Journal of Materials Processing Technology最新文献

{"title":"Analysing the reduction in buckling limit of a flexible roll formed flange due to shape imperfection","authors":"Achuth Sreenivas ,&nbsp;Buddhika Abeyrathna ,&nbsp;Bernard Rolfe ,&nbsp;Matthias Weiss","doi":"10.1016/j.jmatprotec.2025.118767","DOIUrl":"10.1016/j.jmatprotec.2025.118767","url":null,"abstract":"<div><div>Flexible roll-forming can form high-strength sheet metals into components with complex cross-sections but widespread application is limited by flange wrinkling. Previous work has suggested that the low buckling limit in flexible roll forming may be due to the local contact of the forming roll with the metal sheet which produces an imperfection in the flange. In this study, a new plate buckling test is presented and applied to study the effect of imperfections on the buckling limit for conditions that represent flange deformation in flexible roll forming. This is combined with a finite element analysis approach to determine the level of imperfection in a flexible roll formed flange and used to estimate the reduction of the flange buckling limit due to shape imperfection. The results of this study provide for the first time experimental and analytical evidence that the theoretical buckling limit in a flexible roll formed flange is significantly reduced by flange imperfections. The experimental plate buckling test combined with the finite element analysis method for estimating imperfection levels enables the analysis of the effect of forming parameters and geometric conditions on flange imperfection and buckling behaviour and therefore provides a promising alternative to conventional finite element analysis for flexible roll forming process optimisation.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118767"},"PeriodicalIF":6.7,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464394","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}

{"title":"Anisotropy mechanism of material removal and damage formation in single crystal 4H-SiC scratching","authors":"Xiaoyu Bao,&nbsp;Wen Zheng,&nbsp;Huixin Xing,&nbsp;Xingyu Wang,&nbsp;Qingliang Zhao,&nbsp;Yong Lu,&nbsp;Sheng Wang","doi":"10.1016/j.jmatprotec.2025.118768","DOIUrl":"10.1016/j.jmatprotec.2025.118768","url":null,"abstract":"&lt;div&gt;&lt;div&gt;Single crystal 4H-SiC, the third-generation semiconductor material, exhibits excellent properties in short wavelength optical components. However, the high brittleness and hardness of material itself present significant challenges for machining It is crucial to investigate the anisotropy dependence of damage formation and material removal mechanism. The scratching experiments of varying crystallographic orientations online monitored using the acoustic emission (AE) signals and force signals. The surface and subsurface morphologies of the scratch grooves on the C plane, M plane and A plane with different crystallographic orientations were investigated. The anisotropic characteristics of material removal were preliminarily revealed by examining the scratch critical depth. Fast Fourier Transform (FFT) of AE signals was utilized to extract peak frequencies associated with material removal behavior. The peak value of signal frequency at 78.71 kHz and 82.82 kHz indicated the pronounced plastic removal, while that at 82.82 kHz and 91.88 kHz exhibited the positive correlation with the salience of brittle fracture removal. The variations in scratch orientation on the same plane were reflected in the peak amplitude of the medium frequency bands. Surface morphology revealed significant differences, which were affected by the material atomic arrangement and crystal orientation characteristics, and thus affected the stress distribution and crack propagation behavior. Slip deformation was the primary mechanism for plastic flow in materials, which delayed material fracture. As the stress concentration was reached, shear stress facilitated the cleavage of Si-C bonds, which propagated along slip/twinning planes. Furthermore, the anisotropic crystal structure of the single crystal 4H-SiC resulted in significant differences in mechanical responses. The atom arrangement and bonding characteristics endowed the material deformation capabilities. Along specific crystallographic orientations on the C plane, the robust atomic bonds impeded the material ability to relieve stress through dislocation slip, which resulted in a pronounced brittle fracture tendency. The changes in friction coefficients were related to crystallographic orientation, it fluctuated most significantly on the C plane, while remained relatively stable on the M plane. According to the stress field model, compressive stress induced the nucleation of lateral cracks aligned with the direction of the compressive forces, while tensile stress facilitated the nucleation and propagation of median cracks. The subsurface crack propagation behavior was influenced by the anisotropy in the crystal structure, local stress field distribution and interatomic bond strength. The propagation direction of subsurface cracks exhibited anisotropy depending on the scratch crystallographic plane. Specifically, lateral cracks propagated horizontally and deflected by approximately 30°, while median cracks propagated v","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118768"},"PeriodicalIF":6.7,"publicationDate":"2025-02-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143446114","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}

