Journal of Materials Processing Technology最新文献

{"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}

{"title":"Study on plasma behaviour, ablation mechanism, and surface morphology of CFRP by underwater laser-induced plasma micro-machining","authors":"Peng Wang ,&nbsp;Zhen Zhang ,&nbsp;Shichuan Wei ,&nbsp;Bo Hao ,&nbsp;Haozhe Chang ,&nbsp;Yu Huang ,&nbsp;Guojun Zhang","doi":"10.1016/j.jmatprotec.2025.118757","DOIUrl":"10.1016/j.jmatprotec.2025.118757","url":null,"abstract":"<div><div>Carbon fibre-reinforced plastic (CFRP) is an excellent non-metallic composite material with advanced mechanical properties. Laser-induced plasma micro-machining (LIPMM) is a high-quality method of processing CFRP with less thermal damage. This study explored the interaction mechanism between plasma and CFRP material at different liquid depths and laser energies. A numerical model considering heterogeneity and anisotropy was proposed to study the anisotropic heat transfer of CFRP. The relationship between the plasma plume and material ablation was also investigated. The results revealed that a considerable ablation depth was obtained with a high aspect ratio of the plasma. In addition, the influence of surface tension on bubble attachment was studied, and it was found that decreasing the surface tension of a liquid could reduce bubble attachment. Machining CFRP by LIPMM in 40 % ethanol solution can effectively reduce the bubbles on the sample surface and improve the processing quality. As the thermal conductivity of the liquid medium is greater than that of the air, the thermal damage of epoxy resin was effectively reduced. The ablation depth with LIPMM increased by about 17.5 % compared to laser process in air.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118757"},"PeriodicalIF":6.7,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378299","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 correlation between weld structure and fracture modes in laser welding of aluminum and copper using data-driven methods","authors":"Kyubok Lee ,&nbsp;Teresa J. Rinker ,&nbsp;Changbai Tan ,&nbsp;Masoud M. Pour ,&nbsp;Peihao Geng ,&nbsp;Blair E. Carlson ,&nbsp;Jingjing Li","doi":"10.1016/j.jmatprotec.2025.118752","DOIUrl":"10.1016/j.jmatprotec.2025.118752","url":null,"abstract":"<div><div>In laser welding, the complex characteristics of weld structure features, including weld geometry and defects such as porosities and cracks, pose significant challenges in analyzing the relationship between weld structure and mechanical performance. This study tackles this issue by introducing a data-driven approach to quantify the significance of specific weld structure features and their correlation with mechanical performance in laser-welded aluminum-copper thin sheets. High-resolution, three-dimensional micro-X-ray tomography provides detailed characterization of weld structure features, including weld geometry and defect attributes. Advanced deep learning techniques and interpretable machine learning models are employed to analyze weld geometry and defect features with precision. Importance analysis identifies a strong correlation between weld geometry and fracture behavior. Further investigation demonstrates that weld geometry exerts a significant influence on other structural features, such as porosity and crack characteristics, highlighting its critical role in predicting fracture behavior. To improve predictions of fracture mode, a novel dimensionless failure mode index is proposed and validated using data from this study and existing literature. This index establishes a robust relationship between weld geometry, defect features, and fracture modes, offering a practical and reliable tool for evaluating weld performance.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118752"},"PeriodicalIF":6.7,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387637","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":"Corrigendum to “Influence of weld size on energy input and interfacial strength during dissimilar ultrasonic welding of stainless steel to titanium” [J. Mater. Process. Technol. 