Journal of Materials Processing Technology最新文献

{"title":"Surface microstructuring strategy for suppressing hump defects in ultra-high-power laser penetration welding of thick plates: Experimental and numerical insights","authors":"Yiyang Hu ,&nbsp;Fei Yan ,&nbsp;Zehui Liu ,&nbsp;Zhongshun Zhao ,&nbsp;Chunming Wang","doi":"10.1016/j.jmatprotec.2025.119075","DOIUrl":"10.1016/j.jmatprotec.2025.119075","url":null,"abstract":"<div><div>Ultra-high-power laser enables single-pass welding of thick-section components with high efficiency and low cost. However, its application is hindered by the frequent occurrence of hump defects. In this work, a method based on surface microstructuring of the butt joint cross section is proposed to suppress hump defects, achieving well-formed single-pass welding of 20 mm thick stainless steel. A computational fluid dynamics model incorporating surface microstructural features is developed and shows good agreement with experimental results. Surface microstructuring introduces two direct effects: it facilitates molten pool expansion and enhances laser energy absorption. These effects promote the transition of the keyhole from a non-penetrating to a penetrating state. The melt near the keyhole wall exhibits a higher tangential velocity while the downward flow of molten material is suppressed. No low-speed zone is observed at the bottom of the molten pool, enabling rear-side melt contraction driven by surface tension, which contributes to hump suppression. The resulting weld exhibits finer grains and a higher fraction of low-angle grain boundaries. The tensile strength and elongation reach 96 % and 65 % of those of the base metal, respectively. The changes in weld microstructure are attributed to the higher temperature thermal history experienced by the molten pool. The improved mechanical properties are primarily due to the enhanced weld formation quality. The proposed method requires no additional auxiliary equipment during welding and provides a promising solution for the industrial application of ultra-high-power laser single-pass welding in thick-section component manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119075"},"PeriodicalIF":7.5,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106286","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":"Pulse laser energy deposition of Inconel 625 alloy: Effects on microstructure and high-temperature oxidation resistance","authors":"Xiang Li,&nbsp;Xinlin Wang,&nbsp;Zhiqiang Hu,&nbsp;Yanqing Zhao,&nbsp;Jinkun Jiang","doi":"10.1016/j.jmatprotec.2025.119073","DOIUrl":"10.1016/j.jmatprotec.2025.119073","url":null,"abstract":"<div><div>Despite the laser energy deposition technology has been applied in the field of surface modification and repair of Ni-based high-temperature alloys. However, the utilization of this technology to improve the high-temperature oxidation resistance of nickel-based alloys is still an important topic that needs to be solved urgently. In this study, a processing strategy involving modulation of the laser heat source output was adopted, utilizing five different pulsed laser waveforms—pulse, continuous, triangle, declining, and rising—to tailor the microstructure and elemental distribution of the coating, thereby enhancing the high-temperature oxidation performance of Inconel 625. Under all five waveforms, the coating phases showed no significant differences and consisted primarily of the γ phase with an FCC structure. In addition, waveforms with periodic oscillation characteristics (pulse and decline) effectively reduced pore volume and refined the microstructure. Among these, the pulse waveform yielded the lowest porosity of 0.131 %, compared to 1.176 % for the conventional continuous wave. Conversely, the triangle laser output form was smooth and produced a slow cooling rate that provided an optimal ratio of cooling gradient (<em>G</em>) to solidification rate (<em>R</em>) conducive to continuous growth of dendritic structures. The results of oxidation weight gain curve analysis showed that the pulsed-wave and falling-wave coatings had less mass gain after 100 h of oxidation at 900°C, demonstrating superior high-temperature oxidation resistance, which was mainly benefited from the cellular grain boundaries that provided more channels for the diffusion of elemental Cr after the grain refinement, and increased the concentration of elemental Cr at the edges. The reaction with O formed a denser Cr₂O₃ oxide layer, which inhibited the external diffusion of Ni ions and thus reduced the oxide defects. This study confirmed that modulating the laser output waveform was also an effective method to enhancing the high-temperature oxidation resistance