Journal of Materials Processing Technology最新文献

{"title":"A novel method to eliminate Laves phases in Ni-based superalloy laser cladding by in-situ theory","authors":"Xinyu Yao ,&nbsp;Qiang Lin ,&nbsp;Haohao Ding ,&nbsp;Yi Yang ,&nbsp;Hongtao Zhu ,&nbsp;Hongbin Zhu ,&nbsp;Wenjian Wang ,&nbsp;Huan Qi ,&nbsp;Zhongrong Zhou","doi":"10.1016/j.jmatprotec.2025.118972","DOIUrl":"10.1016/j.jmatprotec.2025.118972","url":null,"abstract":"<div><div>During the laser cladding of GH4169 superalloy, the high concentration of Nb elements in the interdendritic regions promotes the formation of large, chain-like Laves phases, which significantly deteriorate the mechanical properties of the cladding layer. Traditional methods for eliminating Laves phases usually involve optimizing the solidification conditions of molten pools and applying post-cladding heat treatments. However, solely adjusting the solidification conditions cannot completely eliminate the Laves phases, and post-cladding heat treatment may alter the microstructure of the substrate. This study proposes a new in-situ elimination technology to effectively remove Laves phases by leveraging the reaction between C produced by WC decomposition and Nb segregated in the interdendritic region at high temperatures. Additionally, high-frequency ultrasonic vibration enhances the uniform distribution of WC particles and promote the diffusion of C, further facilitating the in-situ reaction. The results indicate that the in-situ elimination technology effectively eliminated the Laves phase. As WC content increased, more C reacted with Nb at high-temperature, reducing Nb segregation in the interdendritic regions and subsequently decreasing Laves phase content. At 30 % WC content, all Laves phases were transformed into carbide-reinforced phases. Moreover, higher ultrasonic vibration current improved the uniform distribution of unmelted WC particles. The coating with 30 % WC content exhibited optimal wear resistance, with the wear width and wear depth reduced by 22.97 % and 40.45 %, respectively. Furthermore, the hardening ratio of the coating after wear is only 4.48 %, indicating superior performance. The research results indicate that the in-situ elimination theory can effectively eliminate the Laves phase. This provides a new solution approach for eliminating the Laves phase formed during laser cladding of GH4169 Ni-based superalloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118972"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587624","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":"Non-quadratic and asymmetric yield locus evolution of AA2219-T87 aluminum alloy under in-plane biaxial loading","authors":"Priya Tiwari ,&nbsp;Amir Hamza Siddiqui ,&nbsp;Jeet Patil ,&nbsp;Amit Singh ,&nbsp;SVS Narayan Murty ,&nbsp;Sushil K. Mishra","doi":"10.1016/j.jmatprotec.2025.118973","DOIUrl":"10.1016/j.jmatprotec.2025.118973","url":null,"abstract":"<div><div>Uniaxial and planar biaxial tests for AA2219-T87 alloy were carried out using a modified in-house developed design of cruciform specimens, and the yield behaviour was investigated for all four quadrants of the stress space. The alloy exhibited a pronounced dependence of the yield behaviour on the stress state. For the uniaxial tests, higher yield stress was observed in compression than in tension. The opposite trend was observed for the biaxial tests, where the biaxial tension showed higher yield stress in comparison to the biaxial compression. Different yield criteria were used to capture the experimental yield loci, and the Yld2000 criterion captured the experimental data with the most accuracy. Moreover, the incremental plastic strain direction was closely aligned with the Yld2000 predicted normal across different load ratios. The strain hardening behaviour was also analysed under uniaxial and biaxial loading conditions. It was found that the strain hardening was significantly increased under the biaxial loading, which was further confirmed by the work hardening analysis and a detailed study of the microstructure and texture evolution. The fractography study further revealed a transition from ductile fracture with voids and dimples under uniaxial loading to ductile-brittle mixed mode with prominent facet formation under biaxial loading.