Journal of Materials Processing Technology最新文献

{"title":"Laser-solid interaction and energy accumulation in melt ejection formation during T2 copper oscillation laser welding","authors":"Hao Dong,&nbsp;Yan Cai ,&nbsp;Wucheng Li,&nbsp;Weidong Mu","doi":"10.1016/j.jmatprotec.2025.118874","DOIUrl":"10.1016/j.jmatprotec.2025.118874","url":null,"abstract":"<div><div>The phenomenon of melt ejection during pure copper laser welding exhibits the characteristics of randomness, accidentality, and abruptness. However, the current understanding of this mechanism cannot be used to conduct a detailed analysis of its random and sudden occurrence. Laser oscillations create a constantly changing environment for the laser, keyhole, and molten pool. In this study, a detailed analysis of the formation and development mechanisms of melt ejection was conducted under different laser-oscillation profiles and frequencies. Based on process observations and a self-designed energy and keyhole distortion calculation model, it was found that the random interaction between the laser and solid base metal contributed significantly to the sudden formation of the molten pool by transferring the heat accumulation zone to the rear bottom of the keyhole, which created an abnormal keyhole bulge. This was caused by the very low absorption rate of the solid surface of the T2 copper. The oscillation trajectory of the laser spot changed the frequency and time span when the laser moved near the liquid–solid boundary, as well as the heat input rate at different positions in the molten pool, resulting in a difference in stability with different oscillation strategies. Based on these results, we hypothesized that the formation of melt ejections is closely related to the random contact of a fluctuating keyhole with a highly reflective solid interface. Severe melt ejection was caused by the continuous accumulation of laser energy. This hypothesis led to a better understanding of the instabilities during the laser welding of highly reflective materials and can be applied to analyze most cases where melt ejection occurs.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118874"},"PeriodicalIF":6.7,"publicationDate":"2025-04-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143894943","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":"Influence of laser powder bed fusion of high-entropy alloy transition layer on the wetting and spreading behaviour of Al alloy on steel substrate surface","authors":"Yijian Zeng ,&nbsp;Jin Yang ,&nbsp;Tianyu Dou ,&nbsp;Min Zheng ,&nbsp;Yixuan Zhao ,&nbsp;J.P. Oliveira ,&nbsp;Jiajia Shen ,&nbsp;Caiwang Tan ,&nbsp;Hongbo Xia ,&nbsp;Hua Zhang","doi":"10.1016/j.jmatprotec.2025.118872","DOIUrl":"10.1016/j.jmatprotec.2025.118872","url":null,"abstract":"<div><div>The high-quality joining of Al alloys to steel is widely used in automotive manufacturing. However, because of the significant differences in their thermophysical properties, the wetting of Al alloys on steel is very limited, which affects the joining quality. To address this challenge, the laser powder bed fusion (LPBF) technique was used to prepare an FeCoNiCrMn high entropy alloy (HEA) with a dense transition layer (DTL) and micropillar transition layer (MTL) on a steel substrate for the first time. Then, the dynamic wetting and spreading behaviours of Al-12Si alloy over the transition layer-free, DTL, and MTL steels were comparatively studied. The spreading mechanisms were revealed by the spreading dynamics and an analysis of the interfacial microstructure. This study investigated a new method to improve the wetting of Al alloys on steel substrates and elucidated the mechanism of the effect of the HEA transition layer formed using LPBF on Al/steel wetting, which may provide some guidance for improving brazing, welding, coating, and other processes involving solid/liquid interfacial interactions.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118872"},"PeriodicalIF":6.7,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143887322","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":"Microstructure evolution mechanism of dual-phase Mg-Li alloy in laser surface melting for hardness and wear resistance enhancement","authors":"Liwei Wang ,&nbsp;Lihua Zhu ,&nbsp;Zhengfei Guo ,&nbsp;Shuo Lin ,&nbsp;Heju Sun ,&nbsp;Qing Li ,&nbsp;Jun Lin ,&nbsp;Yanjin Guan ,&nbsp;Zongshen Wang ,&nbsp;Guangming Zhu ,&nbsp;Qihua Ren ,&nbsp;Wenming Wang ,&nbsp;Yongling Wu ,&nbsp;Hongyu Zheng","doi":"10.1016/j.jmatprotec.2025.118871","DOIUrl":"10.1016/j.jmatprotec.2025.118871","url":null,"abstract":"<div><div>Mg-Li alloy exhibits great application potential in fields with an