{"title":"An optimization strategy based on critical recrystallization strain to improve the recrystallization rate of ultrasonic impact treatment assisted laser directed energy deposition","authors":"Chuanming Liu ,&nbsp;Chunhuan Guo ,&nbsp;Tao Dong ,&nbsp;Fengchun Jiang ,&nbsp;Zubin Chen ,&nbsp;Wenyao Sun ,&nbsp;Guorui Jiang ,&nbsp;Zhen Wang ,&nbsp;Shubang Wang ,&nbsp;Haixin Li","doi":"10.1016/j.jmatprotec.2025.118774","DOIUrl":"10.1016/j.jmatprotec.2025.118774","url":null,"abstract":"<div><div>In laser directed energy deposition (LDED), the epitaxial growth of long columnar grains often results in performance anisotropy in the component. Severe plastic deformation is a method commonly employed to refine grains. However, current research tends to focus on applying larger pressure loads and strains, which increases the demand for auxiliary equipment and reduces the convenience of application. In this study, we design and optimize a hybrid manufacturing method that combines synchronous ultrasonic impact treatment (UIT) with LDED, leveraging the cumulative characteristics of ultrasonic impact micro-deformation and the principle of critical recrystallization strain. Through mechanical compression and heat treatment experiments, we establish the strain-recrystallization relationship of the material and identified the minimum plastic strain necessary for achieving the maximum recrystallization rate (as the critical recrystallization effective strain). We predicted the plastic strain transfer depth under the current impact parameters using a model and optimized the thickness of the single deposition layer to prevent the recrystallization zone from being covered by the remelted molten pool. Using 316L stainless steel as the verification material, we induced synchronous recovery recrystallization at an exceptionally low output pressure (about 600 N). This optimization led to a significant 56 % refinement in grain size. Compared to the unoptimized experiment, the recrystallization rate increased from 9.14 % to 25.75 %. Furthermore, the yield strength of the material improved by 34 % (compared to a 19 % increase without optimization), all while maintaining high ductility. Additionally, we elucidated the strain and temperature conditions achieved during synchronous recovery recrystallization through a finite element model, and verified the accuracy of this model, allowing for the method's extension to other materials. These findings significantly reduce the demand for high pressure loads on equipment in deformation strengthening methods and enhance practicality.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118774"},"PeriodicalIF":6.7,"publicationDate":"2025-02-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143437352","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}

{"title":"Resistive thermal fusion interface: A novel additive manufacturing process of titanium alloy","authors":"Jiawen Lv ,&nbsp;Bobo Li ,&nbsp;Zhanxin Li ,&nbsp;Yitao Chen ,&nbsp;Jingchi Liu ,&nbsp;Bingheng Lu","doi":"10.1016/j.jmatprotec.2025.118773","DOIUrl":"10.1016/j.jmatprotec.2025.118773","url":null,"abstract":"<div><div>Additive manufacturing of titanium alloy has promoted their wider application in the aerospace and automotive industries. However, safety, cost and forming quality pose serious challenges to existing additive manufacturing technologies. Additionally, complete melting and rapid cooling inhibit the gas from escaping in the melt pool during solidification, leading to the presence of pores inside the sample, which deteriorates the properties of components. Herein, a novel additive manufacturing process of resistive thermal fusion interface with low cost is presented. The contact resistance heat is generated when the current passes through the contact interface between metal wires, which causes the interface to fuse while the rest part of material remains solid. This novel additive manufacturing process was employed to fabricate Ti-5Al-2.5Sn Ti-alloy components in this work. The macrostructure, defects feature, grain structure, tensile properties of the additively manufactured samples with different currents were analyzed systematically. The results reveal that, components without pore defects are obtained by selecting appropriate parameters. Samples possess strength-ductility synergy (yield strength of 864 ± 7 MPa, ultimate tensile strength of 896 ± 4 MPa and elongation of 17.7 ± 1.11 %), which is similar to samples fabricated by L-PBF with annealing treatment. Besides, the mechanisms of resistive thermal fusion interface as well as the microstructure–mechanical property relationships were elucidated in detail. Therefore, this work provides a promising way to fabricate high performance titanium alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118773"},"PeriodicalIF":6.7,"publicationDate":"2025-02-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421271","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}

