Journal of Materials Processing Technology最新文献

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Revealing the gradient strain forming mechanism: The semi-analytical modeling of chamfer extrusion machining 揭示梯度应变成形机理:倒角挤压加工的半解析建模
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-29 DOI: 10.1016/j.jmatprotec.2025.119085
Xueqin Pang , Junyu Zhao , Wenjun Deng , Zhenping Wan , Yu Cheng
{"title":"Revealing the gradient strain forming mechanism: The semi-analytical modeling of chamfer extrusion machining","authors":"Xueqin Pang ,&nbsp;Junyu Zhao ,&nbsp;Wenjun Deng ,&nbsp;Zhenping Wan ,&nbsp;Yu Cheng","doi":"10.1016/j.jmatprotec.2025.119085","DOIUrl":"10.1016/j.jmatprotec.2025.119085","url":null,"abstract":"<div><div>In extrusion machining (EM), when the chip compression ratio is below a certain value (0.5–1.5), the interior microstructure of the formed chip can be transformed into the gradient structure. However, the low chip compression ratios (&lt;1) induce fragmentation in the tool-tip region. To address this limitation, the chamfer extrusion machining (CEM) process is proposed, enabling the production of the gradient structure chips while mitigating tool damage. This study develops a semi-analytical model to evaluate the strain gradient along the chip thickness direction in CEM. The core innovation of the model lies in the incorporation of non-constant material deviating angles in the calculations. This approach offers a more accurate representation of dynamic material flow and a reduction in prediction errors within variable shear zones. Additionally, the model incorporates the actual chip compression ratio <span><math><mi>λ</mi></math></span> as a critical variable, further enhancing the precision of the analysis. The results demonstrate that the predicted strain closely matches both experimental data and finite element values. As a result, a novel methodology is established for strain gradient calculation. This approach provides a universal framework that can be applied to a wide range of machining contexts, ensuring its versatility and reliability across different conditions.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119085"},"PeriodicalIF":7.5,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217148","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
Wire-based refill friction stir spot welding with the modified sleeve towards non-thinning and high mechanical properties joint 采用改良套筒进行丝基搅拌摩擦点焊,实现高力学性能、不减薄接头
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-26 DOI: 10.1016/j.jmatprotec.2025.119084
Zhanwen Feng , Zeyu Zhang , Youlong Shi , Yong Yang , Qi Wen , Long Wan
{"title":"Wire-based refill friction stir spot welding with the modified sleeve towards non-thinning and high mechanical properties joint","authors":"Zhanwen Feng ,&nbsp;Zeyu Zhang ,&nbsp;Youlong Shi ,&nbsp;Yong Yang ,&nbsp;Qi Wen ,&nbsp;Long Wan","doi":"10.1016/j.jmatprotec.2025.119084","DOIUrl":"10.1016/j.jmatprotec.2025.119084","url":null,"abstract":"<div><div>The inherent issues of weld thinning, hook-induced stress concentration, and the weak region of bonding ligament severely impaired the general appearance and mechanical properties of the refill friction stir spot welding (RFSSW) joint. Herein, wire-based refill friction stir spot welding (W-RFSSW) and modified sleeve were devised to achieve non-thinning and well-formed 5A06/2219 aluminum alloy lapped joints with ER5356 wires. The weld thinning was compensated by paraxial feeding wire through the clamp sidewall. The trapezoidal groove in the modified sleeve functioned like mechanical \"shovels,\" promoting vertical material flow and mixing, which subsequently increased shear strain and heat generation. Internal formation and material flow were improved by severe plastic deformation effect of the modified sleeve. The joint formation, microstructural evolution, mechanical properties and thermal cycle measurements of joints produced by all three methods: conventional RFSSW, W-RFSSW, and W-RFSSW with modified sleeve, were systematically investigated. Compared to conventional RFSSW joint, W-RFSSW with a modified sleeve joint’s properties enhanced from 8015 ± 2438 N to 13106 ± 143 N, increasing by 63.5 %. The hook angle increased from 59° to 117°, mitigating stress concentration at the hook. This method provided a novel approach for material-deficient joints and significantly enhanced joints with hook mitigation and sufficient material flow.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119084"},"PeriodicalIF":7.5,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217147","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
