Journal of Manufacturing Processes最新文献

High-efficiency laser wire deposition process by programmed laser scanning on cage-arrayed quad wires 采用程控激光扫描技术对笼型阵列四线进行高效率激光线沉积

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.013

Weixing Sheng , Jun Xiao , Xin Xu , Zhifei Xu , Shengnan Gai , Shujun Chen

{"title":"High-efficiency laser wire deposition process by programmed laser scanning on cage-arrayed quad wires","authors":"Weixing Sheng , Jun Xiao , Xin Xu , Zhifei Xu , Shengnan Gai , Shujun Chen","doi":"10.1016/j.jmapro.2026.02.013","DOIUrl":"10.1016/j.jmapro.2026.02.013","url":null,"abstract":"<div><div>Laser wire deposition (LWD) is gaining significant attention for its application in additive manufacturing. However, its development is constrained by the inherently low laser absorptivity of materials, which severely limits the achievable deposition rate. This study proposes a novel oscillating-laser quad-wire deposition (OLQD) process. In this setup, four wires are arranged in a symmetrical cage-like configuration around the laser beam. The process utilizes laser oscillation patterns, including three widely used standard types (linear, circling, and infinite shape) and three self-defined patterns, to alternately melt the wires and the substrate. A comprehensive experimental investigation was conducted to evaluate the influence of oscillating-laser patterns and parameters on the deposited bead morphology and deposition rate. Results demonstrate that the cage-arrayed wires effectively capture more direct and reflected laser energy during laser oscillation, particularly under circular oscillation, leading to a considerable increase in the deposition rate. A laser-scan path planning system was developed to enable the three self-defined oscillation patterns, which are characterized by a controlled laser spot travel distance on the wires and thus regulated energy distribution. The results show that a maximum deposition rate of 85.44 g/min for aluminum wire can be achieved, while maintaining low porosity and a smooth surface morphology. The proposed OLQD process achieves a deposition rate comparable to that of wire arc additive manufacturing, while retaining the capability for precise heat input control.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 70-80"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192745","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}

引用次数: 0

Effect of cooling time and residual layer of Al-Si coating on nugget growth and weldability in resistance spot welding of 1.5-GPa-grade 22MnB5 press hardened steels 冷却时间和Al-Si涂层残余层对1.5 gpa级22MnB5压淬钢电阻点焊熔核生长和可焊性的影响

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.016

Gi Wook Song , Deepak Kumar , Wookjin Oh , Chang Wook Lee , Taeseon Lee

{"title":"Effect of cooling time and residual layer of Al-Si coating on nugget growth and weldability in resistance spot welding of 1.5-GPa-grade 22MnB5 press hardened steels","authors":"Gi Wook Song , Deepak Kumar , Wookjin Oh , Chang Wook Lee , Taeseon Lee","doi":"10.1016/j.jmapro.2026.02.016","DOIUrl":"10.1016/j.jmapro.2026.02.016","url":null,"abstract":"<div><div>Al-Si-coated 22MnB5 press-hardened steel exhibits a strong tendency toward interfacial fracture (IF) in resistance spot welding (RSW) due to coating-derived interfacial seams. We evaluate a production-feasible three-pulse stepped waveform, tuning inter-pulse cooling time (CT = 1–3 cycles; 16.7–50.0 ms) against a pre-pulse benchmark under matched total energy. A coupled 2-D axisymmetric electro-thermal-mechanical model is used to interpret how dwell modulates heat partitioning and nugget growth, and predictions are corroborated by lap-shear tests, metallography/SEM, SEM–EDS, and hardness mapping. The stepped schedule with CT = 2 cycles delivers the best performance: peak load increased by 29% than the pre-pulsed schedule, nugget diameter increased by 15%, and a consistent shift from IF to button pull-out (BPF) without expulsion. Etched-SEM quantifies a markedly finer FZ packet/cell scale under stepped pulse (143.1 μm) than pre-pulse (238.3 μm). SEM–EDS shows the FZ interior at/below detection for Al and Si in both schedules, while the interfacial rim/notch is Al<img>Si enriched but becomes thinner/fragmented with the stepped pulsed cycles. Zone-wise Vickers profiles for optimized conditions are nearly coincident, indicating that the failure-mode transition is governed by waveform-controlled interfacial geometry/coalescence rather than bulk hardening. Overall, short, staged cooling expands the weldability window of coated PHS, enabling BPF at larger load and nugget size without peak-current escalation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 150-162"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192746","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}