{"title":"Study on the structural evolution of Al–15Sn–1Cu alloys solidified at different electromagnetic vibration frequencies","authors":"Ganpei Tang,&nbsp;Zhe Sun,&nbsp;Boyi Luo,&nbsp;Wenhao Lin,&nbsp;Zhongze Lin,&nbsp;Tianxiang Zheng,&nbsp;Bangfei Zhou,&nbsp;Peijian Shi,&nbsp;Qiang Li,&nbsp;Chunmei Liu,&nbsp;Haibiao Lu,&nbsp;Zhe Shen,&nbsp;Biao Ding,&nbsp;Yunbo Zhong","doi":"10.1016/j.jmatprotec.2025.118771","DOIUrl":"10.1016/j.jmatprotec.2025.118771","url":null,"abstract":"<div><div>For most alloys, columnar grains can lead to solidification defects and mechanical property anisotropy, making it a significant challenge in metallurgical sciences to promote columnar-to-equiaxed transition and control segregation. This study investigated the effects of convection induced by electromagnetic vibration frequency on the evolution of the directional solidification structure of Al–15Sn–1Cu alloys. The experimental results revealed that as the electromagnetic vibration frequency decreased from 100 to 1 Hz, the solidification front shape gradually transformed from sloping to planar. Moreover, the number of equiaxed grains increased as the frequency decreased, ultimately leading to the columnar-to-equiaxed transition at 1 Hz. The numerical results indicated that the formation of the planar solidification front can be attributed to a more uniform solute distribution and temperature oscillations. Additionally, the oscillatory flow-induced back-and-forth solute transport distance increases with decreasing frequency. Consequently, dendrite fragmentation is promoted as inter-dendrite solute fluctuations increase. The columnar-to-equiaxed transition occurs when the growth of columnar dendrites is completely blocked by equiaxed grains grown from the dendrite fragmentation ahead of them. Furthermore, owing to solute homogenisation and refinement of the solidification structure, a fine and uniform distribution of Sn phases in the Al matrix was achieved at 1 Hz. This study elucidates the effects of oscillatory convection driven by electromagnetic vibration on the temperature, solute transport behaviour, and directional solidification structure. These findings provide critical insights and practical guidelines for the production of fine and uniform equiaxed grain structures using electromagnetic vibration.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118771"},"PeriodicalIF":6.7,"publicationDate":"2025-02-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421272","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}

{"title":"Effects of “free flow” coupled with severe shear strain on the volume of the refined microstructure in a 7075 aluminum alloy under rotary extrusion","authors":"Yongbiao Yang ,&nbsp;Bowen Hu ,&nbsp;Xinxin Liang ,&nbsp;Jing Chen ,&nbsp;Luxin Gao ,&nbsp;Jiaxing Chen ,&nbsp;Zhimin Zhang ,&nbsp;Qiang Wang ,&nbsp;Xing Zhang ,&nbsp;Xianwei Ren ,&nbsp;Moazam Ali ,&nbsp;Baohong Zhang","doi":"10.1016/j.jmatprotec.2025.118772","DOIUrl":"10.1016/j.jmatprotec.2025.118772","url":null,"abstract":"<div><div>Hot deformation processing of aluminum alloys usually leads to a coarse fiber microstructure and strong deformation texture. In this study, rotary extrusion (RE) at 480 ℃ using a 7075 aluminum alloy hollow billet (HB) was studied and compared with a conventional extrusion (CE) HB. Simulation results obtained using DEFORM-3D indicated a unique vortex velocity field during RE. The equivalent strain for RE was higher than that for CE. RE exhibited weaker texture intensity and better grain refinement than CE. New vortex flow lines comprising fine equiaxed grains for the 7075 aluminum alloy were observed for the RE billet, whereas elongated coarse grains were the main features of the CE billet. The equivalent strain, grain size, and texture intensity for RE and CE were 6.47, 7.25 µm, and 1.36 and 1.08, 35.39 µm, and 1.93, respectively. Both continuous dynamic recrystallization and discontinuous dynamic recrystallization contributed to grain refinement and texture weakening, regardless of RE or CE. A 7075 aluminum alloy solid billet (SB) deformed by RE is known to exhibit a low severe deformation depth (&lt; 1 mm) with fine microstructure. Herein, high-volume severe deformation areas consisting of refined grains with a thickness of 5 mm and a diameter of 6 mm were obtained due to the “free flow” combined with severe shear strain during hot deformation, in contrast to the “constrained flow” observed in the SB. Additionally, these findings offer a potential method for overcoming the limited volume and depth of refined microstructures in torsion-related deformations.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118772"},"PeriodicalIF":6.7,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395189","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}

