Journal of Materials Processing Technology最新文献

{"title":"Material removal mechanism in ultra-precision grinding of hard and brittle materials using small ball-end diamond grinding wheel","authors":"Biao Qin ,&nbsp;Henan Liu ,&nbsp;Jian Cheng ,&nbsp;Jinchuan Tian ,&nbsp;Jiangang Sun ,&nbsp;Guang Chen ,&nbsp;Zican Yang ,&nbsp;Mingjun Chen","doi":"10.1016/j.jmatprotec.2025.118977","DOIUrl":"10.1016/j.jmatprotec.2025.118977","url":null,"abstract":"<div><div>Small ball‐end fine-grained diamond grinding wheel offers notable advantages in the ultra-precision grinding of small complex curved-surface components, owing to their excellent machining flexibility and material removal capability. Reducing abrasive grain size is considered an effective strategy for achieving plastic-regime removal of hard and brittle materials while suppressing subsurface damage. However, the material removal mechanism during the machining of hard and brittle materials using small ball-end grinding wheels remains inadequately understood, thereby limiting their broader application in ultra-precision machining. In this study, fused silica, a representative hard and brittle material, was selected to investigate the influence of abrasive grain size on surface integrity and grinding characteristics. The results demonstrated that although the finer-grained grinding wheel produced excellent surface quality, it induced significant ploughing effects during grinding, which reduced material removal efficiency, accelerated grinding wheel wear, and increased grinding force. Furthermore, single-grain SPH scratching simulation and stress field analysis were conducted to clarify the subsurface damage evolution of fused silica under different abrasive grain sizes. Moreover, the damage mechanisms in both plastic-regime and brittle-regime removal modes when using small ball-end grinding wheels were revealed through TEM analysis. Finally, grinding experiments on typical small complex curved-surface components, hemispherical resonators, were performed to validate the feasibility of abrasive grain size modulation in practical machining. This study establishes a damage mechanism framework for grinding of hard and brittle materials using small ball-end grinding wheels, providing both theoretical and process guidance for low-damage precision machining of small complex curved-surface components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118977"},"PeriodicalIF":6.7,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144632024","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Achieving ultrahigh-strength Cu sintering joints prepared by ultrasonic spraying of thin Cu nanoparticle films","authors":"Xiuqi Wang ,&nbsp;Zheng Lian ,&nbsp;Dashi Lu ,&nbsp;Mingyu Li ,&nbsp;Hongjun Ji","doi":"10.1016/j.jmatprotec.2025.118981","DOIUrl":"10.1016/j.jmatprotec.2025.118981","url":null,"abstract":"<div><div>The application of nanoparticle sintering technology for third-generation semiconductor packaging is usually hindered by the difficulty in volatilization of organic vehicles, the nanoparticle (NP) agglomeration of its solder paste zone, and poor mechanical properties due to the inherent pores/cracks. In this work, these obstacles can be overcome using ultrasonic-spraying Cu NP film and vacuum thermal-pressure sintering. This work first controlled the ultrasonic spraying process parameters (power, flow, pressure) to achieve uniform and stable atomization effects yielding a homogeneous Cu NP film. The Cu NP film was further employed to realize Cu die-Cu substrate interconnection, and the microstructure and mechanical properties of the sintering joints was emphatically analyzed. Results demonstrate that near-monolayer fine Cu sintering structures are successfully produced. The sintering joints have good interfacial bonding ratio (∼ 94 %) and low porosity (∼ 1.6 %), resulting in shear strengths of up to 120.1 MPa. Even when sintering at 250 °C, the shear strength can reach 96.1 MPa. Because of the \"contact activation effect\" and the removal of interfacial cracks, these ultrasonic-spraying samples are stronger than printing sintering joints (with cracks) under the same sintering processes. We expect this approach to improve the performance of the sintering joints and broaden the application of Cu NP films, the microstructure of which less dependent on paste composition and sintering procedure (temperature, pressure, and time, etc.).