urgent need for lightweighting, such as electronics, automobiles, and aerospace, owing to its advantage of low density. However, its characteristics of low hardness and poor wear resistance have become key bottlenecks hindering its widespread application. Thus, this study applies Laser Surface Melting (LSM) to enhance the hardness and wear resistance of the dual phase Mg-Li alloy. The influence of LSM parameters on the microstructure evolution, microhardness, and wear resistance of the dual phase Mg-Li alloy and the microstructure evolution mechanism for hardness and wear resistance enhancement were revealed. The experimental results show that the grains in the melting layer are significantly refined compared with substrate layer. With the increase of depth in the melting layer, the grains gradually change from equiaxed grains to columnar grains, and the grains near the surface are refined to nanometer level. As the off-focus amount increases, the scanning speed rises, and the overlap ratio decreases, the laser energy density shows a downward trend. This change makes the melting layer thickness of the sample thinner and the grain size smaller, which in turn promotes the improvement of the hardness and wear resistance of the sample. The maximum hardness of the melting layer is increased by 95 % compared with that of the original sample, the average friction coefficient is reduced from 0.311 to 0.235, the quality loss is a decrease of 53.1 % compared with the original sample, and the width and depth of the wear scars are also significantly reduced. From the observation of microstructure, it is found that besides grain refinement, α-Mg and β-Li phases form supersaturated solid solution, and the hardness of both phases is higher than that of the substrate. Moreover and the hardness of β-phase is higher and its proportion is increased. The hardness and wear resistance of dual-phase Mg-Li alloy are significantly enhanced by the synergistic effect of grain refinement strengthening, solid solution strengthening and increasing the proportion of β-Li phase. This study provides crucial theoretical foundations and technical routes for expanding the application boundaries of Mg - Li alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118871"},"PeriodicalIF":6.7,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143869038","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 porous Cu-Al-Mn alloy via nanoscale Al2O3 introduced in-situ through staged powder metallurgy process","authors":"Xide Li ,&nbsp;Jili Liu ,&nbsp;Yujian Tong ,&nbsp;Haoyu Wang ,&nbsp;Dawei Qiu ,&nbsp;Junsheng Yang","doi":"10.1016/j.jmatprotec.2025.118868","DOIUrl":"10.1016/j.jmatprotec.2025.118868","url":null,"abstract":"<div><div>Currently, the simultaneous enhancement of mechanical strength and ductility in porous composite alloys remains a formidable challenge. To address this limitation, we have innovatively synthesized in-situ nanoscale amorphous Al₂O₃ in porous composite Cu-Al-Mn (CAM) alloys utilizing a well-orchestrated staged powder metallurgy (PM) process, employing Cu, Mn, and oxygen-containing Al elemental powder as raw materials. In the optimized porous CAM/Al₂O₃ processed by staged PM, strong equiaxed crystals in average grain size 29.20 μm with a near-unity aspect ratio, and the pore soft phase characterized by pore sizes ranging from 0.1 to 10 μm and its porosity of 33.20 % was found. Crucially, in-situ formation of amorphous Al₂O₃ nanoparticles strategically positions themselves along grain boundaries and pore edges, constructing a protective shell structure that safeguards grains against fracture under severe compressive deformation. This protective architecture, coupled with the abundant soft phase providing ample deformation accommodation, facilitates an exceptional balance of strength and ductility. Consequently, a remarkable enhancement in ultimate compressive strength (∼ 570.6 MPa) by 1.8 times is achieved, while maintaining a ductility capability (∼ 44.3 %) 3.0 times that of comparable porosity porous CAM alloy. The staged PM process for fabricating porous Cu-Al-Mn alloys with high strength and ductility via utilizing partially oxidized Al powder as one of the raw materials without relying on the difficult-to-obtain microstructure required in high strength structural materials. This approach demonstrates the capability of staged PM process in fabricating high performance porous Cu-Al-Mn alloys with controllable structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118868"},"PeriodicalIF":6.7,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143873550","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":"Low-temperature