Construction and deformation of density-graded origami Voronoi honeycombs with tunable energy absorption and enhanced in-plane strength 具有可调能量吸收和增强面内强度的密度梯度折纸Voronoi蜂窝的构造和变形
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-26 DOI: 10.1016/j.jmatprotec.2025.119083
Jun-Yuan Zheng , Dien Hu , Cong Du , M.W. Fu
{"title":"Construction and deformation of density-graded origami Voronoi honeycombs with tunable energy absorption and enhanced in-plane strength","authors":"Jun-Yuan Zheng ,&nbsp;Dien Hu ,&nbsp;Cong Du ,&nbsp;M.W. Fu","doi":"10.1016/j.jmatprotec.2025.119083","DOIUrl":"10.1016/j.jmatprotec.2025.119083","url":null,"abstract":"<div><div>The design of density-graded honeycombs with dimension-varying Voronoi cells is an approach that aims to achieve lightweight and multifunctional applications, which require consideration of both out-of-plane structural support and in-plane tunable energy absorption. In this research, an integrated structure enhancing the in-plane strength of Voronoi honeycomb by introducing origami-based folding, named density-graded origami Voronoi honeycomb (DOVH) was developed. Design configurations incorporating three density gradients and four fold angles were fabricated by micro laser powder bed fusion, and their mechanical responses, energy absorption, and crushing behaviors were investigated and validated. It is revealed that the density-graded structures exhibit two hardening stages without densification strain, whereas the non-gradient structures display an apparent plateau and densification stages. A larger fold angle not only enhances the elastic modulus, yield stress, stress after yielding, and energy absorption capacity, but also expands the area of stress concentration and promotes cushioning under blast loading. Meanwhile, a higher density gradient deteriorates the elastic performance and energy absorption due to the lower relative density involved in deformation, as the crushing mode changes from entire collapse to a progressive mode. It also leads to a uniform crushing boundary, maintaining a larger non-deformed region during later deformation, with smaller stress-concentrating regions. The crushing boundary develops in a wave-like morphology, following the fold angle. Additionally, a segmented empirical model was developed to describe the various deformation stages and to evaluate the strengthening effects of fold angle. This research provides design optimization to tailor structural performances for diverse cushioning requirements.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119083"},"PeriodicalIF":7.5,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217149","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
Advancements in process monitoring and quality control for electrical discharge machining: A comprehensive review 电火花加工过程监控与质量控制研究进展综述
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-25 DOI: 10.1016/j.jmatprotec.2025.119081
Zequan Yao , Jia Ge , Peiyao Cao , Ming Wu , Jun Qian , Yong Li , Dominiek Reynaerts
{"title":"Advancements in process monitoring and quality control for electrical discharge machining: A comprehensive review","authors":"Zequan Yao ,&nbsp;Jia Ge ,&nbsp;Peiyao Cao ,&nbsp;Ming Wu ,&nbsp;Jun Qian ,&nbsp;Yong Li ,&nbsp;Dominiek Reynaerts","doi":"10.1016/j.jmatprotec.2025.119081","DOIUrl":"10.1016/j.jmatprotec.2025.119081","url":null,"abstract":"<div><div>As an unconventional machining technology, electrical discharge machining (EDM) enables the processing of any electrically conductive material through a thermoelectrically coupled material removal mechanism. With the growing demand for increasingly sophisticated and miniaturized high-end components, particularly in mold manufacturing, aviation, and biomedical sectors, EDM has become an indispensable machining solution and continues to attract significant industrial and academic attention. However, the extremely narrow inter-electrode gap and inherently complex gap conditions make discharge behavior highly stochastic and dynamic. This characteristic