Journal of Materials Processing Technology最新文献

{"title":"Intralayer deposition mechanism of dissimilar materials by multi-material additive manufacturing based on laser powder-bed fusion","authors":"Yasong Shi ,&nbsp;Taitong Jin ,&nbsp;Jiawei Ding ,&nbsp;Yong Wang ,&nbsp;Wei Zhang ,&nbsp;Yingbo Peng","doi":"10.1016/j.jmatprotec.2025.119163","DOIUrl":"10.1016/j.jmatprotec.2025.119163","url":null,"abstract":"<div><div>The “layer-by-layer” processing nature of laser powder bed fusion (LPBF) presents challenges for the distribution of multi-materials in the horizontal direction, thereby limiting the design flexibility and functionality of multi-material components. In this study, a \"powder + entity\" interfacial processing model was proposed to achieve intralayer deposition of dissimilar materials via LPBF. In the intralayer deposited SS316L/FeCoCrNi high entropy alloy (HEA)-diamond composites dissimilar-material samples, there was no newly formed phase at the interface, which preserved the γ-austenite and HEA face-centered cubic (FCC) structures, with good interfacial metallurgical bonding. Thermal-fluid coupling simulations showed the asymmetric flow of the mixed molten pool caused by the combined effects of thermal/solute-induced Marangoni flow and gravity, influencing the solidification paths on both sides of the interface. SS316L side characterized by directional melt flow exhibited a preferential crystal-grow orientation that transitioned from &lt; 111 &gt; to &lt; 101 &gt; . Conversely, the composites side displayed anisotropic crystal growth with an increasing dislocation density due to local melt reflux. The interfacial bonding performance of the dissimilar-material samples achieved a yield strength of 430 MPa and a fracture strain of 28 %, attributed to substitutional solution strengthening and reduced dislocation density. This study not only proposes a strategy for achieving multi-material distribution perpendicular to building direction, but also provides new insights and theoretical complements regarding the molten pool behavior in LPBF.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119163"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145690647","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":"Multi-field coupling traceability method for non-metallic inclusion agglomeration in continuous casting under dual-mode electromagnetic control","authors":"Siyuan Zhang ,&nbsp;Yanwen Sun ,&nbsp;Zeyi Liu ,&nbsp;Meijia Sun ,&nbsp;Tianyu Zhang ,&nbsp;Xiaoming Liu ,&nbsp;Wangzhong Mu ,&nbsp;Tie Liu ,&nbsp;Qiang Wang","doi":"10.1016/j.jmatprotec.2025.119142","DOIUrl":"10.1016/j.jmatprotec.2025.119142","url":null,"abstract":"<div><div>The agglomeration of inclusions in continuous casting blooms destroys the continuity and compactness of the steel matrix, which seriously restricts the fatigue life and corrosion resistance of the steel. A novel traceability method for the distribution of inclusions was introduced to reveal the evolution of inclusion agglomeration. This method demonstrated the position evolution of inclusions when they passed through different planes by assigning colors for inclusions. In this study, a mathematical model coupled with electromagnetic field, flow, heat transfer, solidification, and non-metallic inclusion movement was developed to study the agglomeration behavior of inclusions under dual-mode electromagnetic field control modes (edge-to-center flow mode and the coupled mode of center-to-edge flow and edge-to-center flow). Numerical simulation revealed that the coupled mode significantly enhanced inclusion distribution uniformity in the solidified shell, with a 63.7 % reduction of the number in the localized agglomeration zone compared to the edge-to-center flow mode. Experimental measurements demonstrated a 46.7 % decrease in inclusion number density near the quarter position of the loose side under coupled mode compared to edge-to-center flow mode. Under coupled mode, the flow of molten steel at the center and the edge of the mold with the opposite directions helped to disperse the inclusions and promote the uniform distribution of inclusions in the cross-section. This study provides a new strategy to suppress inclusion agglomeration in continuous casting blooms by electromagnetic metallurgy technology.