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118973"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587622","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":"Full domain power-modulated galvanometer-scanned laser welding of zirconium alloys/nickel-based superalloys dissimilar joints: microstructural evolution and strength enhancement","authors":"Gang Zhang ,&nbsp;Jianbo Wang ,&nbsp;Yu Shi ,&nbsp;Ding Fan","doi":"10.1016/j.jmatprotec.2025.118975","DOIUrl":"10.1016/j.jmatprotec.2025.118975","url":null,"abstract":"<div><div>Dissimilar joining of zirconium alloys to nickel-based superalloys presents critical challenges in nuclear fuel assembly applications, where interfacial brittle intermetallic compounds (IMCs) and thermal stress concentration fundamentally limit the structural integrity of Zr/Ni joints. This study developed an innovative full domain power-modulated (FDPM) galvanometer-scanned laser welding technique with multiscale thermal management to address these critical issues in Zr-N36/IN718 joints. Through a series of experiments with dynamic heat input redistribution, temperature gradient optimization, and multi-stage residual stress mitigation, a quantitative correlation between thermal process and joint strengthening mechanism is established. Results indicate that reducing heat input by 42 % effectively alleviates excessive Ni/Cr/Fe elemental diffusion, decreasing IMCs layer thickness from 39 μm to 17 μm. The thermal management strategy (300 W preheating +360 W in-situ heat treatment) results in a 23.5 % reduction in small-angle grain boundaries (55.4–31.9 %) and 30 % decrease in kernel average misorientation (KAM) indicating substantial residual stress release. The joint tensile strength is enhanced from 23.73 MPa to 103 MPa, with the fracture mode transitioning from intergranular brittle to ductile dimple-dominated failure. Microstructural analysis demonstrates a γ-(Ni, Cr, Fe) matrix reinforced by nano-Ni₃Nb precipitates in the fusion zone, while gradient-distributed NiZr₂ and σ-FeCr phases at the reaction layer effectively mitigate thermal expansion mismatch.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118975"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587625","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":"From high cooling rates to high creep performance: Role of metastable beta in in-situ alloyed Ti64-TiAl alloys fabricated by laser powder bed fusion","authors":"Hatem A. Soliman ,&nbsp;Ali Ghasemi ,&nbsp;Mohamed Elbestawi ,&nbsp;Swee Leong Sing","doi":"10.1016/j.jmatprotec.2025.118957","DOIUrl":"10.1016/j.jmatprotec.2025.118957","url":null,"abstract":"<div><div>This study employs a novel processing approach using laser powder bed fusion (L-PBF). It leverages rapid cooling to develop a metastable microstructure that can retain or revert to suit both room and high-temperature applications. This approach is paired with a cost-effective blending strategy to fabricate novel alloys with microstructures that integrate ductile and hard phases. The study demonstrates the effectiveness of this approach in significantly enhancing the creep performance of Ti-6Al-4V (wt%) through in situ alloying with Ti-48Al-2Cr-2Nb (at%) at weight fractions of 20 % and 40 % via L-PBF. A tailored microstructure was achieved, leading to crack free samples. X-ray diffraction (XRD) phase analysis identified a metastable microstructure comprising the ductile β phase alongside hard α/α′/α₂ phases. A significant presence of β phases was observed in the 40 % TiAl alloy, comprising 80 % of the scanned area according to electron backscatter diffraction (EBSD) analysis, demonstrating the influence of rapid cooling in retaining high-temperature phases. Results from transmission electron microscopy (TEM), energy dispersive spectroscopy (EDS), and selected area electron diffraction (SAED) indicated a high dislocation density within the α phase, which contributed to crack nucleation during mechanical testing. The heat-treated alloys, in which the β phase revert to α₂, exhibited creep lifetime that surpassed Ti64 by 380 % for the 20 % TiAl alloy and over 600 % for the 40 % TiAl alloy. The combination of β and α phases at room temperature contributed to a yield strength of 966 MPa for 20 % TiAl and 741 MPa for 40 % TiAl, along with elongation percentages of 6.8 % for 20 % TiAl and 3.2 % for 40 % TiAl, both of which surpassed those of TiAl. These results pave the way for processing other materials beyond these specific alloys, enabling a wide range of applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118957"},"PeriodicalIF":6.7,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144557691","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":"Exploiting damage for inhibiting damage: A counterintuitive reasoning out of