Journal of Materials Processing Technology最新文献

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Stress interaction analysis and mitigation in multi-process bellows manufacturing using continuous finite element simulation
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-26 DOI: 10.1016/j.jmatprotec.2025.118826
Yuanyang Gao , Yanhong Wei , Xiangbo Liu , Honghe Jia , Wenyong Zhao
{"title":"Stress interaction analysis and mitigation in multi-process bellows manufacturing using continuous finite element simulation","authors":"Yuanyang Gao ,&nbsp;Yanhong Wei ,&nbsp;Xiangbo Liu ,&nbsp;Honghe Jia ,&nbsp;Wenyong Zhao","doi":"10.1016/j.jmatprotec.2025.118826","DOIUrl":"10.1016/j.jmatprotec.2025.118826","url":null,"abstract":"<div><div>A major challenge in the bellows manufacturing process is the accumulation of complex stresses due to the multi-step forming and welding processes, which can significantly impact the bellows’ service life under varying and complex thermal/mechanical loads in engine fuel systems. This research focuses on the full process chain for 1Cr18Ni9Ti bellows and innovatively conducts a multi-process direct finite element analysis of the full process chain, including hydraulic forming (HF), end-corrugation flattening (ECF), resistance spot welding (RSW), and full circumferential welding (FCW). Firstly, finite element models (FEM) for four individual processes were established and were integrated into a continuous simulation model of the full process chain. Subsequently, the high reliability of the model was verified. The research further investigated the influence of each process on the stress distribution and evolution and concluded that the stress in the trough was mainly affected by HF and FCW. Corresponding optimization based on HF and FCW effectively reduced the stress level in the trough by 10.4 %. The significance of this research lies in providing critical insights for efficient multi-aspect process optimization and offering valuable references for simulating other complex manufacturing process chains.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118826"},"PeriodicalIF":6.7,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143706269","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
A molten pool and keyhole dynamics study in near IR-blue hybrid laser welding of AZ31B magnesium alloy: A dual-mode synergy strategy for defect suppression in reflective low-melting materials
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-22 DOI: 10.1016/j.jmatprotec.2025.118814
Haolin Deng , Yi Li , Zhongqing Peng , Yunfei Huang , Wei Wei , Yu Long
{"title":"A molten pool and keyhole dynamics study in near IR-blue hybrid laser welding of AZ31B magnesium alloy: A dual-mode synergy strategy for defect suppression in reflective low-melting materials","authors":"Haolin Deng ,&nbsp;Yi Li ,&nbsp;Zhongqing Peng ,&nbsp;Yunfei Huang ,&nbsp;Wei Wei ,&nbsp;Yu Long","doi":"10.1016/j.jmatprotec.2025.118814","DOIUrl":"10.1016/j.jmatprotec.2025.118814","url":null,"abstract":"<div><div>Magnesium alloy with excellent strength-to-weight ratio and good formability has been primarily applied in automotive and aerospace applications. However, the laser welding of magnesium alloys is often challenged by low absorption efficiency, tendency to oxidize, thermal sensitivity and susceptibility to evaporation because of low boiling point, leading to instability of molten pool and keyhole. In light of the current lack of sufficient research, the effects of blue and hybrid laser welding were clarified, and the mechanisms behind the observed phenomenons were analyzed in this study. The research found that near-infrared (NIR) laser welding caused porosity defects due to keyhole collapse and turbulent molten pools. Blue laser improved hardness (76.7 Hv) and strength (305.44 MPa) but induced discontinuous solidification from gravity-driven fluid accumulation. Hybrid laser welding stabilized the molten pool by reducing temperature gradients and stress concentrations, enhancing recoil pressure to counteract gravity. This achieved superior hardness (78 Hv) and maintained strength (287.86 MPa), with surface roughness reduced by 23.1 % compared to NIR and 3.5 % compared to blue laser, demonstrating synergistic benefits for magnesium alloy welding performance through optimized energy and fluid dynamics. This research not only employs an energy-morphology-defect correlation analysis to investigate the welding process of magnesium alloys which bridging critical knowledge gaps in blue and hybrid laser welding mechanisms but also introduces a interesting hybrid laser welding technique that overcomes the longstanding challenges in magnesium alloy welding, offering a substantial methodological innovation with potential applications in high-performance manufacturing industries.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118814"},"PeriodicalIF":6.7,"publicationDate":"2025-03-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143703968","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