of Ni-based alloys, which effectively saved the cost of the laser processing compared with methods such as adding mixed powders in the laser energy deposition process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119073"},"PeriodicalIF":7.5,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106284","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":"Process scheme for the stabilized standoff distance formation based on powder behavior during laser directed energy deposition","authors":"Huanqiang Liu ,&nbsp;Weiwei Liu ,&nbsp;Jianrong Song ,&nbsp;Wanyang Li ,&nbsp;Zongyu Ma ,&nbsp;Bozhan Shen ,&nbsp;Tao Li ,&nbsp;Shujie Liu ,&nbsp;Hongchao Zhang ,&nbsp;Shitong Peng ,&nbsp;Fengtao Wang","doi":"10.1016/j.jmatprotec.2025.119071","DOIUrl":"10.1016/j.jmatprotec.2025.119071","url":null,"abstract":"<div><div>Geometric defects, particularly for the uniformity interlayer height distribution due to fluctuations in standoff distance (SD), tend to occur in the laser directed energy deposition (DED-LB) forming of thin-walled parts, which can severely compromise the dimensional accuracy and quality of final manufactured parts. To address this challenge, a novel control framework is developed through the integration of real-time layer height monitoring and dynamic SD adjustment. First, the full analytical model of the laser-powder-melting pool interaction was solved using the finite difference method, and the optimal powder feeding process parameters for forming were obtained. Then, the geometric accuracy of thin-walled parts under different SD was analyzed. A Z-axis uplift compensation strategy was proposed to control the stability of the SD amount in DED-LB thin-walled part formation. Finally, experimental analysis was performed to validate the effectiveness of the control method for the geometric accuracy and material properties of the formed thin-walled parts. The results indicated that the flight speed and acceleration of the powder particles followed a linear trend. The highest powder utilization occurred during the zero SD deposition process. The optimal forming SD for the thin-walled parts was found to be 0 mm. Instability in energy input caused by fluctuating SD was identified as the primary factor contributing to the reduced geometric accuracy and performance of the thin-walled parts. Under stable zero SD (SZ-SD) control, the surface roughness of the thin-walled parts improved by 49.1 %, layer height uniformity increased by 38.5 %, and the forming height rose from 14.71 mm under unstable negative SD (UN-SD) to 19.37 mm, significantly boosting forming efficiency. Moreover, the high cooling rate refined the grain structure, reduced the harmful Laves phase and texture strength, leading to a 12.9 % increase in tensile strength and a more uniform hardness distribution. This study provides valuable theoretical and technical support for enhancing the forming quality and efficiency of DED-LB thin-walled parts, contributing to the advancement of intelligent manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119071"},"PeriodicalIF":7.5,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106350","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":"Effect of pouring temperature on distribution characteristics and formation mechanism of eutectic-rich band in vacuum-assisted high pressure die casting AlSi9MnMg alloy","authors":"Ganlin Qin ,&nbsp;Jian Lin ,&nbsp;Xiao Liu ,&nbsp;Hanlin Xiang ,&nbsp;Congchang Xu ,&nbsp;Luoxing Li","doi":"10.1016/j.jmatprotec.2025.119066","DOIUrl":"10.1016/j.jmatprotec.2025.119066","url":null,"abstract":"<div><div>The distribution characteristics and formation mechanism of the microstructure in vacuum-assisted high pressure die casting (HPDC) AlSi9MnMg alloy were elucidated by varying pouring temperature. The results show that the casting sample was divided into five distinct regions from the surface to the center, namely the chilling layer, the skin layer, the near-skin layer, the eutectic-rich band, and the core region. Externally solidified crystals (ESCs) play a critical role in the formation of heterogeneous microstructures within the casting. At excessively low pouring temperatures, a large number of ESCs form in the sleeve and enter the die cavity rapidly through the ingate, promoting uniform mixing with the liquid phase. The concentration of ESCs increases the melt viscosity, preventing them from migrating to the center of the casting. Consequently, the solute-rich liquid phase is dispersed within the dendritic network formed by the interconnected ESCs. The eutectic structure is dispersed by the primary α-Al dendrite network, and no distinct eutectic-rich band is formed within the casting. With increasing