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119142"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145527602","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":"Adjustable ring mode laser lap welding of low-carbon steels to pure copper in various forms: Sheets, foil stacks, and gapped foil stacks","authors":"Qun Ma ,&nbsp;Zhekai Huang ,&nbsp;Li Cui ,&nbsp;Shuhan Yang ,&nbsp;Zhaotong Li ,&nbsp;Xiang Li ,&nbsp;Dingyong He ,&nbsp;Shenglong Chen ,&nbsp;Xiaolong Duan","doi":"10.1016/j.jmatprotec.2025.119152","DOIUrl":"10.1016/j.jmatprotec.2025.119152","url":null,"abstract":"<div><div>Steel/copper dissimilar metal lap joints are key structural components for achieving efficient joining in applications such as new energy vehicles (NEVs). However, their welded joints exhibit extremely high hot crack susceptibility. In this study, adjustable ring mode (ARM) laser welding was employed to systematically investigate the joining of low-carbon steels (LCS) with three forms of copper base metal (BM): copper sheets (CS), copper foil stacks (CFS), and gapped copper foil stacks (G-CFS). The results reveal that the thermal conductivity of the base metal (BM) influences molten pool flow and consequently affects hot crack susceptibility. In particular, the low-carbon steels (LCS)/ gapped copper foil stacks (G-CFS) joint, owing to its unique local thermal resistance, optimizes the thermal behavior of the molten pool, thereby achieving completely crack-free welding. Tensile fracture behavior shows that the low-carbon steels (LCS)/ gapped copper foil stacks (G-CFS) joint, exhibiting no crack initiation, achieved the highest tensile strength of 371 MPa. The low-carbon steels (LCS)/copper foil stacks (CFS) joint exhibiting liquid phase separation demonstrated a tensile strength of 249 MPa, approximately 30.8 % lower than that of the low-carbon steels (LCS)/copper sheets (CS) joint containing hot cracks (360 MPa). This study clarifies the physical mechanism by which the thermophysical properties of the base metal (BM) regulate hot crack initiation in steel/copper lap joints, providing an important theoretical foundation for achieving reliable connections in new energy vehicles (NEVs) systems.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119152"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145577347","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":"Regulating microstructure and strength-ductility synergy of laser-arc hybrid additive manufactured Al-Zn-Mg-Cu alloy","authors":"Dehua Liu ,&nbsp;Haoyang Wang ,&nbsp;Jiang Bi ,&nbsp;Zhuoyun Yang ,&nbsp;Guojiang Dong ,&nbsp;Fangyong Niu ,&nbsp;Guangyi Ma ,&nbsp;Bo Cheng ,&nbsp;Dongjiang Wu","doi":"10.1016/j.jmatprotec.2025.119156","DOIUrl":"10.1016/j.jmatprotec.2025.119156","url":null,"abstract":"<div><div>High-strength Al alloy fabricated by laser powder bed fusion or wire and arc additive manufacturing usually exhibits excessive defects, inherent columnar grain structure and poor performance. To address these problems, we proposed a feasible approach of combination for laser-arc hybrid process and subsequent heat treatment to manufacture the Al-Zn-Mg-Cu alloy with superior mechanical properties. The influences of laser power on defects, microstructure, and corresponding mechanical behavior were systematacially evaluated. The results showed that the laser power could effectively change melting mode and solidification conditions in the molten pool. The porosity in the as-built specimen exhibited a tendency of initial decreased followed by increasing as the laser power ranged from 0 W to 240 W. Compared with laser power of 0 W, the grain size was decreased by 57 % with laser power of 180 W. A number of η precipitates distributed at grain boundary, causing element segregation. Meanwhile, rising the laser power leaded to the reduction of element segregation as well as the content of coarse eutectics. Following the heat treatment, high-density η′ precipitates were uniformly dispersed, generating the precipitation strengthening effect. Hence, an optimized strength-ductility balance with ultimate tensile strength of 602 MPa and elongation of 8.9 % was achieved. This research can provide valuable insights for customizing the high-strength Al alloy component with low porosity and desired microstructure.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119156"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145577373","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":"A novel pathway to realize the columnar-to-equiaxed transition and mechanical anisotropy suppression in SEBM of 316L","authors":"Hongjun Qi ,&nbsp;Zhifu Huang ,&nbsp;Ziyi Yang ,&nbsp;Jiaqi Deng ,&nbsp;Zihan Chen ,&nbsp;Jian Wang ,&nbsp;Yongxin Jian","doi":"10.1016/j.jmatprotec.2025.119155","DOIUrl":"10.1016/j.jmatprotec.2025.119155","url":null,"abstract":"<div><div>To address the critical challenge of anisotropy in metal additive manufacturing (AM), a novel strategy has been proposed in this work using SEBM-fabricated 316L stainless steel to achieve the columnar-to-equiaxed transition (CET) and suppress mechanical anisotropy. By simultaneously reducing the power and speed, the thermal gradient (G) and solidification rate (R) were tuned under the constant Volumetric Energy Density (VED). Associating with in-situ recrystallization activated by the sustained thermal dwell at ∼800 °C, CET can be achieved in SEBM 316L. This yields