electrochemical machining of titanium alloys: A universal approach for phase-uniform dissolution and improved surface integrity","authors":"Jinzheng Li,&nbsp;Dengyong Wang,&nbsp;Di Zhu","doi":"10.1016/j.jmatprotec.2025.118870","DOIUrl":"10.1016/j.jmatprotec.2025.118870","url":null,"abstract":"<div><div>Titanium alloys have become indispensable materials in the aerospace engine industry owing to their superior mechanical properties. Aerospace engines operate under extreme conditions, placing stringent demands on the surface integrity of titanium alloys. Although electrochemical machining (ECM) offers numerous advantages for machining difficult-to-cut materials, challenges remain, such as inconsistent dissolution rates of the α and β phases and unsatisfactory surface quality during titanium alloy machining. This study presents a novel low-temperature ECM approach that achieves unparalleled phase uniformity and surface integrity in aqueous electrolyte solutions, while providing insights into the underlying mechanism. Notable phenomena and key technical breakthroughs are as follows: First, low temperatures reverse the contact potential difference between the α and β phases on the TA15 alloy surface, effectively mitigating galvanic corrosion and promoting uniform nanoscale dissolution of the α and β phases. Second, under low-temperature conditions, the passive film has been demonstrated to exhibit instability and insufficient corrosion resistance, leading to its faster removal during ECM. Furthermore, low-temperature ECM has been proved to be universal, consistently achieving surface roughness values between Sa 0.23 μm and Sa 0.36 μm across various titanium alloys and different ECM processes. These values are significantly lower than the surface roughness values of Sa 1.32 μm to Sa 4.81 μm obtained in high-temperature ECM. The low-temperature ECM method effectively overcomes the challenges associated with surface quality and integrity in the ECM of titanium alloys, thereby enhancing the performance of aerospace engine components and making it a promising technique in the aerospace industry.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118870"},"PeriodicalIF":6.7,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143873624","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":"New insights into variable thermomechanical loads due to chip formation size effects in machining of Ti-6Al4V alloy","authors":"Victor Onome Sodje ,&nbsp;Avery Bishop Hartley ,&nbsp;Jenna Nicole Money ,&nbsp;Julius Malte Schoop","doi":"10.1016/j.jmatprotec.2025.118869","DOIUrl":"10.1016/j.jmatprotec.2025.118869","url":null,"abstract":"<div><div>Using state-of-the-art in-situ characterization via high-speed optical microscopy and full-field digital image correlation analysis with nanometer resolution, Particle Image Velocimetry (PIV) as well as high bandwidth time-correlated process force analysis, this paper provides new quantitative insights into the complex dynamic variability present in the machining of Ti-6Al4V alloy, particularly at low uncut chip thicknesses where microstructural effects are most influential. Dynamically varying loads were analyzed across a wide range of uncut chip thicknesses (from 6 µm to 150 µm) and typical industrial cutting speeds for Ti-6Al4V alloy (30–120 m/min). The results reveal three distinct regimes of uncut chip thickness: from microstructural size effects at low thicknesses to quasi-steady state chip formation at intermediate uncut chip thickness to continuum-scale adiabatic shear banding at higher uncut chip thicknesses. Each regime is characterized by significantly different dominant mechanisms of chip formation, leading to variable sub-surface elastic and plastic loading with varying frequency/time and characteristic length scales. To minimize variability in thermomechanical loading and improve surface integrity in the cutting of Ti-6Al4V alloy at speeds between 30 and 120 m/min, our findings indicate an optimal uncut chip thickness range of 20–60 µm. These findings advance machining practices for Ti-6Al4V alloy, contributing to a new process optimization paradigm based on minimizing process and material-specific load variability to maximize as-machined component quality across multiple length scales.