pouring temperature, the eutectic-rich phenomenon becomes more pronounced, the eutectic-rich band shifts toward the center of the casting. At middle pouring temperatures (650 ℃, 690 ℃, and 730 ℃), an increase in pouring temperature leads to a reduction in the number of ESCs, causing the ESCs dendritic network front to shift closer to the casting center, thereby driving the eutectic-rich band toward the center as well. These conclusions enabled the establishment of the relationship between the spatial distribution of ESCs and eutectic-rich band, thereby revealing the formation mechanism of the eutectic-rich band. This study sheds light on the formation mechanism of eutectic-rich band in HPDC Al-Si alloy and offers guidance for improving HPDC process design, not limited to such alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119066"},"PeriodicalIF":7.5,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106353","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":"Hierarchically ultrafine grains with the embedded nanotwins structure produced in ultra-high strain rate deformation of coarse-grained titanium alloy","authors":"Qinghong Jiang ,&nbsp;Binbin He ,&nbsp;Shuai Li ,&nbsp;Chunlei Yang ,&nbsp;Wei Fan ,&nbsp;M.W. Fu ,&nbsp;Bi Zhang","doi":"10.1016/j.jmatprotec.2025.119070","DOIUrl":"10.1016/j.jmatprotec.2025.119070","url":null,"abstract":"<div><div>Grain boundaries and coherent twin boundaries are two-dimensional defects which can effectively impede dislocation movement and thus contribute to high strength in metals and alloys. However, the simultaneous engineering of the coherent twin boundaries and ultrafine grains in an originally coarse-grained material is believed to be challenging by conventional processing strategies. In this research, we applied a high-strain-rate scratching to obtaining a hierarchically Ultrafine-Grain with the Embedded NanoTwins (UGENTs) structure in the coarse-grained commercial titanium alloy. Systematic experiments revealed an intriguing transition from dislocation-based deformation to twin-mediated plasticity with increasing strain rate. The enhanced twinning activities at high strain rates facilitated the generation of intensive high-angle grain boundaries, leading to the formation of a complex UGENTs structure. It is thus believed that such a UGENTs structure endows the structural component with a strong and tough skin to withstand harsh environmental attacks, such as wear during service.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119070"},"PeriodicalIF":7.5,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155667","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":"Ultrasonic vibration frequency as a governing mechanism for microstructure-property relationships in cold metal transfer-based wire arc directed energy deposited 316 L stainless steel","authors":"Sudhir Behera ,&nbsp;Ramamoorthy Velayutham ,&nbsp;Ashwin Shah ,&nbsp;Mahesh Patel ,&nbsp;S. Sridharan ,&nbsp;Jayaprakash Murugesan","doi":"10.1016/j.jmatprotec.2025.119072","DOIUrl":"10.1016/j.jmatprotec.2025.119072","url":null,"abstract":"<div><div>In wire-arc directed energy deposited (wire-arc DED) 316 L stainless steel, heterogeneous grain structures, porosity, and strength anisotropy have long been critical factors limiting performance. Recent studies have shown that ultrasonic vibration can refine microstructures and improve material properties, yet the influence of vibration frequency on melt dynamics, microstructure, fretting wear, and corrosion behaviour remains insufficiently explored. In this study, ultrasonic vibration (USV) at frequencies of 15, 25, and 40 kHz was applied during cold metal transfer (CMT)-based wire-arc arc directed energy deposition to systematically evaluate its effects. The results reveal that 25 kHz produced the finest average grain size (∼34 µm), significantly reduced Cr, Ni, and Mo segregation at grain boundaries, and enhanced structural homogeneity. This condition achieved the highest hardness (221 HV, +22 % over the without-ultrasonic vibration condition), improved ultimate tensile strength, and reduced tensile anisotropy by ∼29 %. Wear resistance and corrosion performance were also maximized at 25 kHz, whereas 40 kHz led to grain coarsening and degraded properties due to excessive heat input. Mechanistic analysis indicates that property improvements at the optimal frequency arise from three coupled effects: (i) grain refinement strengthening through vibration-enhanced nucleation, (ii) defect reduction via acoustic-driven melt stirring and porosity suppression, and (iii) enhanced corrosion resistance through uniform solute distribution and refined passive film formation. Beyond this case study, the findings establish ultrasonic frequency as a transferable process parameter for microstructural engineering, offering generic insights applicable to steels and other alloys with comparable melting behaviour.