in-situ orthogonal cutting for brittle fiber composite","authors":"Jie Xu ,&nbsp;Pingfa Feng ,&nbsp;Youhong Gong ,&nbsp;Jianjian Wang ,&nbsp;Haitang Yang ,&nbsp;Feng Feng","doi":"10.1016/j.jmatprotec.2025.118961","DOIUrl":"10.1016/j.jmatprotec.2025.118961","url":null,"abstract":"<div><div>The low-damage manufacturing of brittle fiber-reinforced composites has been facing significant challenges due to subsurface damage (SSD) caused by stochastic crack propagation. Traditionally, aggressive machining processes have been deliberately avoided during precision finishing of brittle fiber-reinforced composites to prevent SSD. Inspired by nature, we propose a counterintuitive concept (i.e., exploiting damage for inhibiting damage). To this end, in-situ observation experiments using optical microscopy and high-speed camera were developed to comparatively characterize subsurface fiber deflection, subsurface conditions at different time points and real-time cutting forces. Scanning electron microscopy was employed to observe the transformation of material removal modes with and without controlled damage layer (CDL), as well as the final SSD depth. The experiment results showed that the CDL significantly reduced fiber deformation, cutting force, and subsurface damage. Furthermore, based on the relationship between uncut chip thickness and CDL depth, two CDL scenarios of mechanism for SSD improvement were discussed. The fundamental mechanisms lie in a shielding effect that localizes stress concentration above the CDL. And a stress-mode transition that shifts tool-workpiece tensile and compressive stress status. Meanwhile, mesoscale numerical modeling was used to analyze stress concentration and tensile-compressive stress states, providing deeper insights into the influence of CDL, particularly the positive effect of the pinning phenomenon on damage inhibition. Based on experiment observation and mechanism understanding, the concept opens a counterintuitive yet effective avenue for precision manufacturing of brittle fiber-reinforced.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118961"},"PeriodicalIF":6.7,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144579636","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":"Unified wrinkling limit diagram for sheet metals under entire in-plane stress domain","authors":"Fenghua Liu ,&nbsp;Bing Du ,&nbsp;Chaoyang Huang ,&nbsp;Hailong Cui ,&nbsp;Ziwei Feng ,&nbsp;Xingze Zhen ,&nbsp;Lei Fu ,&nbsp;Lijun Wu","doi":"10.1016/j.jmatprotec.2025.118971","DOIUrl":"10.1016/j.jmatprotec.2025.118971","url":null,"abstract":"<div><div>The Wrinkling Limit Diagram (WLD) is crucial for applying wrinkling instability research to engineering. However, existing WLD frameworks lack robust theoretical foundations, and their empirical construction under diverse experimental conditions compromises generality. This study introduces a novel Unified Wrinkling Limit Diagram (Uni-WLD) theory applicable to entire in-plane stress domain by establishing a coupled analytical framework integrating nonlinear elastoplastic constitutive modeling with wrinkling instability criteria to address these limitations. This study innovatively designs a Large-hole Yoshida buckling test (YBT-H) to characterize wrinkling behavior in the whole stress domain effectively and constructs a finite element model containing material anisotropy based on the Hill48 and Hill90 yield criterion. Uni-WLDs for four types of anisotropic plates, employing the principal stress ratio-principal strain ratio coordinate system, are developed through two distinct methodologies: theoretical derivation and test and simulation combination verification. Key findings include: (1) When loading along the rolling direction, the Hill90 criterion demonstrates superior performance over conventional Hill48 in reconstructing wrinkling morphology and predicting <em>z</em>-direction displacement; (2) Uni-WLDs constructed through different methodologies exhibit remarkable consistency, obeying an inverse function characteristic equation; (3) Principal stress ratio and principal strain ratio (<em>K</em>_ss) of non-wrinkling nodes evolve along the Uni-WLD trajectory, while that of wrinkled nodes deviate from the trajectory. This work advances fundamental theories in sheet metal plasticity and provides theoretical guidelines for optimizing forming process parameters under complex stress states.