引用次数: 0

Multiscale modelling with data-calibrated material parameters for microstructure evolution in Ti5553 machining 基于数据校准材料参数的Ti5553加工微观结构演变多尺度建模

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-10 DOI: 10.1016/j.jmapro.2026.02.007

Shuyuan Chen , Liang Hou , Huaizhong Li , Xiubing Jing , Huikun Cai , Yun Chen

{"title":"Multiscale modelling with data-calibrated material parameters for microstructure evolution in Ti5553 machining","authors":"Shuyuan Chen , Liang Hou , Huaizhong Li , Xiubing Jing , Huikun Cai , Yun Chen","doi":"10.1016/j.jmapro.2026.02.007","DOIUrl":"10.1016/j.jmapro.2026.02.007","url":null,"abstract":"<div><div>Precise prediction of microstructural evolution is essential for improving the machinability of high-strength titanium alloys. This study presents a multiscale modelling framework for Ti5553 machining by coupling FE, JMAK, and CA models. To ensure accuracy across macro–micro scales, key material parameters are calibrated using a hybrid strategy that integrates quasi-static, high strain rate, and high-temperature thermomechanical tests. TANH constitutive parameters are refined through inverse optimization based on cutting force data, while CA nucleation and dislocation parameters are identified using high-temperature SHPB tests. JMAK parameters are extracted from Gleeble-based deformation experiments. The model is validated under both orthogonal cutting and milling conditions. In orthogonal cutting, the maximum prediction error for cutting force is 3.5%, and grain size errors are within 15.8% (CA) and 8.7% (JMAK). In milling, the model captures the evolution of a work-hardened layer, with grain size predictions below 15% error. The dual-phase microstructure of Ti5553 leads to distinctive heterogeneous shear banding behaviors, which are clearly captured by the proposed multiscale model. The CA model effectively resolves grain size gradients in the subsurface, while JMAK provides a macro/<em>meso</em> view about average grain size distribution. This work offers a validated modelling tool for predicting machining-induced microstructure and provides guidance for process optimization.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 21-42"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192807","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}

引用次数: 0

An incremental learning method for resistance projection welding quality evaluation in complex multi-condition working environments 复杂多工况环境下电阻投影焊接质量评价的增量学习方法

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.018

Lei Zhou , Weiqiang Luo , Zhongdian Zhang

{"title":"An incremental learning method for resistance projection welding quality evaluation in complex multi-condition working environments","authors":"Lei Zhou , Weiqiang Luo , Zhongdian Zhang","doi":"10.1016/j.jmapro.2026.02.018","DOIUrl":"10.1016/j.jmapro.2026.02.018","url":null,"abstract":"<div><div>Due to limited model generalization ability and complex industrial environments, the failure of resistance welding quality evaluation models is often inevitable. Enabling models to iteratively update and evolve their cognition based on continuously changing external conditions, akin to human learning, is crucial for reliable quality monitoring in complex scenarios. However, this problem remains under-explored. Focusing on the nut resistance projection welding process, this study categorized experimental data into an initial dataset and six incremental learning datasets based on environmental variations. The initial dataset was employed to train a meta-model, and the incremental datasets are devoted to facilitating incremental learning. This paper proposed a progressive incremental learning framework for multi-condition scenarios. This framework employed dynamic time warping combined with principal component analysis to quantify the discrepancies between incremental and initial datasets, thereby optimizing the model's incremental learning path. A configurable LSTM-based quality evaluation model was designed, which preserves acquired knowledge by freezing the parameters of the LSTM-Attention backbone and incorporates new knowledge by updating adapter. Results demonstrate that, compared to model retraining, the meta-model-based incremental learning approach achieved higher evaluation accuracy across all incremental datasets. This confirmed the effective retention and transfer of historical knowledge, laying a solid foundation for the industrial application of resistance spot welding quality evaluation models.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 53-69"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192808","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}