</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118981"},"PeriodicalIF":6.7,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605318","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-strength Ti-Mg interface with 3D interlocking structure via Ti mesh interlayer: fabrication, microstructure, and mechanical properties","authors":"Lun Yang,&nbsp;Wenbo Wang,&nbsp;Yunzhu Ma,&nbsp;Wensheng Liu,&nbsp;Zuosheng Li","doi":"10.1016/j.jmatprotec.2025.118979","DOIUrl":"10.1016/j.jmatprotec.2025.118979","url":null,"abstract":"<div><div>Composite materials combining titanium (Ti) and magnesium (Mg) alloys promise synergistic benefits—lightweight, high strength, corrosion resistance, and biocompatibility, but their development is stymied by the inability of Ti and Mg to form a strong metallurgical bond. To address this issue, a two-step method is proposed: first diffusion-weld the Ti mesh to the TC4 substrate, then hot-press sinter AZ91 Mg alloy into the mesh pores to form a three-dimensional(3D) interlocking interface. The resulting 3D interlock mechanically locks the two phases, redirecting load away from the inherently weak Ti-Mg phase boundary into the stronger Ti mesh and Mg matrix. Finite-element analysis and microstructural characterization confirm this transition from a planar to a volumetric stress field. Under optimized conditions, the interface attains a tensile strength of 147.8 MPa (66.8 % of the Mg matrix) and a shear strength of 110.5 MPa (84.8 % of the Mg matrix), substantially outperforming conventional flat-interface joints. Beyond the Ti-Mg system, this design paradigm can be extended to bond dissimilar metals with weak metallurgical affinity—or even metal-nonmetal hybrids—provided the 3D-skeleton phase remains intact during densification, thereby offering a generalized solution for high-performance interfaces in multi-material assemblies.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118979"},"PeriodicalIF":6.7,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144632022","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":"Investigation on enhanced strength in W/(Ti/Cu) composite interlayer/steel diffusion bonding joint based on controlled diffusion mechanism","authors":"Zida Wang ,&nbsp;Shiqiang Zhang ,&nbsp;Jinghao Xu ,&nbsp;Zhihang Zhang ,&nbsp;Wei Shao ,&nbsp;Yue Zhao ,&nbsp;Jihua Huang ,&nbsp;Shuhai Chen ,&nbsp;Zheng Ye ,&nbsp;Wanli Wang ,&nbsp;Jian Yang","doi":"10.1016/j.jmatprotec.2025.118978","DOIUrl":"10.1016/j.jmatprotec.2025.118978","url":null,"abstract":"<div><div>The development of W/steel composite structures has become one of the focuses in the advancing nuclear fusion reactor cladding subassembly, leveraging the complementary strengths of both materials. The interlayers currently used in diffusion joining either fail to establish effective metallurgical bonding with the substrates or induce excessive reactions and leading to the formation of large number of brittle compounds. This makes it difficult to meet the strength requirements of the W/steel composite structure. Considering a controlled chemical reaction at the interface is beneficial for improving metallurgical bonding, the “controlled diffusion” concept was proposed in this work. Specifically, a Ti/Cu composite interlayer with thin Ti foil and thick Cu foil was employed for diffusion bonding steel and W with the double-layer sandwich structure of steel substrate/Cu/Ti/W substrate. The Ti interlayer diffuses through the Cu interlayer and reacts with the steel substrate under appropriate interlayer thickness design and processing conditions to promote metallurgical bonding at the Cu interlayer/steel substrate interface. The activity of Ti is fully utilized to address the challenge of forming a strong bond between the Cu layer and the steel substrate, while reducing thermal stresses in the joint and preventing excessive formation of brittle intermetallic compounds. Finally, the high-performance W/steel composite structure (tensile strength of 280.7 MPa) with a Ti/Cu composite interlayer were successfully prepared based on controlled diffusion mechanism. This work provides a novel interlayer design concept and mechanistic insight for improving the diffusion bonding quality of dissimilar materials in high-performance structural applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118978"},"PeriodicalIF":6.7,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605317","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 influence of slight energy density variation within the optimized parameters scope on the grain growth, precipitation behavior and mechanical property of laser direct energy deposited AA7075 alloy","authors":"Jiming Lv,&nbsp;Haifei Lu,&nbsp;Kaiyu Luo,&nbsp;Jinzhong Lu","doi":"10.1016/j.jmatprotec.2025.118976","DOIUrl":"10.1016/j.jmatprotec.2025.118976","url":null,"abstract":"<div><div>The laser direct energy deposition (LDED) of high-strength AA7075 alloy is highly challenging owing to its inherent cracks and porosity, exhibiting narrow low-defect processing window. Meanwhile, its precipitate behavior and dislocation density, the primary source of strength, are significantly influenced