a microstructure with a pronounced increase in equiaxed fraction (13.9 % → 81.9 %) and strong texture weakening (Multiple of Uniform Distribution, MUD 23.75 → 3.01). Consequently, the strength–ductility synergy (Ultimate Tensile Strength, UTS ≈ 603 MPa; Elongation, EL ≈ 71 %) can be realized as well as the near-isotropic mechanical behavior (Index of Plane Anisotropy, IPA ≈ 1.75 %–1.79 %). This study demonstrates that CET can be realized through the combined effect of solidification control and in-situ recrystallization in SEBM, thereby suppressing anisotropy in both microstructure and mechanical performance. The findings can offer transferable guidance for microstructural design and process–structure–property optimization in other alloys AM systems, including nickel-based and other alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119155"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145577371","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":"Dynamic behaviors of keyhole and weld pool during the digging stage in variable polarity plasma arc welding of thick aluminum alloy","authors":"Wenlong Li ,&nbsp;Fan Jiang ,&nbsp;Bin Xu ,&nbsp;Jiankang Song ,&nbsp;Haowen Suo ,&nbsp;Wei Cheng ,&nbsp;Xinqiang Ma ,&nbsp;Zhenzhen Zhang ,&nbsp;Di Yang ,&nbsp;Shujun Chen","doi":"10.1016/j.jmatprotec.2025.119139","DOIUrl":"10.1016/j.jmatprotec.2025.119139","url":null,"abstract":"<div><div>Variable polarity plasma arc welding (VPPAW) is a high-energy-density keyhole welding technique with considerable potential for the efficient and defect-free joining of thick aluminum alloy. However, the extended digging depth in thick workpieces intensifies the complexity of the welding process, as torch travel at different digging depths, even under optimized parameter, results in distinct variations in weld quality. In this study, a transparent observation system was established by butt-jointing a thick aluminum alloy plate with a quartz glass sheet, enabling direct visualization of the dynamic behaviors of the keyhole and weld pool during the digging stage. A deep learning-based image processing approach utilizing the SegFormer architecture was developed to extract these dynamic features. The findings reveal that the weld pool depth evolution is a highly dynamic multi-phase process, progressing through three alternating cycles of rapid growth and quasi-steady behavior, ultimately reaching a blasting-type penetration. The mechanism involves the establishment of thermal-force equilibrium when the molten metal reaches a critical thickness, halting the digging process. Arc-induced oscillations break this equilibrium, triggering molten metal outflow and keyhole deepening, which reflects the transient and non-equilibrium characteristics of energy transfer in plasma-metal coupling. Molten metal droplet cluster represents a distinctive phenomenon during the digging stage, arising from the continuous outflow of molten metal from the interior of keyhole. The externally observable weld pool and droplet cluster areas effectively indicate the internal digging stage, offering characteristic features to guide torch travel and ensure weld quality. Observations under varying welding parameters demonstrate that the dynamic, multi-phase digging process persists, confirming its governance by transient, non-equilibrium energy transfer mechanisms. The timing of droplet cluster detachment serves as a crucial indicator for assessing the suitability of welding parameter. This work provides a solid foundation for intelligent control in advanced VPPAW of thick aluminum alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119139"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145464850","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":"Investigation of the mechanisms of structure-induced acoustic modulation in WA-DED metal additive manufacturing with an adaptive modelling approach","authors":"Fengyang He ,&nbsp;Zening Wu ,&nbsp;Zhao Zhang ,&nbsp;Donghong Ding ,&nbsp;Jun Tong ,&nbsp;Huijun Li ,&nbsp;Zengxi Pan ,&nbsp;Lei Yuan","doi":"10.1016/j.jmatprotec.2025.119160","DOIUrl":"10.1016/j.jmatprotec.2025.119160","url":null,"abstract":"&lt;div&gt;&lt;div&gt;As metal additive manufacturing (AM) advances toward intelligent and data-driven paradigms, reliable sensing has become essential for enabling real-time monitoring, process control and decision making. Among various sensing modalities, acoustic sensing offers unique advantages including high temporal resolution, sensitivity to arc dynamics, and low deployment cost, which have resulted in its widespread adoption in industrial applications. However, most existing acoustic-based methods are developed under static or simplified conditions, without accounting for the dynamic structural evolution inherent in metal AM. This often leads to significant performance degradation, especially