引用次数: 0

Development of damage energy based process signature for machined surface quality in CFRP cutting 基于损伤能量的CFRP切削加工表面质量过程特征研究进展

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.010

Zhitong Zhou , Hao Li , Zhengwei Bao , Shiguang Zhang , Shipeng Li , Xuda Qin , Guoyu Fu , Qing Zhao

{"title":"Development of damage energy based process signature for machined surface quality in CFRP cutting","authors":"Zhitong Zhou , Hao Li , Zhengwei Bao , Shiguang Zhang , Shipeng Li , Xuda Qin , Guoyu Fu , Qing Zhao","doi":"10.1016/j.jmapro.2026.02.010","DOIUrl":"10.1016/j.jmapro.2026.02.010","url":null,"abstract":"<div><div>A “Process Signature” is inherent to every cutting operation and serves as a crucial link between cutting parameters and the resulting component performance. It provides a potential pathway to directly correlate the energy or internal loads generated in the cutting zone with the resulting surface quality. Considering the anisotropic nature of carbon fiber reinforced plastics (CFRP), this study proposed a theoretical model of surface damage energy in CFRP cutting based on the law of energy conservation. Moreover, for the first time, an energy based process signature component (PSC) was established by examining the relationship between energy consumption and surface quality. Single-factor experiments were conducted using a specially designed pendulum cutting device to analyze cutting energy distribution. The total dissipated energy is divided into four components: friction energy on the rake and flank faces, surface damage energy, chip formation energy, and new surface energy. Among these, surface damage energy shows the highest linear correlation with surface quality indicators (<em>S</em><sub>q</sub>, <em>S</em><sub>a</sub>, <em>H</em><sub>v</sub>, <em>H</em><sub>t</sub>) (<em>R</em><sup>2</sup> > 0.9). Furthermore, a three-level classification method based on surface damage energy is proposed to distinguish surface quality under different parameter combinations. These findings deepen the understanding of the process signature in CFRP cutting and provide a new, performance-oriented approach for process modeling in CFRP machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 163-177"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192747","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}

引用次数: 0

Microstructure and micro-mechanical property evaluation of high-aspect-ratio micro-ribs constructed via elliptical vibration chiseling 椭圆振动凿凿高纵横比微肋的微观结构及微力学性能评价

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.006

Zhiwei Li , Hansong Ji , Pingfa Feng , Jianfu Zhang , Dingwen Yu , Qilin Li , Chaojiang Li , Jianjian Wang

{"title":"Microstructure and micro-mechanical property evaluation of high-aspect-ratio micro-ribs constructed via elliptical vibration chiseling","authors":"Zhiwei Li , Hansong Ji , Pingfa Feng , Jianfu Zhang , Dingwen Yu , Qilin Li , Chaojiang Li , Jianjian Wang","doi":"10.1016/j.jmapro.2026.02.006","DOIUrl":"10.1016/j.jmapro.2026.02.006","url":null,"abstract":"<div><div>Elliptical vibration chiseling (EV-chiseling) is a novel superior process to create micro-ribs on metallic surfaces. However, the formation mechanism and mechanical properties of micro-ribs are still unclear, which hinders its deterministic fabrication. This study concentrates on the formation mechanism clarification and mechanical property characterization of the as-constructed micro-ribs. A mechanistic cutting force model was developed and validated experimentally, revealing that the strain rate in EV-chiseling can reach up to 10<sup>3</sup> s<sup>−1</sup>. Crystallographic analysis on the microstructural evolution inside the micro-ribs exhibited that high strain rate deformation induced significant grain refinement, up to 41 times finer than the material matrix. Dislocation analysis further revealed high-density dislocation accumulation and extensive twin formation, contributing to microstructural refinement. As compared to the material matrix, in-situ micro-mechanical testing confirmed substantial improvements in mechanical properties, with hardness and reduced modulus increased by up to 27.4% and 24.2%, respectively. These enhancements were correlated with grain size reduction through the Hall-Petch relationship. The findings bring valuable insights into the interplay between high strain rate deformation, microstructural evolution, and mechanical property enhancement in the EV-chiseling process, and highlight the potential of constructed metallic micro-ribs for improved durability. Furthermore, higher frequency in EV-chiseling process is believed to introduce higher deformation strain rates, more significant grain refinement and more micro-mechanical property improvement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 197-213"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192748","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}