Dynamic laser beam shaping by means of a deformable mirror to tailor microstructure in Directed Energy Deposition
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-20 DOI: 10.1016/j.jmatprotec.2025.118797
Scholte J.L. Bremer , Martin Luckabauer , Ronald G.K.M. Aarts , Gert-willem R.B.E. Römer
{"title":"Dynamic laser beam shaping by means of a deformable mirror to tailor microstructure in Directed Energy Deposition","authors":"Scholte J.L. Bremer ,&nbsp;Martin Luckabauer ,&nbsp;Ronald G.K.M. Aarts ,&nbsp;Gert-willem R.B.E. Römer","doi":"10.1016/j.jmatprotec.2025.118797","DOIUrl":"10.1016/j.jmatprotec.2025.118797","url":null,"abstract":"<div><div>In Laser-based Direct Energy Deposition (DED-L), the resultant mechanical properties depend on thermal cycles during deposition. Traditionally these cycles are usually optimized by tuning the laser power, traverse speed of the laser beam or material feed rate. By adapting, in real-time, the spatial power density distribution (intensity profile) in the focal spot of the laser beam, thermal cycles and thus the microstructure can be further tailored during processing. In this paper, a developed dynamic beam shaping setup, based on a deformable mirror, is used to deposit single tracks, where the high power laser intensity distribution is adapted during deposition. Melt pool monitoring showed that this setup allows to significantly change melt pool morphology during deposition. Next, microstructure analysis (EBSD) of the deposited track shows that various microstructures can be achieved, ranging from a track with larger equiaxed grains in the centre and columnar grains at the bottom and sides of the track to equiaxed grains with a strong crystallographic texture throughout the track. This proofs that the dynamic beam shaping setup is a powerful tool to steer the microstructure and therefore the functional properties of the material.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118797"},"PeriodicalIF":6.7,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143706270","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Rolling in-situ generation of metallurgical and mechanical bonding improves mechanical properties and synergistic deformation ability of semi-solid cast-rolled aluminum/steel composite plate
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-20 DOI: 10.1016/j.jmatprotec.2025.118821
Jin Qiu , Yuandong Li , Wenjing Liu , Hongwei Zhou , Chi Cao , Guangli Bi
{"title":"Rolling in-situ generation of metallurgical and mechanical bonding improves mechanical properties and synergistic deformation ability of semi-solid cast-rolled aluminum/steel composite plate","authors":"Jin Qiu ,&nbsp;Yuandong Li ,&nbsp;Wenjing Liu ,&nbsp;Hongwei Zhou ,&nbsp;Chi Cao ,&nbsp;Guangli Bi","doi":"10.1016/j.jmatprotec.2025.118821","DOIUrl":"10.1016/j.jmatprotec.2025.118821","url":null,"abstract":"<div><div>A nowel processing technology was developed to solve the problem of low bonding strength caused by intermetallic compounds (IMCs) of aluminum/steel composites. This approach utilizes semi-solid cast-rolling to fabricate composite plates with a thin metallurgical bonding layer, followed by in situ formation of metallurgical and mechanical bonding through rolling, thereby enhancing the mechanical properties of aluminum/steel composite plate. Results demonstrated that a primary metallurgical bonding layer of approximately 6 μm formed after semi-solid cast-rolling, with a shear strength of only 38.8 MPa, while a reduction rate of 20 % increased the mechanical bonding strength to 46.0 MPa. The optimal mean mechanical bonding strength of 59.5 MPa was achieved at a reduction rate of 30 % with five rolling passes, exceeding the lower limit of the critical reduction rate required for aluminum/steel composite plate preparation by traditional rolling. With an increasing reduction rate, steel deformation, crack gaps (equivalent deformation) in IMCs, and coordinated deformation in composite plates also increase, promoting the formation of secondary bonding with alternating soft and hard phases. At a 50 % reduction rate, the shear strength of the aluminum/steel composite plate reaches 119.0 MPa, representing a 206.7 % increase compared to semi-solid cast-rolling. The ultimate tensile strength (UTS) of the composite plates with a 50 % reduction rate exceeded that predicted by the rule of mixtures by 17.1 MPa, while uniform elongation (UE) and fracture elongation (FE) increased by 35.3 % and 120.0 %, respectively, compared to high-elongation steel. The current study presents a novel investigation into the influence of bonding modes on the shear strength of aluminum/steel composite plates, offering new perspectives for designing and manufacturing dissimilar alloy interfaces.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118821"},"PeriodicalIF":6.7,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
A duplex surface modification method for increasing bending fatigue life of aviation carburized gear steel considering its mechanical properties and microstructure gradients
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-19 DOI: 10.1016/j.jmatprotec.2025.118812