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118869"},"PeriodicalIF":6.7,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143873621","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":"Spatial control of microstructure and material hardness in functionally graded stainless steels by DED-LB/M and in-situ alloying","authors":"Andreas Maier ,&nbsp;Katja Tangermann-Gerk ,&nbsp;Dimitrios Nikas ,&nbsp;Manuel Rühr ,&nbsp;Lova Chechik ,&nbsp;Stephan Roth ,&nbsp;Pavel Krakhmalev ,&nbsp;Michael Schmidt","doi":"10.1016/j.jmatprotec.2025.118867","DOIUrl":"10.1016/j.jmatprotec.2025.118867","url":null,"abstract":"<div><div>Duplex stainless steels (DSS) are characterized by a two-phased microstructure (δ-ferrite and γ-austenite) with equal phase fractions, providing an exceptional combination of high strength, toughness, and corrosion resistance. This duplex microstructure is conventionally achieved by a precise thermo-mechanical process (e.g., hot rolling) followed by multiple post-processing steps (coating, joining, assembly) to meet the requirements in high-performance applications (e.g., advanced wear and corrosion resistance). Laser directed energy deposition of metals (DED-LB/M) enables simultaneous processing of multiple materials in a single component, allowing for the customization of the functionality while reducing the number of process steps required. In this study, a 1.4462 DSS was manufactured by DED-LB/M and compositionally modified (in-situ alloyed) with increasing proportions of elemental Cr and/or Mo powder to control both the phase formation and material hardness. Subsequent solution annealing (1050 °C; 2 h) and quenching homogenized the as-built microstructure within each grading increment. Microstructure analysis (phase fraction, morphology, and grain size using electron backscattered diffraction) was correlated with the local chemical composition by energy dispersive X-ray spectroscopy. Hardness profiles along the grading direction indicated a gradual increase in material hardness due to the stabilization of δ-ferrite (+ 69 HV10) or σ-phase (+ 683 HV10) with the addition of Cr and/or Mo. This approach demonstrates that in-situ alloying in DED-LB/M facilitates the spatial control of phase structures and the customization of functional properties. Components can now be manufactured in a single process with smooth compositional transitions and locally enhanced material properties, e.g. ductile core with wear and corrosion resistant shell.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118867"},"PeriodicalIF":6.7,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855549","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":"Micromechanical behavior and microcrack evolution in continuous casting slab: Experimental characterization, multiscale simulation and industrial validation","authors":"Zhida Zhang ,&nbsp;Cheng Ji ,&nbsp;Junlong Ju ,&nbsp;Kaixiang Li ,&nbsp;Miaoyong Zhu","doi":"10.1016/j.jmatprotec.2025.118866","DOIUrl":"10.1016/j.jmatprotec.2025.118866","url":null,"abstract":"<div><div>Transverse corner cracks in peritectic continuous casting slabs may develop into severe defects and line ruptures during the rolling process, thereby significantly restrict the steel production yield. In this study, the combined effect of low ductility microstructure and local deformation on the micromechanical behavior and microcrack evolution of the peritectic slab corner during the straightening processes are investigated based on the integration of experimental characterization, multiscale simulation and industrial validation. The macroscopic Arrhenius-type thermal-mechanical model is established to describe the slab deformation, and the dynamic displacement is supplied to the mesoscopic model as boundary conditions. In the meso-scale simulation, representative modeling parameters are obtained based on the quantitative characterization of microstructure (e.g., size of austenite, volume fraction of ferrite and morphology of oscillation mark), and a dual-phase coupled model based on crystal plasticity (CP) for austenite combined with continuum damage coupled von Mises plasticity for ferrite is proposed to predict the deformation and damage of materials. Constitutive model parameters calibrated by the genetic algorithms are converted into a continuous function through spatial interpolation to account for the effect of microstructure evolution on mechanical properties. Predicted microcrack morphology is in good agreement with that of the industrial production sample. Simulation results indicate that the inhomogeneous stress/strain distribution of dual phases can be explained by the competitive relationship between lattice rotation and plastic deformation of slip systems. The cavity damage nucleates preferentially at the high-angle grain boundary and the triple grain boundary junction of the oscillation mark valley, and then propagates along the ferrite film of internal coarse columnar austenite with three stages of “intermittent propagation - accelerated propagation - low-speed propagation”. Moreover, the mapping relationship between the microcrack evolution and the macroscopic external field is established in which the stress softening effect caused by damage accumulation can be accurately captured. This study provides a comprehensive integration framework for corner crack control and process optimization in the continuous casting process of similar steel.