study introduces a parameter-driven method for suppressing Mg evaporation-induced defects across various Mg alloy AM technologies, with potential applicability to other highly evaporative metal AM processes. Moreover, it represents the first successful fabrication of micro-complex structures using highly evaporative metals, expanding the material selection for MDBM.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104281"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143892295","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grindability and microstructural effect of nickel-based superalloys in magnetic field-assisted ultra-precision grinding","authors":"Te Zhao,&nbsp;Tengfei Yin,&nbsp;Dongbo Wu,&nbsp;Yi Tan,&nbsp;Denghui Li,&nbsp;Waisze Yip,&nbsp;Suet To","doi":"10.1016/j.ijmachtools.2025.104284","DOIUrl":"10.1016/j.ijmachtools.2025.104284","url":null,"abstract":"<div><div>The nickel-based superalloy Inconel 718 is essential in the aerospace and automotive industries due to its exceptional mechanical strength, fatigue resistance, and resistance to corrosion and oxidation. However, machining nickel-based alloys poses significant challenges in ultra-precision grinding (UPG), resulting in excessive grinding wheel vibration and poor surface quality. This study introduces an innovative magnetic field-assisted ultra-precision grinding (MFAUPG) technology, representing an advancement in the application of magnetic fields to assist grinding processes. A theoretical model was developed that links magnetic fields to grinding dynamics, elucidating the electromagnetic damping effects that significantly reduce wheel vibration and improve grinding performance. Experimental results reveal microstructural changes in Inconel 718 under magnetic field influence, including reduced grain size, deformation, and dislocation movement. Furthermore, the study elucidates the effects of magnetic fields on thermodynamics and recrystallization during the grinding process. These findings provide critical insights into the behavior of materials under magnetic field-assisted conditions, offering a promising solution to improve the grindability and surface integrity of difficult-to-machine nickel-based superalloys. The research underscores the potential of MFAUPG to achieve ultra-precision machining and enhance mechanical properties, thereby laying the groundwork for future innovations in economically sustainable grinding practices.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104284"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Single-sensor-based reconstruction of force and displacement fields for thin-walled cylindrical shells milling","authors":"Jie Chen ,&nbsp;Haifeng Ma ,&nbsp;Qinghua Song ,&nbsp;Yukui Cai ,&nbsp;Zhanqiang Liu","doi":"10.1016/j.ijmachtools.2025.104282","DOIUrl":"10.1016/j.ijmachtools.2025.104282","url":null,"abstract":"<div><div>The cutting process of thin-walled cylindrical shells involves complex working conditions, and it is difficult to measure the cutting force and vibration displacement at the cutting point in real time. To address this issue, a method is proposed to reconstruct the force and displacement fields of the cylindrical shell in real time using only a single displacement sensor. Based on the first-order shear deformation theory and the artificial spring technique, the wave method can be employed to simultaneously obtain the natural frequencies and analytical mode shape functions of the cylindrical shell with elastic boundary. The dynamic behavior of the cylindrical shell is characterized by the superposition of mode shapes, thereby determining the force-displacement mapping relationship for the entire cylindrical shell. Utilizing in-situ measurement, the time-varying force and displacement fields are reconstructed in real time. Unlike existing methods for reconstructing the displacement field of thin-walled workpieces, one unique feature of this study is the simultaneous real-time reconstruction of the force and the displacement fields using single-point measurement information, providing higher reconstruction accuracy with fewer sensors, thus ensuring practicality and reliability of the results. Through simulation and experimental application to the force and displacement fields reconstruction of cylindrical shell under concentrated and moving force (e.g., cutting process), its practicality as a real-time tool for continuously monitoring cutting force and displacement of cylindrical shell during the cutting process has been demonstrated.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104282"},"PeriodicalIF":14.