poses substantial challenges to machining stability, mechanism analysis, and quality improvement, hindering its efficient application and development. Addressing these problems requires robust process monitoring and effective quality control strategies to ensure the stable production of high-precision parts. Previous literature reviews have primarily focused on theoretical modeling, application, and optimization, without systematically addressing the aforementioned challenges. With the ultimate goal of enabling stable and high-performance EDM processes, this paper investigates state-of-the-art monitoring strategies and broadly explores solutions to quality control. The review begins with an overview of the fundamental principles of EDM, its process variants, and the key challenges encountered in practice. Then, a detailed examination of sensing techniques (direct or indirect monitoring) that are employed to capture machining information is provided, which can assess process condition and workpiece performance. The paper further discusses the causes of quality defects, presenting strategies for controlling dimensional accuracy and surface integrity through parameter optimization, process hybridization, and advanced monitoring methods. Finally, promising directions for potential EDM development are highlighted from the perspective of process monitoring level, quality control level, and versatility of EDM applications. This review offers valuable insights and practical guidance for advancing intelligent EDM technology, providing a roadmap for its increased industrial application.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119081"},"PeriodicalIF":7.5,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155669","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-physics modeling of contour scanning mechanisms affecting surface and subsurface features in laser powder bed fused 304L steel 影响激光粉末床熔合304L钢表面和亚表面特征的轮廓扫描机制的多物理场建模
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-22 DOI: 10.1016/j.jmatprotec.2025.119080
Hongzhuang Zhang , Tianbiao Yu , Bing Li , Punit Kumar , Yanan Hu , Changyou Li
{"title":"Multi-physics modeling of contour scanning mechanisms affecting surface and subsurface features in laser powder bed fused 304L steel","authors":"Hongzhuang Zhang ,&nbsp;Tianbiao Yu ,&nbsp;Bing Li ,&nbsp;Punit Kumar ,&nbsp;Yanan Hu ,&nbsp;Changyou Li","doi":"10.1016/j.jmatprotec.2025.119080","DOIUrl":"10.1016/j.jmatprotec.2025.119080","url":null,"abstract":"<div><div>Surface and subsurface defects in laser powder bed fusion affect fatigue performance, limiting its application in safety-critical components. Applying contour scanning potentially improves side surface quality and near-surface features, but the involved multi-scale physical mechanisms for defect formation and suppression remain unclear. In this study, we develop a comprehensive and high-fidelity numerical simulation model that simultaneously captures melt pool dynamics, surface roughness formation, and subsurface defect evolution during contour scanning. Model predictions show good agreement with experimental results of melt pool geometry, surface roughness, and near-surface defects. The results demonstrate that controlling energy density near the keyhole regime improves melt pool stability and track uniformity, thereby reducing surface roughness and suppressing the formation of lack-of-fusion and keyhole-induced pores. A mechanism is identified where gas bubbles undergo expansion, shrinkage, and convection-driven motion, influenced by vapor condensation, Marangoni flow, and buoyancy. These dynamics determine whether bubbles coalesce, migrate, or become entrapped within the melt pool. Optimized contour parameters reduce surface roughness by more than 50 % (Sa from ∼10 to ∼4 μm; Sq from ∼10 to ∼5 μm), and extend fatigue life by over threefold (from ∼7000 to ∼25,000 cycles) relative to suboptimal conditions. Moreover, the remelting effect of multi-layer scanning promotes pore closure at intermediate depths but increases porosity near the top layers. A gradient-decreasing laser energy strategy is proposed to balance these effects. The identified contour mechanisms provide a scientific basis for developing in-situ laser control strategies aimed at enhancing surface quality and fatigue resistance in additively manufactured metallic components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119080"},"PeriodicalIF":7.5,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155670","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