引用次数: 0

Integrating microstructural defect mapping into geometric refinement of LPBF lattices for enhanced mechanical performance 将微结构缺陷映射集成到LPBF晶格的几何细化中以提高力学性能

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.015

Shahid Ghafoor, Minyang Wang, Xinzhi Li, Xuefang Guo, Xuewei Fang, Muhammad Jawad Ahmad, Ke Huang

{"title":"Integrating microstructural defect mapping into geometric refinement of LPBF lattices for enhanced mechanical performance","authors":"Shahid Ghafoor, Minyang Wang, Xinzhi Li, Xuefang Guo, Xuewei Fang, Muhammad Jawad Ahmad, Ke Huang","doi":"10.1016/j.jmapro.2026.02.015","DOIUrl":"10.1016/j.jmapro.2026.02.015","url":null,"abstract":"<div><div>Additive manufacturing of Ti-6Al-4V lattices via laser powder bed fusion (LPBF) is often limited by unquantified geometric deviations and process-induced porosity that degrade mechanical reliability and design predictability. This work introduces a metrologically calibrated, Micro-CT driven framework that quantitatively links measured defect morphology and dimensional uncertainty to geometric refinement, while integrating finite-element and digital image correlation (DIC) validation to ensure experimental correlation of stress distribution and strain localization. A custom calibration phantom with engineered strut variations and controlled porosity zones (2–8%) was fabricated to calibrate Micro-CT accuracy and establish regional uncertainty maps, ensuring traceable dimensional fidelity across the lattice geometry. Guided by these data, defect-prone junctions and overhangs were re-engineered to improve local heat dissipation and geometric continuity, thereby mitigating melt-pool instability, stress distribution and suppress premature fracture. The optimized configuration (OC) lattice achieved 47.5% higher compressive strength, 47.1% greater energy absorption, and improved strain-rate insensitivity relative to the initial configuration (IC) at identical relative density (0.29). CT-derived geometry was embedded into stochastic FEM, reproducing measured deformation patterns, confirming more uniform stress propagation, and delayed fracture initiation. This study establishes a micro-CT calibrated design methodology that transforms high-resolution microstructural information into mechanical performance optimization, offering the predictive engineering of reliable, lightweight architectures for aerospace, biomedical, and energy-absorbing systems.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 81-98"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192744","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}

引用次数: 0

Biomimetic 4D printing of heterogeneous metals: Stress-mismatch-driven self-morphing for stimuli-free dynamic architectures 异质金属的仿生4D打印：应力不匹配驱动的自变形无刺激动态架构

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.001

Chao Xu , Yan Xu , Jinmin Qi , Kaizhou Ma , Qingping Liu , Xueli Zhou , Lu Zhang , Yunlong Tang , Luquan Ren