when applied to large-scale, high-layer components. This study first identifies and investigates a critical but underexplored phenomenon—&lt;em&gt;structure-induced acoustic modulation&lt;/em&gt;—in which the progressive accumulation of volume and variation of geometry throughout the build alters the vibration characteristics and acoustic transmission paths, thereby modulating the emitted acoustic signals. Subsequently, the existence of this modulation and its adverse impact on acoustic-based applications are confirmed through controlled experimental validation. To address this challenge, a dedicated framework based on a ConvNeXt-Adapter-Transformer architecture is then proposed to model the temporal evolution of acoustic signals and enable adaptive generalization across varying builds. The framework is evaluated through the fabrication of a 203-layer circular hollow section component as a case study, demonstrating its ability to effectively adapt to long-duration, structure-evolving metal AM processes. Ultimately, building on this result, a practical acoustic-based application—fabrication process tracing—is deployed and integrated with the proposed framework. The integrated system is further validated through the fabrication of a gear shaft component with complex structures, where results show that the integrated system maintains reliable performance under conditions where baseline systems fail. Specifically, the integrated system achieves a 39.3 % improvement in process tracing accuracy compared to the baseline. Overall, this pioneer study presents the first systematic analysis of structure-induced acoustic modulation in metal AM and introduces an adaptive modelling framework to effectively mitigate the adverse effects of this modulation. Beyond the specific case studies, the identification of structure-induced acoustic modulation itself constitutes a generic scientific finding, revealing that acoustic signals in layer-by-layer AM are inherently modulated by structural evolution. The proposed ConvNeXt-Adapter-Transformer framework further provides a transferable modelling strategy with strong potential for broad adoption in acoustic signal-based applications across the metal AM domain and beyond, enabling reliable performance throughout the manufacturing process and enhan","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119160"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145690646","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":"Thermal fracture phenomenon in laser-assisted direct glass imprinting (LADGI)","authors":"Takehiro Mitsuda ,&nbsp;Keisuke Nagato ,&nbsp;Masayuki Nakao","doi":"10.1016/j.jmatprotec.2025.119131","DOIUrl":"10.1016/j.jmatprotec.2025.119131","url":null,"abstract":"<div><div>This study proposes a laser-assisted direct glass imprinting (LADGI) process. In LADGI, laser irradiation is used to directly heat the microstructures on a mold, and a glass surface is locally heated and softened through thermal conduction, which enables rapid imprinting. However, this process involves rapid heating and cooling, which can induce local tensile stress and increases the risk of thermal fractures in the glass. Therefore, the ability to replicate microstructures while preventing thermal fractures is required. Model experiments with laser spot irradiation and coupled thermal stress analysis were conducted using the finite element method to investigate the temperature conditions required for imprinting and the thermal fracture phenomenon. During LAGDI, imprinting occurred at temperatures above the yield point of the glass. After laser irradiation, thermal fractures initiated in areas of the glass surface near the annealing point because the coefficient of linear expansion of the glass changed rapidly around the annealing point; hence, the volumetric expansion rate at the boundary between the high-temperature region and surrounding low-temperature regions was in a non-equilibrium state. This generated local tensile stress during cooling. This study showed that the relative risk of thermal fractures can be evaluated based on the rate at which the glass volume increased when it was heated above the annealing point. Based on these findings, new indicators <span><math><msub><mrow><mi>E</mi></mrow><mrow><mi>i</mi></mrow></msub></math></span> and <span><math><msub><mrow><mi>I</mi></mrow><mrow><mi>spot</mi></mrow></msub></math></span> were defined to evaluate the LADGI process conditions. These indicators can be used to quantify the efficiency of the process conditions and guide the optimization of the LADGI process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119131"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145527656","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":"Crater-free through-silicon vias formation by hybrid multi-step femtosecond laser