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118971"},"PeriodicalIF":6.7,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144579524","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":"Achieving strength-ductility synergy in laser powder bed fused near-β titanium alloy via process optimization","authors":"Jie Wang ,&nbsp;Dongdong Gu ,&nbsp;Jingjia Sun ,&nbsp;Guangjing Huang ,&nbsp;Huiping Liu ,&nbsp;Menghuan Yin ,&nbsp;Xibin Chen ,&nbsp;Xin Liu","doi":"10.1016/j.jmatprotec.2025.118960","DOIUrl":"10.1016/j.jmatprotec.2025.118960","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) shows significant potential for fabricating dual-phase titanium alloys, but remains limited by the inherent strength-ductility trade-off arising from rapid solidification-induced cross-scale microstructural features. Overcoming these challenges requires precise process optimization to tailor microstructures and achieve synergistic enhancement of mechanical properties. This study systematically investigates the processing window and microstructure-property relationship in <em>β</em>-rich Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti17) alloy fabricated via LPBF, with an emphasis on elucidating the process-induced mechanisms governing strength and ductility. An optimal processing window was established, achieving near-full density (&gt;99.0 %) and excellent surface quality (&lt;11 μm), attributed to the controlled balance between melt pool lifetime and viscosity. Within this range, an exceptional strength-ductility synergy was realized, with an ultimate tensile strength of 903–925 MPa and an elongation of 15.4–27.4 %, alongside enhanced hardness (320.7–322.3 HV_0.2) and reduced friction coefficient (0.411–0.414). These superior mechanical properties originated from a hierarchical microstructure characterized by improved metallurgical bonding, refined grain features, and controlled dislocation density driven by precise thermal modulation. Temperature field simulation further revealed that variations in the temperature gradient, solidification rate and nucleation dynamics induced by laser processing significantly governed grain size and morphology, elucidating the underlying mechanisms of microstructural tailoring. This work demonstrates that the microstructure and properties of LPBF-processed Ti17 alloy can be effectively tailored through precise process parameters optimization, achieving remarkable forming quality and strength-ductility synergy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118960"},"PeriodicalIF":6.7,"publicationDate":"2025-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144563890","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":"Microstructural evolution and strengthening mechanisms in multi-pass friction stir additive manufacturing of Al6061-Al5083 dissimilar builds: A study of overlapping thermo-mechanical zones","authors":"A. Saravana Sundar ,&nbsp;Chuansong Wu ,&nbsp;Leijun Li ,&nbsp;Amlan Kar ,&nbsp;Adepu Kumar","doi":"10.1016/j.jmatprotec.2025.118956","DOIUrl":"10.1016/j.jmatprotec.2025.118956","url":null,"abstract":"<div><div>This study investigates the microstructural evolution and mechanical properties of a five-layer friction stir additive manufacturing (FSAM) build composed of alternating layers of Al6061 and Al5083. A significant microstructural gradient along the build direction is observed along the build direction. Fine, equiaxed grains and dynamic precipitate transformations collectively influence the mechanical strengths observed throughout the build. EBSD analysis reveals a pronounced grain size variation, with the finest grains located in the pin-affected zone(PAZ) + PAZ regions where intense deformation and dynamic recrystallization occur, and the coarsest grains found in the bottom PAZ, which undergoes a lower degree of deformation upon the initial passes. HRTEM reveals fine, coherent β″ precipitates in regions subjected to severe shear, while larger β precipitates form in areas exposed to prolonged thermal exposure. Repeated heating cycles, driven by incremental increases in peak and baseline temperatures with each pass, further contribute to local transformations in both precipitate and dispersoid populations. Tensile testing of interfacial samples (T1 to T4) shows yield strengths (YS) ranging from 105 to 129 MPa and ultimate tensile strengths (UTS) from 229 to 256 MPa, which are consistently lower than those of the base materials. These reduced values are a result of localized deformation and repeated thermal cycles. A combination of grain boundary strengthening, dislocation strengthening, and precipitation hardening mechanisms contributes to the anisotropic mechanical properties observed in these multi-material FSAM builds. This study advances fundamental understanding of importance of repeated overlapping thermo-mechanical cycles on dynamic recrystallization, precipitation kinetics, dislocation evolution, and strengthening behaviour in multi-layer FSAM builds.