Fei Yang , Peng He , Wenhe Wang , Yanqing Yu , Xinlei Pan , Hongwei Yang , Xiaoqing Liang , Cenchao Xie , Liucheng Zhou
{"title":"A duplex surface modification method for increasing bending fatigue life of aviation carburized gear steel considering its mechanical properties and microstructure gradients","authors":"Fei Yang ,&nbsp;Peng He ,&nbsp;Wenhe Wang ,&nbsp;Yanqing Yu ,&nbsp;Xinlei Pan ,&nbsp;Hongwei Yang ,&nbsp;Xiaoqing Liang ,&nbsp;Cenchao Xie ,&nbsp;Liucheng Zhou","doi":"10.1016/j.jmatprotec.2025.118812","DOIUrl":"10.1016/j.jmatprotec.2025.118812","url":null,"abstract":"<div><div>As an effective surface modification technology, laser shock peening can improve the fatigue performance of aerospace components. However, for gear components with complex configurations, this technology exhibits significant technical limitations such as difficulties in adhering absorbed layers and distortion of the laser spot due to the curvature at tooth roots. This paper innovatively introduces a method combining laser shock peening without coatings and vibratory polishing, aiming to enhance the bending fatigue performance of gear steel. Underlying mechanisms of bending fatigue resistance have been elucidated through the examination of mechanical properties, surface integrity, and microstructural evolution during modification. After LSP without coatings combined with vibratory polishing, a gradient structure of nanocrystals-fine grains was formed along the depth direction, with significant increases in dislocation density and types of dislocations. The mechanical properties of samples were improved by introducing a work hardening layer with thickness of 570 μm and a residual compressive stress layer with thickness of 510 μm. Adverse surface factors such as ablation and remelting morphologies were mitigated. Compared to as-received samples, bending fatigue limit was significantly increased by approximately 86.1 %. Fatigue resistance mechanisms can be attributed to combined effects of the second-phase strengthening mechanism caused by amorphous dispersed carbides, residual compressive stress, high-density dislocations, and interlocking structure coupled with nanotwins and intergranular dislocations. The duplex surface modification process integrates the advantages of the shockwave force effect induced by laser with the exceptional surface integrity achieved through vibration polishing, which renders impetus for the researchers striving for aerospace gear performance improvement.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118812"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682240","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
Liquid bridged deposition for 3D shaping
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-19 DOI: 10.1016/j.jmatprotec.2025.118820
Jiahao Zhao , Xiaolong Yang , Di Zhu
{"title":"Liquid bridged deposition for 3D shaping","authors":"Jiahao Zhao ,&nbsp;Xiaolong Yang ,&nbsp;Di Zhu","doi":"10.1016/j.jmatprotec.2025.118820","DOIUrl":"10.1016/j.jmatprotec.2025.118820","url":null,"abstract":"<div><div>Additive manufacturing has emerged as a vital technology for fabricating three-dimensional (3D) structures. However, in many cutting-edge applications, creating sophisticated 3D metallic structures with high surface quality and precision is required, which remains a significant challenge. Here we developed the liquid bridge-constrained electrodeposition for 3D shaping. Leveraging the discontinuous dewetting of wettability contrast pattern, the catenoid-like liquid bridge was spontaneously formed between the electrolyte pool and the surface plate. The liquid bridge serves a tunnel, to effectively confine the deposition and enable precision growth of 3D curved structures. The generated umbrella-shaped structure exhibits a base diameter of 0.4 mm, a maximum width of 1.0 mm, and achieves an aspect ratio of 0.6, with its sidewall profile perfectly conforming to the catenary equation. Furthermore, these structures have fine surface quality while exhibiting hardness comparable to those of pure copper. Notably, leveraging engineered wettability patterns enables scalable fabrication of 3 × 3 arrayed 3D structures, demonstrating that utilizing liquid bridge electrodeposition to achieve bulk fabrication is readily feasible. This method simultaneously considers the manufacturing requirements of 3D complexity, accuracy, scalability and discontinuous dewetting, which holds promise for applications ranging from heat transfer, microfluidic and electronic devices where 3D shaping of exquisite structures matters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118820"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682254","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
Mechanisms for manufacturing NiAl thin-walled spherical shell by combining superplastic forming of Ni/Ni2Al3 heterogeneous bimodal-grained composite sheet with subsequent in-situ reaction
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-19 DOI: 10.1016/j.jmatprotec.2025.118813
Peng Lin , Pengle Kong , Bingyao Yan , Yupeng Lu , Dong Sun , Hao Feng , Lin Yang , Shuyong Jiang