drilling: Surface morphology control and residual stress reduction","authors":"Taesik Kim ,&nbsp;Jaebeom Lee ,&nbsp;Seon-Jin Choi ,&nbsp;Jiyong Park","doi":"10.1016/j.jmatprotec.2025.119157","DOIUrl":"10.1016/j.jmatprotec.2025.119157","url":null,"abstract":"<div><div>Through-silicon vias are a key technology in advanced semiconductor packaging to enable high-performance computing applications. Femtosecond laser drilling provides faster processing speed and selective modification compared to conventional dry etching. However, the high pulse energy of the single mode generates rapid plasma expansion, resulting in high residual stress, rough cross-sections, and a low aspect ratio. In contrast, the burst mode, which irradiates low-energy sub-pulses at narrow intervals, produces large surface craters and a wide heat-affected zone owing to the heat accumulation effect. These defects generated by conventional femtosecond laser drilling degrade the overall performance of through-silicon vias. To overcome these limitations, this study proposes a novel hybrid multi-step femtosecond laser drilling process. The proposed process consists of three steps: Step 1 involves guide hole formation using single mode, which provides a plasma expansion path to suppress residual stress generation. Step 2 conducts via hole drilling using burst mode. The guide hole in Step 1 mitigates heat accumulation during this step, which results in a reduction of the heat-affected zone and surface craters. Step 3 focuses on crater trimming using single mode. By designing the ablation diameter according to the laser fluence, the residual craters are effectively removed. This process demonstrates that crater trimming can be achieved solely through laser processing. Experimental results show that the proposed process increased the aspect ratio by approximately 1.7 times, achieved a taper angle of 0.25° at a depth of 100 µm, and produced crater-free via holes. In addition, it improved sidewall roughness (R_q) by approximately 59.3 %, reduced the residual stress by approximately 34.2 %. The proposed process improved via hole quality using solely laser processing technology and validated its applicability for high-density semiconductor packaging.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119157"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145620998","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":"Exploring the origin of Mo alloy incompatibility with additive manufacturing for room-temperature strength-ductility synergy","authors":"Shiqi Ma ,&nbsp;Nian Yin ,&nbsp;Bo Zhao ,&nbsp;Shiru He ,&nbsp;Zhinan Zhang ,&nbsp;Quanquan Han ,&nbsp;Min Zhu ,&nbsp;Nan Xu ,&nbsp;Hailong Dai ,&nbsp;Xiaolei Guo ,&nbsp;Xuehui Shen ,&nbsp;Shilong Liu ,&nbsp;Zhihui Xiong ,&nbsp;Shuaihang Pan","doi":"10.1016/j.jmatprotec.2025.119158","DOIUrl":"10.1016/j.jmatprotec.2025.119158","url":null,"abstract":"<div><div>Molybdenum (Mo) alloys are long-desired in aerospace, electronics, and biodevice fields. However, their compatibility with additive manufacturing (AM) is challenging to achieve for room-temperature strength-ductility synergy, hindering post-processing and applications. Sadly, different yet inconsistent reasons like oxygen (O) control are believed responsible for Mo alloys’ notorious AM incompatibility. In this study, we have presented a lean Mo-Titanium (Ti) alloy design to elucidate the origin of Mo alloys’ AM incompatibility. Using laser powder bed fusion (LPBF) with different O control and representative solid-solution Mo-Ti (Ti=0.8 wt%) alloys, it is found that the commercial O level LPBF (3000 ppm, <em>i.e.</em>, Mo-0.8Ti-0.3 O) enables easier crack-free printing, higher densification, and reduced overall mechanical anisotropy. With this, our investigation, supported by simulations of O and Ti behavior, has validated the interactions of Ti- and O-induced clusters, deformation-induced body-center cubic (BCC)→face-centered cubic (FCC) phase change, and delamination initiation. More specifically, Ti can facilitate BCC→FCC phase change and form Ti-O clusters with a different Orowan strengthening capacity to impede dislocations. Therefore, cracks are likely to form, and gradual delamination occurs when the BCC and FCC phase boundary encounters accumulated dislocations and larger-sized Ti-O and Ti-dilute O-O clusters. With advanced characterization and quantitative strengthening analysis, our approach can be readily adopted to understand the Mo alloy incompatibility with AM, as well as the mechanical outcomes. With this, we highlight and summarize a generic direction of improving Mo alloy strength-ductility synergy at room temperature by AM.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119158"},"PeriodicalIF":7.5,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621001","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}