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143904261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhanced strength-ductility synergy in laser directed energy deposited IN718 superalloys through heterogeneous deformation nanostructures","authors":"Yao Li ,&nbsp;Mengyang Li ,&nbsp;Hao Yang ,&nbsp;Xiaofeng Dang ,&nbsp;Luqing Cui ,&nbsp;Yang Jiao ,&nbsp;Zhiping Sun ,&nbsp;Ting Guo ,&nbsp;Weifeng He","doi":"10.1016/j.ijmachtools.2025.104280","DOIUrl":"10.1016/j.ijmachtools.2025.104280","url":null,"abstract":"<div><div>Laser directed energy deposition (LDED) shows great promise for repairing superalloy components of aeroengines but often results in coarse microstructures, porosity, and tensile residual stresses. Herein, post-process ultrasonic impact treatment (UIT) is adopted to effectively regulate the surface microstructure and residual stresses in LDED-fabricated IN718 superalloys, enhancing the strength-ductility synergy. The UIT process optimization is achieved through a systematic investigation of the effect of output powers on surface roughness, porosity, deformation microstructure, microhardness distribution, residual stress profile, and tensile behavior. Particularly, a finite element model for simulating residual stress field induced by ultrasonic impact is established, showcasing excellent agreement with experimental measurements. UIT-induced substantial dislocation and twinning activities result in depth-dependent heterogeneous deformation nanostructures, including alternating nano-grains and nano-laminated composite structures on the top surface (&lt;8 μm), dense nanotwins (∼30 μm depth), and substantial dislocation tangles and pile-ups (∼150 μm depth). Compared to untreated samples, the yield strength of the samples treated with optimal UIT parameters increased by ∼40%, with negligible ductility loss. The synergistic strengthening mechanisms are mainly attributed to the work hardening and boundary strengthening. To decouple these effects, a quantitative framework that correlates with depth-dependent dislocation populations and grain/nanotwin sizes is proposed, demonstrating good consistency with experimental measurements. The preserved ductility stems from a macroscopic deformation delocalization strategy facilitated by the hetero-deformation induced stress, compressive residual stress, and reduced porosity, together with the near-surface heterogeneous nanostructures enabling deformation accommodation at the micro-scale. This work elucidates the enhanced strength-ductility synergy through surface heterogeneous nanostructures and provides practical guidance for the additive manufacturing of high-performance materials.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104280"},"PeriodicalIF":14.0,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859343","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"On-line laser shielding of hydrogen-induced pores in arc-directed energy deposition","authors":"Qinghu Guo ,&nbsp;Yangyi Pan ,&nbsp;Yili Wang ,&nbsp;Shiwei Hua ,&nbsp;Ling Cen ,&nbsp;Ming Gao ,&nbsp;Xinyuan Jin ,&nbsp;Xianfeng Li ,&nbsp;Chen Zhang ,&nbsp;Sheng Liu","doi":"10.1016/j.ijmachtools.2025.104279","DOIUrl":"10.1016/j.ijmachtools.2025.104279","url":null,"abstract":"<div><div>The detrimental effects of pollutant elements in arc-directed energy deposition (arc-DED), particularly hydrogen-induced porosity in aluminum alloys, pose critical challenges for structural integrity. While pollutant shielding is commonly employed for pore suppression, the risk of hydrogen contamination from repeated remelting of deposited layers remains largely overlooked. This study revealed that even trace surface oxides on deposited layers critically governed hydrogen pore nucleation. Microstructural characterization demonstrated a synergistic clustering mechanism among oxides, hydrogen, and pores, where oxides act as dual-functional sites for hydrogen carriers and trappers. To address this, we developed an innovative on-line laser shielding-enhanced arc-DED system integrating a high-frequency nanosecond pulsed laser with arc plasma. This hybrid approach achieved in situ oxide purification within the molten pool, reducing porosity by 98.1 % compared to conventional arc-DED. The laser-arc synergy demonstrated amplified shielding efficiency, with the arc plasma enhancing laser-induced oxide removal rate by 9.6 times. Crucially, this technology disrupted the oxide-mediated hydrogen transportation pathway while eliminating hydrogen-trapping effects in the molten pool. Implementation in Al-Zn-Mg-Cu alloys significantly improves ductility by minimizing porosity at deformation-sensitive interlayer regions. Process scalability was further verified in Al-Mg alloys, achieving comparable porosity reduction. By decoupling the dual roles of oxides in hydrogen carriers and trappers, this work establishes a paradigm-shifting strategy for pore control in arc-DED, offering a versatile platform for processing hydrogen/oxygen-sensitive metals with enhanced mechanical performance.</div></div>","PeriodicalId":14011,"journal":{"name":"International Journal of Machine Tools & Manufacture","volume":"208 ","pages":"Article 104279"},"PeriodicalIF":14.0,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143851790","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}