{"title":"Multi-scale simulation approach for the prediction of overheating under consideration of process parameters in powder bed fusion of metals using a laser beam","authors":"Dominik Rauner,&nbsp;Kai-Uwe Beuerlein,&nbsp;Ruihao Zhang,&nbsp;Michael F. Zaeh","doi":"10.1016/j.jmatprotec.2025.118769","DOIUrl":"10.1016/j.jmatprotec.2025.118769","url":null,"abstract":"<div><div>Powder bed fusion of metals using a laser beam (PBF-LB/M) allows for the tool-free manufacturing of complex parts. During the PBF-LB/M process, local overheating can negatively affect the part quality, which results in an increased surface roughness or the formation of shrink lines. Process simulations are used to predict overheated regions and to initiate suitable countermeasures before the manufacturing process. For large-scale parts, in particular, simplifying heat source models are applied to ensure an appropriate computing time. However, these simplifications partially neglect the consideration of the impact of the process parameters on the thermal behavior. In this work, a physics-based multi-scale simulation approach is presented for the time-efficient prediction of geometry-induced overheating for large-scale parts. The presented methodological approach can be applied for different process parameters, materials, and PBF-LB/M machines. For this purpose, a thermal simulation was set up to determine the thermal behavior of a single layer using a moving heat source. By means of an analytical model, the heat source for the simulation of large-scale parts was adapted so that the thermal behavior of the single layer and the impact of the process parameters are represented. The simulation demonstrated that local and global heat accumulations can be predicted independently of the build platform occupancy. The results identified the overheated regions determined in the experiment. The application to a topology-optimized industrial part confirmed the computational efficiency. In the future, this simulation model can be used for the reliable prediction of overheating-caused defects and to allow for a first-time-right manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118769"},"PeriodicalIF":6.7,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395190","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}

{"title":"Investigating the influence of electrode surface morphology on aluminum alloy resistance spot welding","authors":"Yunming Zhu ,&nbsp;Jingyu Bai ,&nbsp;Shanglu Yang ,&nbsp;Zhengqiang Zhu ,&nbsp;Yanjun Wang","doi":"10.1016/j.jmatprotec.2025.118770","DOIUrl":"10.1016/j.jmatprotec.2025.118770","url":null,"abstract":"<div><div>Electrode pitting is a significant challenge that restricts wide applications of resistance spot welding for aluminum alloys in the automotive manufacturing industry. To address this issue, a new electrode was developed and the effects of gradual changes in electrode morphology were systematically studied, which included varying the number of convex rings, ranging from zero to four, to alter the electrode morphology. Microstructural analysis, mechanical property testing, and comparisons of electrode life were investigated. It was found that as the quantity of convex rings increases, the associated crystal defects within the nugget also increase. However, when the number of convex rings surpasses four, the associated crystal defects within the nugget begin to diminish. Moreover, the presence of convex rings plays a pivotal role in regulating current distribution. Properly distributing the quantity of these rings can enhance current utilization, facilitating increased heat input during nucleation process and yielding larger nugget sizes. During the welding process, the puncturing of the oxide film by the convex rings of the electrode enhances current distribution, potentially redirecting pitting corrosion away from the electrode and consequently prolonging its service life.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118770"},"PeriodicalIF":6.7,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378300","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}