by the slight variation of energy density. Therefore, this study firstly explored the operatable parameter scope for the crack-free and low-porosity fabrication of AA7075 alloy through the stepwise regulation of single-track, single-layer, and multi-layer deposition. Results indicated that the porosity was strongly related to the mass flow rate, while the pore type was more affected by energy density. Subsequently, the effects of energy densities on microstructural evolution and mechanical properties were explored among this scope. The average grain size, aspect ratio, texture intensity, and internal strain were all enhanced with the increase of energy densities, while the density of geometrically necessary dislocations peaked at 155.6 W/mm². The point-shaped coherent precipitates pinning dislocations identified as η/η' phase of MgZn₂ were observed under the energy density of 155.6 W/mm², while the stripe-shaped non-coherent precipitates identified as S phase of Al₂CuMg dominated under the energy density of 183.9 W/mm². The precipitation behavior models under different energy densities were then obtained through the LDED thermal history analysis. The largest ultimate tensile strength of ∼347.7 MPa occurred at 155.6 W/mm²-2 mg/mm², which can be attributed to the joint effect of its relatively low porosity, fine grain size, high dislocation density, denser precipitation distribution and η/η' phase pinning dislocation structure. This study reveals the evolution pattern of grain growth, precipitate, and mechanical property of AA7075 alloy among the optimized parameters scope, providing a feasible solution for its in-situ microstructural regulation.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118976"},"PeriodicalIF":6.7,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605321","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 generalized electro-thermo-mechanical framework for electrically assisted tube forming: Case study on TA18 titanium alloy","authors":"Zhiliang Niu ,&nbsp;Zhenming Yue ,&nbsp;Zhicheng Xia ,&nbsp;Weijie Liu ,&nbsp;Shuai Zhang ,&nbsp;Aijun Xu","doi":"10.1016/j.jmatprotec.2025.118974","DOIUrl":"10.1016/j.jmatprotec.2025.118974","url":null,"abstract":"<div><div>Titanium alloy (TA18) tubes have good mechanical properties such high strength,hardness and yield strength ratio, but in thin-walled tubes, cracking on the exterior and shrinking on the interior are common during conventional bending processes, and often accompanied by significant springback upon unloading. This study introduces an electro assisted precision forming process to overcome these defects. Electrically assisted deformation (EAD) offers a promising pathway to improve the formability of high-strength alloys, yet the scientific understanding of its electro-thermo-mechanical coupling effects remains incomplete. This study systematically investigates the electric pulse-assisted tensile and bending behavior of TA18 titanium alloy tubes. A response surface methodology is used to optimize key electric parameters (current density, frequency, duty cycle), while microstructural mechanisms are examined through EBSD and TEM analyses. The results reveal that electric pulses not only reduce flow stress but also refine grains and enhance phase transformation, thereby improving plasticity. A modified Johnson–Cook model is developed to quantitatively capture the EAD behavior, which is validated through finite element simulations of bending processes. Meanwhile the optimal pulsed current parameters (6.41 A/mm², 258.3 Hz, 56.2 %) significantly released the deformation stress of the titanium alloy, enhanced the ductility, minimized elastic springback during forming, and improved the sectional distortion rate and thickness reduction of the TA18 tube material, markedly enhancing forming precision. Furthermore, a modified Johnson-Cook constitutive model for TA18 titanium alloy considering the Electro Assisted Deformation (EAD) was established, which accurately predicted the experimental outcomes. This case study provides a generalized framework for understanding the interaction between electric pulses, microstructure evolution, and deformation behavior in electrically assisted forming, with implications for other difficult-to-form alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118974"},"PeriodicalIF":6.7,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144632026","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 novel method to eliminate Laves phases in Ni-based superalloy laser cladding by in-situ theory","authors":"Xinyu Yao ,&nbsp;Qiang Lin ,&nbsp;Haohao Ding ,&nbsp;Yi Yang ,&nbsp;Hongtao Zhu ,&nbsp;Hongbin Zhu ,&nbsp;Wenjian Wang ,&nbsp;Huan Qi ,&nbsp;Zhongrong Zhou","doi":"10.1016/j.jmatprotec.2025.118972","DOIUrl":"10.1016/j.jmatprotec.2025.118972","url":null,"abstract":"<div><div>During