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118866"},"PeriodicalIF":6.7,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860468","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 single step sustainable manufacturing technology and synergy map for producing high performance magnesium alloy sheets","authors":"R. Kumar ,&nbsp;A. Maurya ,&nbsp;P. Sekar ,&nbsp;S.K. Panigrahi","doi":"10.1016/j.jmatprotec.2025.118865","DOIUrl":"10.1016/j.jmatprotec.2025.118865","url":null,"abstract":"<div><div>Large scale enterprises across the globe demands an innovative, economical and efficient manufacturing process that ensures the sustainable production of Magnesium (Mg) sheets. The present research establishes the impact of temperature, load and speed on mechanical properties and manufacturability of Mg sheets processed via single step large strain rolling (LSR) with varying deformation zone length conditions. The science of temperature-dependant deformation behaviour and defect formation characteristics is comprehensively studied using extensive experimentation and finite element method (FEM) simulations to provide in-depth insights into dynamic phenomena. A new scientific outcome of identifying critical condition for transitioning twin mode of deformation to slip dominant deformation is established for Mg. The processing windows revealing strength-ductility trade-off/synergy zones using synergy index are established to provide a guideline for producing application specific Mg sheets. The scientific knowhow and the underlying mechanisms leading to extraordinary synergy index of these Mg sheets have been unravelled for the first time. This single step sustainable manufacturing technology opens a new pathway for producing high performance Mg sheets and exhibits a promising potential to be scaled up for industrial use.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118865"},"PeriodicalIF":6.7,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855550","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":"Design and optimization of cruciform tension and shear specimen for forming limit acquisition","authors":"Zinan Cheng ,&nbsp;Cunsheng Zhang ,&nbsp;Yingzhi Li ,&nbsp;Jian Qin ,&nbsp;Fang Su ,&nbsp;Zijie Meng ,&nbsp;Liang Chen ,&nbsp;Guoqun Zhao","doi":"10.1016/j.jmatprotec.2025.118864","DOIUrl":"10.1016/j.jmatprotec.2025.118864","url":null,"abstract":"<div><div>The forming limit diagram (FLD) has been widely employed for the formability estimation and prediction of sheet metal. Recently, the cruciform tension test has emerged as a promising strategy to obtain the forming limit curves (FLCs). Compared to conventional bulging test, cruciform tension can readily achieve various strain paths without changing the specimen shape, and effectively avoid the influence caused by the friction and normal stress. However, the design and manufacturing of the cruciform specimen have always hindered the wider application of this technique, since the trade-off dilemma between deformation requirement and machining difficulty is hard to overcome. In this work, based on the comprehensive investigation on existed cruciform specimens, the advantages/disadvantages of different specimens and effect of various specimen features are clarified. Then, combining different specimen features, a series of experiments and finite element (FE) simulations are conducted to obtain the optimum tension and shear specimen suitable for FLC acquisition. Based on the optimum specimens, the FLC covers a large range of strain path can be obtained, improving the applicability of FLC. Moreover, the fracture behavior and morphology are also analyzed for further unveiling of different loading ratios. Finally, the optimum specimens are successfully applied in AA5052-H14 and Q235A steel sheet to obtain their FLCs, indicating a great applicability of the specimen. Therefore, this work conducts a complete and scientific procedure for the cruciform specimen design and experiment implementation, which could offer a universal solution for cruciform design and manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118864"},"PeriodicalIF":6.7,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847961","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}