{"title":"Mechanisms for manufacturing NiAl thin-walled spherical shell by combining superplastic forming of Ni/Ni2Al3 heterogeneous bimodal-grained composite sheet with subsequent in-situ reaction","authors":"Peng Lin ,&nbsp;Pengle Kong ,&nbsp;Bingyao Yan ,&nbsp;Yupeng Lu ,&nbsp;Dong Sun ,&nbsp;Hao Feng ,&nbsp;Lin Yang ,&nbsp;Shuyong Jiang","doi":"10.1016/j.jmatprotec.2025.118813","DOIUrl":"10.1016/j.jmatprotec.2025.118813","url":null,"abstract":"<div><div>As a novel lightweight and heat-resisting alloy, NiAl intermetallic compound has become the best candidate for replacing Ni-based high-temperature alloy to manufacture thin-walled component. However, NiAl intermetallic compound is characterized by intrinsic brittleness, so it fails to be made into sheet to be directly used for forming complex thin-walled component. A novel approach of “fabrication-forming-reaction” is proposed to NiAl thin-walled spherical shell in the present work. Firstly, Ni/Ni<sub>2</sub>Al<sub>3</sub> composite sheet with heterogeneous bimodal grains containing coarse-grained Ni layer and fine-grained Ni<sub>2</sub>Al<sub>3</sub> layer is fabricated by first-order reaction between Ni foil and Al foil and it exhibits a certain superplasticity at the temperatures of 700–850 ℃ in the case of 1 × 10<sup>−3</sup> s<sup>−1</sup>, where the maximum elongation to fracture achieves to 348 %. Then, Ni/Ni<sub>2</sub>Al<sub>3</sub> composite sheet is made into thin-walled spherical shell by superplastic forming at 750 ℃. Finally, NiAl thin-walled spherical shell is manufactured by subsequent in-situ reaction of Ni/Ni<sub>2</sub>Al<sub>3</sub> thin-walled spherical shell and it is completely composed of homogeneous bimodal grains. The current work contributes to the fundamental advancement in superplastic deformation mechanism of Ni/Ni<sub>2</sub>Al<sub>3</sub> composite sheet with heterogeneous bimodal grains as well as manufacturing NiAl thin-walled components with complex shape.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118813"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682255","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
Fabrication of different shapes of tool electrodes using a variable-parameter bipolar-pulsed liquid membrane electrochemical etching method
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-17 DOI: 10.1016/j.jmatprotec.2025.118798
Xiujuan Wu , Li Wang , Tao Yang , Weijing Kong , Yusen Hang , Yongbin Zeng
{"title":"Fabrication of different shapes of tool electrodes using a variable-parameter bipolar-pulsed liquid membrane electrochemical etching method","authors":"Xiujuan Wu ,&nbsp;Li Wang ,&nbsp;Tao Yang ,&nbsp;Weijing Kong ,&nbsp;Yusen Hang ,&nbsp;Yongbin Zeng","doi":"10.1016/j.jmatprotec.2025.118798","DOIUrl":"10.1016/j.jmatprotec.2025.118798","url":null,"abstract":"<div><div>With traditional liquid membrane electrochemical etching methods, it is difficult to effectively control the electrolytic products. In this paper, a variable-parameter bipolar-pulsed liquid membrane electrochemical etching technique is proposed for the preparation of microelectrodes. The introduction of negative voltage will generate insoluble electrolytic products on the electrode surface. By adjusting the processing parameters, these electrolytic products can be precisely controlled, thereby shaping the morphology of the electrodes. In step one, the positive voltage is larger and the electrode surface is coated with a layer of insoluble electrolytic products. In step two, the positive voltage is smaller and hydrogen is generated on the electrode surface, dispersing the electrolytic products. The effects of positive voltage, negative voltage and processing time on the distribution of electrolytic products and electrode morphology were investigated in different steps. It was found that the upper and lower electrodes changed significantly with the change of processing time. Based on the experimental results, the droplet-shaped upper electrode and conical-shaped lower electrode with tiny size and controllable shape were prepared. In addition, a repeated-variable-parameter method was used to mitigate the problem of inconsistent etching speed that was caused by the electrolytic product coating, and enabled the preparation of cylindrical electrodes that are uniform in size. While keeping the processing mode unchanged, different shaped electrodes can be manufactured by simply adjusting the parameters to control the distribution of electrolytic products, demonstrating good processing flexibility.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118798"},"PeriodicalIF":6.7,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682301","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
Unveiling the mechanisms behind the inconsistent impact of casting pressure on macro and microsegregation
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-17 DOI: 10.1016/j.jmatprotec.2025.118804
Hong-Chun Zhu , Zhuo-Wen Ni , Hua-Bing Li , Zhi-Yu He , Zheng-Rong Ai , Zhou-Hua Jiang , Hao Feng , Shu-Cai Zhang
