Journal of Materials Processing Technology最新文献

{"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}

{"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}

{"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}

{"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/Ni₂Al₃ composite sheet with heterogeneous bimodal grains containing coarse-grained Ni layer and fine-grained Ni₂Al₃ 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 × 10⁻³ s⁻¹, where the maximum elongation to fracture achieves to 348 %. Then, Ni/Ni₂Al₃ 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/Ni₂Al₃ 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/Ni₂Al₃ 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}

{"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}

{"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}

{"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}

{"title":"A comprehensive analytical model for tensile-bending straightening in strip processing by coupling residual stress and buckling deformation","authors":"Xue-Meng Li,&nbsp;Yu Liu,&nbsp;Hao Wu,&nbsp;Cheng-Yan Ding,&nbsp;Jie Dong,&nbsp;Wen Peng,&nbsp;Dian-Hua Zhang,&nbsp;Jie Sun","doi":"10.1016/j.jmatprotec.2025.118802","DOIUrl":"10.1016/j.jmatprotec.2025.118802","url":null,"abstract":"<div><div>Tensile-bending straightening machines improve strip quality by optimizing the residual stress distribution within the strip and eliminating plate defects. Straightening involves multiple roller groups and various initial defect shapes. However, previous research has mainly focused on single roller group analyses and finite element models. These approaches cannot fully address the entire straightening process for strips with initial defects, hindering their practical application and reducing straightening accuracy. Therefore, this paper proposes for the first time an analytical mechanistic model for the whole process of strip tensile-bending straightening. Elastoplastic mechanics and symplectic geometry mechanics were applied to reveal the complete mechanism of the stress changes from the initial defect to straightening. First, an offline \"coordinated-uncoordinated-recoordinated\" model is proposed, providing a universal residual stress formula that is adaptable to various defect types. Second, unlike traditional methods, the Hamiltonian approach is used to derive critical buckling load solutions for defective strips. Furthermore, based on pre-straightening residual stress and compressive layer plastic deformation, a comprehensive analytical model is developed to encompass the stress distribution, evolution, buckling, and mechanical changes during straightening. The analytical model predictions closely matched three-dimensional finite element simulation results, outperforming traditional methods in accuracy and efficiency. The model is applicable for various strip defects, enabling the straightening parameters to be optimized, bridging the gap between traditional assumptions and practical applications, and offering precise control, with broad applicability and potential.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118802"},"PeriodicalIF":6.7,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682252","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":"Enhanced mechanical properties of TiAl alloy through Nb alloying by Triple-wire arc directed energy deposition","authors":"Zhen Wang ,&nbsp;Wei Chen ,&nbsp;Zhenwen Chen ,&nbsp;Chenyu Liu ,&nbsp;Jinfei Shi ,&nbsp;Junqiang Xu ,&nbsp;Qi Zhou","doi":"10.1016/j.jmatprotec.2025.118800","DOIUrl":"10.1016/j.jmatprotec.2025.118800","url":null,"abstract":"<div><div>The introduction of alloying elements is an effective strategy to enhance the performance of titanium aluminides (TiAl). Wire arc directed energy deposition (DED) has cost advantages and high deposition rate, making it an emerging technology for fabricating TiAl alloys with promising application prospects. However, the efficient and flexible introduction of alloy elements for wire arc DED fabricated TiAl alloys is a key concern. In the present research, niobium (Nb) was selected as the alloying element, pure Ti, Al, and Nb wires were used as raw materials to introduce Nb into TiAl alloy via in-situ alloying using Triple-wire arc DED. This approach successfully fabricated the high Nb TiAl alloy Ti-45Al-8Nb and the feasibility of this method was confirmed. By comparing the phase composition, microstructure, and mechanical properties of Nb-containing Ti45Al8Nb and Nb-free Ti45Al fabricated by wire arc DED, the influence of Nb on the microstructure and strengthening mechanisms of TiAl alloys was revealed. The results indicate that Nb alloying significantly reduces internal defects, promotes the formation of the B2 phase, increases the content of γ phase and lamellar spacing, and refines the lamellar colonies. The solid solution strengthening, grain refinement strengthening, and dislocation strengthening effects induced by Nb alloying substantially enhanced the tensile strength and elongation of the TiAl alloy. The process for fabricating ternary TiAl alloys via wire arc DED proposed in this study utilizes three pure metal wires as raw materials without relying on the expensive and difficult-to-obtain pre-alloyed materials required in traditional processes. This approach demonstrates the capability of wire arc DED in fabricating multi-component TiAl alloys with controllable compositions.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118800"},"PeriodicalIF":6.7,"publicationDate":"2025-03-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682253","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":"Atomic diffusion kinetics in IMC formation: A molecular dynamic insight into a novel friction stir backward extrusion cladding process","authors":"Rishabh Swarnkar ,&nbsp;Omkar Mypati ,&nbsp;Surjya K. Pal","doi":"10.1016/j.jmatprotec.2025.118799","DOIUrl":"10.1016/j.jmatprotec.2025.118799","url":null,"abstract":"<div><div>Bimetallic are in high demand due to their capability to economically integrate two distinct material properties. Bimetallic tubular components composed of stainless steel and aluminum (Al) have gained significant attention in the automobile and aerospace industries for their lightweight advantage. However, fabricating this could be challenging with conventional approaches due to the formation of brittle intermetallic compounds (IMCs) at the interface and the lack of control over the formation of non-favorable IMCs, which reduces joint strength. Mitigating the concern, this study presents a novel friction stir backward extrusion (FSBE) process. This study provides a thorough understanding of IMCs formation through molecular dynamics (MD) simulation and precise temperature prediction through finite element analyses. This work provides a fundamental understanding of diffusion kinetics between Al and iron (Fe) atoms, revealing that Al atoms exhibit significantly higher mean square displacements and intricate trajectory pathways than Fe atoms, signifying a higher diffusion coefficient. MD simulation results reveal that grain boundaries facilitate the infiltration of Al atoms into the Fe lattice. Further insights into the dislocation generation were gained by electron back scattered diffraction analysis, which reveals dislocation density influences the diffusion behavior. This study contributes towards a scalable framework for optimizing the FSBE process and similar thermomechanical processes for different sets of material combinations and providing a foundation for comprehending the process of diffusion and the IMCs formation at the atomistic scale.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118799"},"PeriodicalIF":6.7,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143643363","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}