{"title":"Interface stair-like design and repair performance of Al-Zn-Mg-Cu aluminum alloy based on additive friction stir deposition","authors":"Zexing Zhou ,&nbsp;Yizhou Shen ,&nbsp;Wancheng Lyu ,&nbsp;Weibiao Xiong ,&nbsp;Zhaoru He ,&nbsp;Yuebin Lin ,&nbsp;Zifan Zhou ,&nbsp;Xunzhong Guo","doi":"10.1016/j.jmatprotec.2025.118758","DOIUrl":"10.1016/j.jmatprotec.2025.118758","url":null,"abstract":"<div><div>Additive Friction Stir Deposition (AFSD) is an emerging solid-state additive technology for the fabrication and repair of high-strength alloy structural components, but the affected factors of the AFSD repaired quality remain unclear. In this paper, four types of grooves on the Al-Zn-Mg-Cu alloy plate were repaired using AFSD, the design of repair grooves introduced an interface stair-like structure, and the effect of structural features on the microstructure and properties were investigated. The grain refinement of the repaired grooves with a stair-like structure is significantly higher than the common structure. The V_stair structure has the best effect on grain refinement after repair, with 93.9 % refinement compared to the substrate. The ultimate tensile strength (UTS) on the advancing side was higher than that on the returning side. The UTS of the V_stair structure is the highest after repair, reaching 294 MPa, which reaches 53.8 % of the matrix. The introduction of the stair-like structure provides additional shear action and increases the material contact area during the repair process, and the continuous dynamic recrystallization coexists with geometric dynamic recrystallization at the repair interface, which contributes to microstructure mixing and grain refinement, and further enhances the properties. This research provides insights for guiding the design and optimization of aluminum alloy repair processes.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118758"},"PeriodicalIF":6.7,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143395188","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}

{"title":"High-performance processing for film cooling holes on EB-PVD TBC-coated superalloys utilizing assisted electrode electrochemical discharge machining","authors":"Jin Ning,&nbsp;Zhengyang Xu,&nbsp;Tianyu Geng,&nbsp;Zongju Yang,&nbsp;Wuhui Wang","doi":"10.1016/j.jmatprotec.2025.118759","DOIUrl":"10.1016/j.jmatprotec.2025.118759","url":null,"abstract":"<div><div>With the escalating operating temperatures of turbine blades, single film cooling technique is inadequate, and high-temperature-resistant thermal barriers coatings (TBCs) prepared through electron beam physical vapor deposition (EB-PVD) are extensively adopted. However, due to the distinct physical attributes of each individual layer and the rigorous requirements for no recast layer and high productivity, the fabrication of film cooling holes on EB-PVD TBC-coated superalloys remains challenging. In this study, a novel assisted electrode electrochemical discharge machining approach has been proposed, during which the 8 wt% yttria stabilized zirconia (8YSZ) ceramic topcoat is processed within deionized water rather than hydrocarbon-based dielectric, while the NiCrAlY bond coat and Ni-based superalloy substrate are treated within a low conductivity solution. The 8YSZ ceramic topcoat removal mechanisms of evaporation, melting, thermal spalling, and mechanical erosion were evaluated with morphology analysis. The negligible damage to the 8YSZ ceramic topcoat during processing was revealed through subsurface structure investigation. Then, the voltage/current waveforms and processing phenomena were recorded to examine the processing characteristics of distinct layers. In addition, comparative experiments were conducted to assess the processing performance. The results suggest that compared to assisted electrode electrical discharge machining, assisted electrode electrochemical discharge machining achieves a ten-fold enhancement in material removal rate, but a 58.4 % reduction in tool wear ratio. The processed surface also exhibits superior integrity, evident from the absence of conductive layer on the 8YSZ ceramic topcoat or recast layer on the Ni-based superalloy. Hence, assisted electrode electrochemical discharge machining shows promising application prospects for high-performance processing of film cooling holes on EB-PVD TBC-coated superalloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118759"},"PeriodicalIF":6.7,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143372534","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}