337 (2025) 118727]","authors":"Jhe-Chen Liao ,&nbsp;Yun-Ta Chung ,&nbsp;Jhong-Ren Huang ,&nbsp;Pei-Chun Wong ,&nbsp;Jhe-Yu Lin","doi":"10.1016/j.jmatprotec.2025.118750","DOIUrl":"10.1016/j.jmatprotec.2025.118750","url":null,"abstract":"","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118750"},"PeriodicalIF":6.7,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143428706","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":"Towards understanding the structure-property evolution mechanisms in wrought-to-printed and printed-to-printed linear friction welded Ti alloy near net blanks for aerospace applications","authors":"Mohan Raj Pandiyan ,&nbsp;Arjun Pankajakshan ,&nbsp;Chandra Sekhar Perugu ,&nbsp;Buchibabu Vicharapu ,&nbsp;Satish Vasu Kailas","doi":"10.1016/j.jmatprotec.2025.118756","DOIUrl":"10.1016/j.jmatprotec.2025.118756","url":null,"abstract":"<div><div>The near-net manufactured (NNM) blanks from linear friction welding (LFW) can significantly enhance the buy-to-fly ratio of critical Ti-alloy components for critical space, and energy applications. The severe limitations of the laser powder bed fusion, which include the limited build volume and lower material deposition rates, can be simultaneously addressed by near-net manufacturing for critical space applications that require large-sized complex parts with finer resolutions. A systematically coupled experimental and numerical investigation is presented here for the first time to reveal the feasibility of LFW for the manufacturing of novel near-net blanks in wrought-to-printed and printed-to-printed combinations. Results show that the microstructure and mechanical property evolution in the weld zone of both joints is nearly identical due to dynamic re-crystallization. However, the thermo-mechanically affected zones (TMAZ) in printed specimens exhibited the lowest hardness due to globularized needles. In contrast, the TMAZ of wrought specimen hardness increases considerably towards the weld interface due to the deformed and intact bi-modal microstructure. The proposed heat transfer model coupled with the kinetic model is sensitive enough to predict the measured hardness distribution with a maximum error of 5 %. Further, attempt to empirically relate the hardness with the corresponding yield and ultimate tensile strengths of the joints deemed appropriate for five different welding processes from five independent literature. Overall, printed-to-printed and wrought-to-printed joints exhibited excellent synergy between strength and ductility with improved elongation of 14 % and 164 %, respectively due to the closure of micropores in the printed specimen.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118756"},"PeriodicalIF":6.7,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143348781","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":"Strengthening mechanism of Al/Ti friction stir butt welded joints via ultrasonic-induced fast diffusion effects","authors":"Xinchen Nan ,&nbsp;Li Zhou ,&nbsp;Tingxuan Sun ,&nbsp;Mingrun Yu ,&nbsp;Xiaoguo Song","doi":"10.1016/j.jmatprotec.2025.118754","DOIUrl":"10.1016/j.jmatprotec.2025.118754","url":null,"abstract":"<div><div>The rapid advancement of the aerospace industry has intensified interest in Al/Ti heterostructures. However, the significant property differences between Al alloys and Ti alloys materials pose challenges for high-quality welding. The low interface bonding strength has long been a persistent issue in Al/Ti dissimilar alloy welding. Previous studies have shown that: ultrasonic vibration-assisted technology uniquely influences the types and growth sequence of interfacial compounds in dissimilar alloy friction stir butt welds, thereby improving joint properties. However, the mechanisms by which ultrasonic vibration affects the growth behavior of the compounds and enhances the properties of the joint remain unclear. In this study, ultrasonic-assisted friction stir butt welding of AA6061/Ti6Al4V dissimilar alloy was investigated. The results indicate that ultrasonic vibration induces a significant proliferation of dislocations in the joint without altering the heat input of the weld, thereby promoting element diffusion. As a result, the diffused interface (Al-TiAl₃-Ti) gradually replaces the typical mixed interface (Al-TiAl₃-TiAl-Ti) found in friction stir welding joints, leading to a reduction in lattice mismatch. In addition, ultrasonic vibration helps eliminate welding defects near the interface, further enhancing the quality and integrity of the joint. Consequently, the interface bonding strength increased from 152 MPa to 168 MPa.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118754"},"PeriodicalIF":6.7,"publicationDate":"2025-02-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143377457","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}