Synergistic control of solidification cracks and MC carbides to enhance the tensile strength of electron beam welded GH4251 alloy joints 协同控制凝固裂纹和MC碳化物提高GH4251合金电子束焊接接头抗拉强度
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-18 DOI: 10.1016/j.jmatprotec.2025.119050
Jincan Ma , Houqin Wang , Caiyu Guo , Yifan Wang , Yu Qiu , Binggang Zhang , Hongyao Yu
{"title":"Synergistic control of solidification cracks and MC carbides to enhance the tensile strength of electron beam welded GH4251 alloy joints","authors":"Jincan Ma ,&nbsp;Houqin Wang ,&nbsp;Caiyu Guo ,&nbsp;Yifan Wang ,&nbsp;Yu Qiu ,&nbsp;Binggang Zhang ,&nbsp;Hongyao Yu","doi":"10.1016/j.jmatprotec.2025.119050","DOIUrl":"10.1016/j.jmatprotec.2025.119050","url":null,"abstract":"<div><div>With the continuous advancement of the aviation industry, the demand for high-temperature alloys in aircraft engines has been increasing significantly. However, in the fusion welding of precipitation-strengthened nickel-based alloys with high Al and Ti content, crack formation and the precipitation of brittle phases remain major challenges that severely affect welding quality. This study investigates the fundamental principles governing the weldability and mechanical behavior of such alloys, focusing on the GH4251 alloy welded by electron beam technology. By optimizing the welding parameters, synergistic control of MC carbides and solidification cracks was successfully achieved, resulting in a room-temperature tensile strength of 1471 MPa — equivalent to 92 % of the base metal. Experimental and simulation results reveal that solidification cracks and MC carbides within the weld seam act as stress concentration sites under external loading, thereby accelerating macroscopic fracture of the joint. The occurrence of solidification cracks is further promoted by instantaneous tensile stresses and high-angle grain boundaries during welding. Moreover, a high density of dislocations was observed at the semi-coherent interface between MC carbides and the γ matrix, accompanied by pronounced tensile strain within the carbides themselves. Overall, this research provides new insights into the relationships among welding parameters, microstructural evolution, and room-temperature tensile strength in high Al and Ti precipitation-strengthened nickel-based superalloy joints.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119050"},"PeriodicalIF":7.5,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106352","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
Coordinated control of multi-region solidification in complex-shaped die-cast wheels via cooling adjustment strategies to minimize defects and enhance performance 基于冷却调节策略的复杂形状压铸车轮多区域凝固协调控制以减少缺陷和提高性能
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-17 DOI: 10.1016/j.jmatprotec.2025.119078
Jie Han , Jiang Bi , Jianxin Zhou , Shide Li , Yajun Yin , Ji Wang , Shiwei Guo , Guojiang Dong
{"title":"Coordinated control of multi-region solidification in complex-shaped die-cast wheels via cooling adjustment strategies to minimize defects and enhance performance","authors":"Jie Han ,&nbsp;Jiang Bi ,&nbsp;Jianxin Zhou ,&nbsp;Shide Li ,&nbsp;Yajun Yin ,&nbsp;Ji Wang ,&nbsp;Shiwei Guo ,&nbsp;Guojiang Dong","doi":"10.1016/j.jmatprotec.2025.119078","DOIUrl":"10.1016/j.jmatprotec.2025.119078","url":null,"abstract":"<div><div>Cooling parameter adjustment is essential to minimize defect formation in die-cast components. However, such adjustments induce regional differences in aluminum solidification behavior, potentially improving quality in certain areas while causing degradation in adjacent regions. This study innovatively investigates the evolution of defects, microstructure, and mechanical properties with varying cooling parameters across multiple regions in low-pressure die-cast (LPDC) A356 wheels. Experimental results reveal that the cooling parameter exerts a pronounced impact on defect generation in the thin-walled rim and spoke regions. LPDC wheels exhibit opposing trends in defects and mechanical properties between the rim/spoke and outer flange when subjected to identical