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119072"},"PeriodicalIF":7.5,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046665","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":"Synergistically double-sided probeless friction stir spot welding: The effect of tool rotation modes on joint formation and strengthening mechanisms","authors":"Wenlong Fan ,&nbsp;Wenya Li ,&nbsp;Xiawei Yang ,&nbsp;Qiang Chu ,&nbsp;Yu Su ,&nbsp;Jihong Dong ,&nbsp;Achilles Vairis","doi":"10.1016/j.jmatprotec.2025.119063","DOIUrl":"10.1016/j.jmatprotec.2025.119063","url":null,"abstract":"<div><div>This study systematically investigates the synergistically double-sided probeless friction stir spot welding (SDP-FSSW) applied to 2198-T8 Al–Li alloy sheets. By independently controlling the rotation modes of two tool shoulders, three welding configurations—single-sided rotation, co-rotation, and counter-rotation—were explored. Macro- and microstructural analysis revealed that co-rotation produces an oscillating wavy hook, which effectively suppresses interfacial crack propagation, yielding tensile-shear strengths exceeding 10 kN—even without dwell—and reaching a peak of 13.38 kN at 3 s. In counter-rotation, opposing material flow creates upward- and downward-warping hooks that significantly increase the effective load-bearing area, with tensile-shear strength rising to a maximum of 15.10 kN at 6 s. These results demonstrate that SDP-FSSW effectively addresses the traditional trade-off between metallurgical bonding and geometric defect deterioration in spot-welded aluminium alloys, offering both improved interfacial bonding and enhanced joint stability. This study provides a novel approach to achieving high-performance spot welding, particularly for lightweight structural applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119063"},"PeriodicalIF":7.5,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044828","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":"The mechanisms of material removal and atomic-scale damage in InP during elliptical vibration-assisted nanoscratching integrated with laser processing","authors":"Jiqiang Wang ,&nbsp;Yue Liu ,&nbsp;Yongda Yan ,&nbsp;Shaoqin Liu ,&nbsp;Chen Li ,&nbsp;Yanquan Geng","doi":"10.1016/j.jmatprotec.2025.119069","DOIUrl":"10.1016/j.jmatprotec.2025.119069","url":null,"abstract":"<div><div>Indium phosphide (InP) crystals exhibit significant potential for applications in photoelectric detectors, artificial intelligence and 5 G communication. The quality of the surface and subsurface layers critically influences their performance as substrates. Therefore, gaining an in-depth understanding of the material removal mechanisms and atomic-scale damage behavior during InP machining is essential to enable its broader implementation. This study proposes an atomic force microscopy (AFM) tip-based elliptical vibration-assisted nanoscratching technique combined with laser processing (EVANL). The mechanical properties of InP following laser processing are evaluated through AFM indentation. Transmission electron microscopy (TEM) observations and molecular dynamics (MD) simulations demonstrate that a thin amorphous layer is formed on the sample surface, which accounts for the reduced hardness observed in the laser-processed material. The material removal mechanisms of InP in tip-based elliptical vibration-assisted nanoscratching (EVAN) and EVANL are investigated. Compared with conventional AFM scratching, a relatively high strain rate of up to 5.7 × 10⁶ s⁻¹ is achieved in both EVAN and EVANL, leading to the embrittlement of the pristine crystalline InP sample. However, due to the formation of an amorphous phase, the material removal behavior of the laser-processed InP sample becomes insensitive to strain rate. The effects of driving frequency and voltage on the machined depth are investigated. The depth of the nanogroove fabricated by EVANL is consistently greater than that achieved by EVAN, which can be attributed to the reduced hardness of the material. TEM observations demonstrate that EVANL results in shallower subsurface damage compared to EVAN. The effects of machining trajectories, including conventional array profiling (CAP) and Lissajous trajectory profiling (LTP), on the resulting nanostructures are investigated. Ultimately, a flatter nano-surface with a surface roughness (<em>R</em>a) of 2.06 nm is achieved through EVANL using LTP. This research presents a novel approach for machining InP samples with a high-quality surface and shallow subsurface damage, along with mechanistic insights into conventional grinding processes.