{"title":"Biomimetic 4D printing of heterogeneous metals: Stress-mismatch-driven self-morphing for stimuli-free dynamic architectures","authors":"Chao Xu , Yan Xu , Jinmin Qi , Kaizhou Ma , Qingping Liu , Xueli Zhou , Lu Zhang , Yunlong Tang , Luquan Ren","doi":"10.1016/j.jmapro.2026.02.001","DOIUrl":"10.1016/j.jmapro.2026.02.001","url":null,"abstract":"<div><div>To address the challenges in the metal intrinsic stimuli-free responsiveness and the thermal behavior mismatch between heterogeneous metals, this study proposes a biomimetic 4D printing strategy that activates the shape-morphing capabilities of inert metal through stress-mismatch-driven mechanisms. Inspired by pod-like bilayer structures, the heterogeneous bilayer precursor composed of Fe and Cu filament uses direct ink writing (DIW) alternate deposition. The precursor deformation utilizes the sintering-induced shrinkage differences between axial and radial filaments. By synergistically tuning the powder-to-binder ratio and printing parameters, such as the layer number (<em>n</em>), aspect ratio (<em>L/W</em>), porosity and printing angle (<em>α</em>), the bending curvature and twisting angle can be precisely programmed, creating complex shape self-morphing structures (SMSs). The mean bending curvature and twisting angle of the SMS can be controlled within the ranges of 1.0–17.6 × 10<sup>−4</sup>/mm and 16.9°–50.2°, respectively. The minimum error of curvature between the simulated and experimental values of the bending SMS is 6.7%, and the error in twisting angle is 13.7%. Microstructure analysis reveals a crack-free Fe<img>Cu interface, achieved through pore-mediated stress accommodation and element diffusion. This work further demonstrates potential applications in integrated turbine blades and mold-assisted forming, providing a new paradigm for high-strength and shape-programmable metal structures in fields such as aerospace and microsystems. This work extends the 4D printing material system to metals without response to stimulation, opening a new path for heterogeneous material design and multi-functional structure manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 43-52"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192810","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}

引用次数: 0

Low-cost thermal reshaping of carbon fibre/PEEK thick sections: Experiments and simulations 碳纤维/PEEK厚型材的低成本热成形：实验和模拟

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-12 DOI: 10.1016/j.jmapro.2026.02.002

Antreas Potsis , Fernando Álvarez-Borges , Irene Jiménez-Fortunato , Erick Montes de Oca Valle , Francisca Martínez-Hergueta

引用次数: 0

Annular-shaped laser beam directed energy deposition of a high-strength and high-plasticity Al-Zn-Mg-Cu alloy via coaxial wire feeding 同轴送丝法制备高强度高塑性Al-Zn-Mg-Cu合金的环形激光定向能沉积

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2026-03-30 Epub Date: 2026-02-12 DOI: 10.1016/j.jmapro.2026.02.009

Jie Su , Minglie Hu , Zizheng Zhao , Zhen Li , Jinglong Tang , Zhen Luo

{"title":"Annular-shaped laser beam directed energy deposition of a high-strength and high-plasticity Al-Zn-Mg-Cu alloy via coaxial wire feeding","authors":"Jie Su , Minglie Hu , Zizheng Zhao , Zhen Li , Jinglong Tang , Zhen Luo","doi":"10.1016/j.jmapro.2026.02.009","DOIUrl":"10.1016/j.jmapro.2026.02.009","url":null,"abstract":"<div><div>Laser directed energy deposition (L-DED) of Al–Zn–Mg–Cu alloys is often constrained by a pronounced tendency toward solidification cracking and the formation of coarse columnar grains, which severely restrict their industrial applicability. To overcome these limitations and address the intrinsic drawbacks of conventional lateral wire-fed L-DED, this study proposes a novel DED approach that integrates an annular laser beam with coaxial wire feeding. The technique is designed to simultaneously suppress solidification cracking and promote a transition from columnar to equiaxed grain. By precisely controlling the laser output waveform and wire feeding rate, a stable and repeatable deposition process was established. Within the optimized processing window, defect-free thin-walled Al–Zn–Mg–Cu alloy structures were successfully fabricated. Multi-scale microstructural characterization reveals a distinctive hierarchical morphology composed of equiaxed grains, fine-grained bands, and columnar grains. Mechanical testing demonstrates that the proposed method substantially improves both geometric accuracy and mechanical performance relative to conventional lateral wire-fed DED. The effective material utilization of the thin wall increased by 12%. Ultimate tensile strength, yield strength and elongation increased by 18.2%, 17.6% and 32.5%, respectively. Based on the experimental observations, the synergistic mechanisms responsible for the simultaneous enhancement of strength and plasticity are elucidated. This work provides an effective processing route for precise control of geometry, microstructure and mechanical properties in Al–Zn–Mg–Cu alloy components produced by L-DED. The findings offer both theoretical insight and practical guidance for optimizing DED processes across a range of alloy systems and industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"162 ","pages":"Pages 99-117"},"PeriodicalIF":6.8,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146192812","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}

引用次数: 0