cooling parameter modifications. As the cooling condition changes from process 2 to process 3, the elongation of the rim and the spoke decrease by 8.0 % and 5.4 %, respectively, while the UTS decreases by 43 MPa and 27 MPa, respectively, due to the increased formation of defects. In contrast, the outer flange exhibits improvements, with elongation and UTS increasing by 4.5 % and 7 MPa, respectively, owing to microstructural refinement under long cooling duration. The same trend occurs in the transition from process 4 to process 5. Additionally, mechanical property data indicate that cooling parameter adjustment effectively homogenizes the mechanical properties in LPDC wheels. Moreover, P2 not only achieves balanced mechanical properties across all regions but also reduces the consumption of the cooling medium. These findings provide valuable engineering insights for developing cooling strategies to achieve multi-regional performance control in complex-shaped die-cast components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119078"},"PeriodicalIF":7.5,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106282","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
Region-confined electrochemical float machining with conductive compliant tool 导电柔性刀具的局部电化学浮子加工
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-17 DOI: 10.1016/j.jmatprotec.2025.119079
Jingyuan Wang, Fang Han, Weijian Zhang, Caoyang Xue, Qi Sun, Bingfeng Ju, Wule Zhu
{"title":"Region-confined electrochemical float machining with conductive compliant tool","authors":"Jingyuan Wang,&nbsp;Fang Han,&nbsp;Weijian Zhang,&nbsp;Caoyang Xue,&nbsp;Qi Sun,&nbsp;Bingfeng Ju,&nbsp;Wule Zhu","doi":"10.1016/j.jmatprotec.2025.119079","DOIUrl":"10.1016/j.jmatprotec.2025.119079","url":null,"abstract":"<div><div>Ultrahard materials such as silicon carbide (SiC) are increasingly used in advanced optical and semiconductor applications that require atomic and close-to-atomic scale manufacturing (ACSM). However, its high hardness and brittleness present challenges to ultra-precision surface machining. This study proposes a novel electrochemical float machining (EC-FM) method for non-contact, high-efficiency machining of SiC surfaces. A flow electrochemical model based on fluid-structure interaction was established revealing that shear stress not only governs material removal but simultaneously enhances the local mass transport of oxidation reactants and oxide layer removal, thereby enabling region confinement of oxidation reaction, and the region confinement, which is further regulated by bipolar voltage. In-situ electrochemical characterization was performed to provide the theoretical insights for optimizing process parameters. Material removal rate (MRR) of electrochemical float machining method with silica slurry was significantly improved compared to float machining with diamond slurry. A saddle-shaped freeform with a Sag value of 25 nm and a shape error below 3 nm was fabricated. Low-voltage electrochemical polishing method achieved an atomically smooth surface with a surface roughness (Sa) of 0.103 nm.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119079"},"PeriodicalIF":7.5,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145119408","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
Laser-ultrasonic vibration hybrid assisted machining in advanced difficult-to-cut materials: Technologies, mechanisms, and challenges 先进难切割材料的激光-超声振动混合辅助加工:技术、机制和挑战
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-16 DOI: 10.1016/j.jmatprotec.2025.119076
Haiqiang Yu , Xiaoliang Liang , Feng Guo , Huapan Xiao , Shufei Li , Kexian Liu , Yukui Cai , Zhanqiang Liu
{"title":"Laser-ultrasonic vibration hybrid assisted machining in advanced difficult-to-cut materials: Technologies, mechanisms, and challenges","authors":"Haiqiang Yu ,&nbsp;Xiaoliang Liang ,&nbsp;Feng Guo ,&nbsp;Huapan Xiao ,&nbsp;Shufei Li ,&nbsp;Kexian Liu ,&nbsp;Yukui Cai ,&nbsp;Zhanqiang Liu","doi":"10.1016/j.jmatprotec.2025.119076","DOIUrl":"10.1016/j.jmatprotec.2025.119076","url":null,"abstract":"<div><div>The tech breakthroughs of advanced difficult-to-cut materials have promoted the development of aerospace, defense systems and clean energy. The inherent physicochemical properties and the complex microstructures of these materials make the conventional