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119069"},"PeriodicalIF":7.5,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046666","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":"Integrated multi-scale framework for predicting deformation and damage in hot bulging of Ti-6Al-4V alloy: Experiments, modelling, and simulation","authors":"Dechong Li ,&nbsp;Ziwei Zhao ,&nbsp;Huading Hou ,&nbsp;Zheng Gao ,&nbsp;Jiaxin Lv ,&nbsp;Kailun Zheng","doi":"10.1016/j.jmatprotec.2025.119067","DOIUrl":"10.1016/j.jmatprotec.2025.119067","url":null,"abstract":"<div><div>Accurate prediction of metal bulging forming requires a multi-scale material model that fully describes material flows, microstructures, and forming limits under a plane stress state, as well as a precise bulging control method to maintain constant strain rate throughout the forming process for reliable forming limit data. However, research integrating all these aspects into a unified prediction framework remains limited. This study analyzes the hot bulging of Ti-6Al-4V alloy via experiments, modelling and simulations. Frictionless gas bulging tests were conducted under various temperatures (800–900 ℃), strain rates (0.001–0.1 s⁻¹) and axial length ratios (1, 1.5, 2). A pressure loading model was developed to ensure a constant strain rate across bulging process, with 90.73 % accuracy. Based on bulging tests and post-bulging microstructural observations, a physically based constitutive model with a plane stress state damage mechanism was established, accurately predicting microstructure, macroscopic flows and forming limits. The prediction accuracies for stress-strain curves and average grain size were 91.77 % and 93.40 %, respectively, with the predicted forming limit curves aligning well with experimental data. The validated constitutive model was applied in finite element simulations. The thickness distribution and damage positions from the simulations closely matched the experimental results, which confirmed the reliability of the finite element framework. Finally, optimal bulging conditions were identified via finite element simulations for improved deformation uniformity within 700–900 ℃ and 0.0001–1 s⁻¹. According to this, a large complex tubular component was successfully formed. By integrating an experimental–theoretical–computational framework, this study provides an effective approach to bridge fundamental research and industrial application, offering insights into the multiscale deformation damage mechanisms and practical control during sheet metal forming.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119067"},"PeriodicalIF":7.5,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044826","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":"Mechanism of the high elongation but low formability of high-strength aluminum alloy in W-temper","authors":"J.W. Yu ,&nbsp;X.G. Fan ,&nbsp;L. Wang ,&nbsp;Z.J. Wang ,&nbsp;M. Zhan","doi":"10.1016/j.jmatprotec.2025.119068","DOIUrl":"10.1016/j.jmatprotec.2025.119068","url":null,"abstract":"<div><div>The paradoxical combination of high uniaxial elongation but poor multiaxial formability in W-temper 2219 aluminum alloys presents a long-standing challenge for aerospace forming applications. This study delivers a fundamental advancement by elucidating the underlying stress-state-dependent fracture mechanisms that govern this behavior. Using a hybrid experimental–numerical approach spanning a wide range of stress states, we reveal that the apparent ductility observed in uniaxial tension does not translate to global formability due to the complex interplay between dynamic strain aging (PLC effect), conjugate shear band formation, and the separation of the stress-strain maximum shear planes under large plastic strains. Crucially, we demonstrate that these phenomena induce stress-state-sensitive localization modes that accelerate damage evolution under certain loading paths while retarding it under others. This mechanistic insight bridges a key knowledge gap between microstructural instability and macroscopic formability in solution-treated aluminum alloys. The findings not only explain the failure inconsistency observed across different forming processes but also offer a physics-based foundation for designing better forming strategies and improving the processability of dynamic strain aging-prone aluminum alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119068"},"PeriodicalIF":7.5,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044825","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}