{"title":"Unveiling the mechanisms behind the inconsistent impact of casting pressure on macro and microsegregation","authors":"Hong-Chun Zhu ,&nbsp;Zhuo-Wen Ni ,&nbsp;Hua-Bing Li ,&nbsp;Zhi-Yu He ,&nbsp;Zheng-Rong Ai ,&nbsp;Zhou-Hua Jiang ,&nbsp;Hao Feng ,&nbsp;Shu-Cai Zhang","doi":"10.1016/j.jmatprotec.2025.118804","DOIUrl":"10.1016/j.jmatprotec.2025.118804","url":null,"abstract":"<div><div>Segregation is a common defect in the casting process of metallic materials. This phenomenon leads to uneven variations in the mechanical properties, corrosion resistance, and machinability of the material, ultimately increasing processing difficulty and affecting the quality and performance of the product. In this study, the impact of casting pressure on the segregation of M42 high-speed steel (HSS) during die casting was systematically investigated. The results indicated that there is inconsistency in the impact of casting pressure on macrosegregation and microsegregation, that is, as the casting pressure increases, the degree of macrosegregation mitigates, while the degree of microsegregation enhances. For macrosegregation, increasing the casting pressure reduces the width of the mushy zone and expands the range of the slurry zone, which promotes feeding flow and inhibits the transport of carbon solutes by the flowing molten steel to the center, thereby mitigating macrosegregation in the ingot center. For microsegregation, as the casting pressure increases, the grain size significantly decreases and the cooling rate increases. This leads to a shortened solidification time and a weakening of the back-diffusion effect in the solid phase. Therefore, as the casting pressure increases, the degree of microsegregation is enhanced. This study unveils the mechanisms behind the inconsistent impact of casting pressure on macrosegregation and microsegregation during die casting, providing theoretical guidance for alleviating segregation and reducing processing difficulty by controlling casting pressure.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118804"},"PeriodicalIF":6.7,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143642380","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
Study on the crack healing behavior of aluminum alloy under the action of pulse electric current
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-16 DOI: 10.1016/j.jmatprotec.2025.118803
Li Yu , Zheng Qiu-yang , Jiang Zhi-guo , Yuan Zhi-peng , Shi Hao-han , Zhou Zhen-yu , Piao Zhong-yu
{"title":"Study on the crack healing behavior of aluminum alloy under the action of pulse electric current","authors":"Li Yu ,&nbsp;Zheng Qiu-yang ,&nbsp;Jiang Zhi-guo ,&nbsp;Yuan Zhi-peng ,&nbsp;Shi Hao-han ,&nbsp;Zhou Zhen-yu ,&nbsp;Piao Zhong-yu","doi":"10.1016/j.jmatprotec.2025.118803","DOIUrl":"10.1016/j.jmatprotec.2025.118803","url":null,"abstract":"<div><div>Aerospace structural parts fabricated from aluminum alloy are susceptible to crack damage during service, which diminishes the safety and life of the equipment. Compared with conventional repair methods, pulse electric current treatment can precisely locate cracks distributed throughout the material and enable efficient in-situ repair. Therefore, this study employs the pulse electric current treatment method to repair cracks and investigates the crack healing behavior using a combination of experiments and simulations. The effect of pulse electric current treatment on the crack-containing sample is revealed through a finite element method simulation. The electric current density, temperature, stresses, and displacements are all concentrated in the crack area and influence each other step by step, thereby gradually driving crack healing. The experimental results indicate that after pulse electric current treatment, the mechanical properties of the crack-containing sample are significantly recovered, with the tensile strength and elongation increasing by 23.2 % and ∼ 2 times, respectively. Metallurgical bonding and densification are achieved between the crack surfaces, and the healed interface possesses higher bonding strength. Combined with molecular dynamics simulations, the crack healing process under the action of pulse electric current is elucidated. While recrystallization occurs in the crack area, a large number of dislocations are continuously emitted and move from the crack tip, and the grain boundaries continuously progressively migrate toward the crack. The plastic deformation behavior at high temperature prompts the diffusion and migration between the atoms on both sides of the crack and the formation of fibrous bridging structures. This work provides new insights into the crack healing mechanism under the action of pulse electric current and contributes to the optimization of crack repair technology to enhance the reusability of aerospace equipment.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118803"},"PeriodicalIF":6.7,"publicationDate":"2025-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682239","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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