machining processes facing the significant challenges of poor surface quality and low processing efficiency. Laser-ultrasonic vibration hybrid assisted machining (LUVAM) has been emerged as the transformative solution and gradually applied in high-efficiency, low-damage machining of various advanced difficult-to-cut materials. Such approach mitigated the limitations of single energy field assistance, achieving simultaneous improvements in machining efficiency, tool longevity, and surface integrity. The LUVAM researches has been conducted on different materials, yet few studies have presented comprehensive analyses and systematic summarization. To fill the gap and elucidate the developmental trend of LUVAM, this paper reviews the frontier progress and innovation trends of the LUVAM in advanced difficult-to-cut materials. The principles and the system configurations of different machining equipment have been systematically reviewed. Then, the dynamic time-varying evolution and interaction mechanisms of multi-physical fields were analyzed. Critically, the influence mechanisms and response consequences of the LUVAM have been analyzed under the coupling conditions of various materials and machining parameters. Finally, the machining characteristics, advantages and limitations were summarized, and the future development trends of LUVAM were proposed. This work will provide important reference for theoretical research and industrial applications of the LUVAM and the corresponding machining systems.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119076"},"PeriodicalIF":7.5,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106283","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
Simultaneous laser nitriding and biomimetic texturing: A synergistic strategy for enhancing mechanical properties and corrosion resistance of Ti6Al4V alloy 激光同步氮化和仿生织构:提高Ti6Al4V合金力学性能和耐蚀性的协同策略
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-09-15 DOI: 10.1016/j.jmatprotec.2025.119074
Hongyang Zhang , Hu Huang , Jiwang Yan
{"title":"Simultaneous laser nitriding and biomimetic texturing: A synergistic strategy for enhancing mechanical properties and corrosion resistance of Ti6Al4V alloy","authors":"Hongyang Zhang ,&nbsp;Hu Huang ,&nbsp;Jiwang Yan","doi":"10.1016/j.jmatprotec.2025.119074","DOIUrl":"10.1016/j.jmatprotec.2025.119074","url":null,"abstract":"<div><div>The service reliability and lifespan of Ti6Al4V in high-end equipment application are limited by its poor wear resistance and susceptibility to pitting corrosion. Pulsed laser nitriding and simultaneous microtexturing can improve surface hardness and wear resistance. However, this method faces a mutual constraint between modified layer thickness and structural regularity. In this study, composite microtextures comprising periodic ripples and uniform vein-like structures are fabricated on Ti6Al4V by CW laser nitriding. Inspired by biological surfaces, various biomimetic textures are created, among which the biomimetic fish scale surface (BFS) exhibits remarkable performance enhancement. Its cross-section consists of a dendritic TiN layer on the surface and a dense acicular α'-Ti phase within the molten pool, with the modified layer thickness increasing to nearly 20 μm. Compared with the substrate, the cross-sectional hardness increases by 117 %, while the wear rate decreases by 10 % and 96 % under dry friction and starved lubrication, respectively. Moreover, the corrosion potential shifts positively from −579.84 mV to −299.47 mV, and the corrosion current density decreases by three orders of magnitude. The formation mechanisms of the microtextures are elucidated based on the evolution of microscopic morphologies and finite element simulations. The hardness enhancement is interpreted through analysis of the cross-sectional microstructure, whereas the improvement in corrosion resistance is revealed through impedance spectroscopy and passive film composition. This work provides a new strategy for the integrated construction of nitrided layers and functional microtextures on titanium alloy surfaces.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119074"},"PeriodicalIF":7.5,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106354","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
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