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118956"},"PeriodicalIF":6.7,"publicationDate":"2025-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144557692","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":"Laser-shock-induced flattening of silver nanowires for preparing high-performance composite transparent electrodes with enhanced durability","authors":"Yizhong Hu ,&nbsp;ZeZhou He ,&nbsp;Yuan Liao ,&nbsp;Guangwei Hu ,&nbsp;Minqiang Jiang ,&nbsp;Dangyuan Lei ,&nbsp;Gang Yu ,&nbsp;Xiuli He ,&nbsp;Lihua Huang ,&nbsp;Yaowu Hu","doi":"10.1016/j.jmatprotec.2025.118958","DOIUrl":"10.1016/j.jmatprotec.2025.118958","url":null,"abstract":"<div><div>Flexible transparent electrodes demand seamless integration of conductive nanomaterials with protective layers. However, the geometric incompatibility between three-dimensional (3D) silver nanowire (AgNW) networks and atomically flat two-dimensional (2D) materials remains a fundamental bottleneck, leading to interfacial stress fractures and rapid corrosion. Here, we present a laser shock-driven planarization strategy that actively reconfigures 3D AgNW networks into quasi-2D architectures, addressing interfacial mismatch by simultaneous suppression of surface roughness and stress concentration. By synergizing the mechanical compaction effect of laser shock and the localized plasmon-enhanced heating effect, the method establishes robust metallurgical junction at junction interfaces, reducing the average welded junction height to 53.2 % of its original value while enabling fracture-free and full-coverage integration with graphene oxide (GO). The resulting AgNWs-GO composite exhibits exceptional durability, retaining 97.9 % conductivity after 2000-second exposure in sulfur vapor. By resolving dimensional incompatibility through active structural engineering, this work provides a universal pathway for heterodimensional material integration in robust flexible electronics for wearable, display, and energy applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118958"},"PeriodicalIF":6.7,"publicationDate":"2025-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144572751","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":"Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels","authors":"Junqi Chen,&nbsp;Takuya Miura,&nbsp;Kohsaku Ushioda,&nbsp;Abhishek Sharma,&nbsp;Hidetoshi Fujii","doi":"10.1016/j.jmatprotec.2025.118959","DOIUrl":"10.1016/j.jmatprotec.2025.118959","url":null,"abstract":"<div><div>The widespread adoption of high-Al steels is hindered by weldability challenges due to thermal cracking susceptibility and coarse-grained phase transformations by traditional fusion welding. For the first time, we demonstrate an innovative low-temperature (&lt;700°C) friction stir welding (FSW) for processing Fe-10Al and Fe-0.1C-10 (wt%) Al alloys. The X-ray diffraction (XRD) and transmission electron microscope (TEM) observations confirmed that the ultralow-rotation/high-load FSW process induces order phase DO₃ disordering by severe plastic deformation and κ-carbide shearing by gliding dislocations, collectively relieving stress concentrations while achieving ∼6 μm grain refinement. This unique microstructural evolution promotes dislocation slip-dominated deformation and consequently superior strength-ductility synergy in high-Al steels compared to the existing methods. Quantitatively, the small sized specimens of Fe-10Al alloy exhibited a tensile strength of ∼684 MPa with a total elongation of ∼40 %, local elongation around 28 %, and an impact upper shelf energy of ∼390 kJ/m² with a DBTT of –15 °C. Meanwhile, the Fe-0.1C-10Al alloy achieved a higher strength of ∼725 MPa and a total elongation of ∼38 %, along with an upper shelf energy of 454 kJ/m². However, due to the presence of residual κ-carbides and DO₃, faster crack propagation occurred during impact testing, resulting in an increased DBTT (∼70 °C). The study establishes new FSW parameter-design principles for manufacturing high-performance high-Al steel components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118959"},"PeriodicalIF":6.7,"publicationDate":"2025-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144570008","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}