the laser cladding of GH4169 superalloy, the high concentration of Nb elements in the interdendritic regions promotes the formation of large, chain-like Laves phases, which significantly deteriorate the mechanical properties of the cladding layer. Traditional methods for eliminating Laves phases usually involve optimizing the solidification conditions of molten pools and applying post-cladding heat treatments. However, solely adjusting the solidification conditions cannot completely eliminate the Laves phases, and post-cladding heat treatment may alter the microstructure of the substrate. This study proposes a new in-situ elimination technology to effectively remove Laves phases by leveraging the reaction between C produced by WC decomposition and Nb segregated in the interdendritic region at high temperatures. Additionally, high-frequency ultrasonic vibration enhances the uniform distribution of WC particles and promote the diffusion of C, further facilitating the in-situ reaction. The results indicate that the in-situ elimination technology effectively eliminated the Laves phase. As WC content increased, more C reacted with Nb at high-temperature, reducing Nb segregation in the interdendritic regions and subsequently decreasing Laves phase content. At 30 % WC content, all Laves phases were transformed into carbide-reinforced phases. Moreover, higher ultrasonic vibration current improved the uniform distribution of unmelted WC particles. The coating with 30 % WC content exhibited optimal wear resistance, with the wear width and wear depth reduced by 22.97 % and 40.45 %, respectively. Furthermore, the hardening ratio of the coating after wear is only 4.48 %, indicating superior performance. The research results indicate that the in-situ elimination theory can effectively eliminate the Laves phase. This provides a new solution approach for eliminating the Laves phase formed during laser cladding of GH4169 Ni-based superalloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118972"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587624","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Non-quadratic and asymmetric yield locus evolution of AA2219-T87 aluminum alloy under in-plane biaxial loading","authors":"Priya Tiwari ,&nbsp;Amir Hamza Siddiqui ,&nbsp;Jeet Patil ,&nbsp;Amit Singh ,&nbsp;SVS Narayan Murty ,&nbsp;Sushil K. Mishra","doi":"10.1016/j.jmatprotec.2025.118973","DOIUrl":"10.1016/j.jmatprotec.2025.118973","url":null,"abstract":"<div><div>Uniaxial and planar biaxial tests for AA2219-T87 alloy were carried out using a modified in-house developed design of cruciform specimens, and the yield behaviour was investigated for all four quadrants of the stress space. The alloy exhibited a pronounced dependence of the yield behaviour on the stress state. For the uniaxial tests, higher yield stress was observed in compression than in tension. The opposite trend was observed for the biaxial tests, where the biaxial tension showed higher yield stress in comparison to the biaxial compression. Different yield criteria were used to capture the experimental yield loci, and the Yld2000 criterion captured the experimental data with the most accuracy. Moreover, the incremental plastic strain direction was closely aligned with the Yld2000 predicted normal across different load ratios. The strain hardening behaviour was also analysed under uniaxial and biaxial loading conditions. It was found that the strain hardening was significantly increased under the biaxial loading, which was further confirmed by the work hardening analysis and a detailed study of the microstructure and texture evolution. The fractography study further revealed a transition from ductile fracture with voids and dimples under uniaxial loading to ductile-brittle mixed mode with prominent facet formation under biaxial loading.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118973"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587622","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Full domain power-modulated galvanometer-scanned laser welding of zirconium alloys/nickel-based superalloys dissimilar joints: microstructural evolution and strength enhancement","authors":"Gang Zhang ,&nbsp;Jianbo Wang ,&nbsp;Yu Shi ,&nbsp;Ding Fan","doi":"10.1016/j.jmatprotec.2025.118975","DOIUrl":"10.1016/j.jmatprotec.2025.118975","url":null,"abstract":"<div><div>Dissimilar joining of zirconium alloys to nickel-based superalloys presents critical challenges in nuclear fuel assembly applications, where interfacial brittle intermetallic compounds (IMCs) and thermal stress concentration fundamentally limit the structural integrity of Zr/Ni joints. This study developed an innovative full domain power-modulated (FDPM) galvanometer-scanned laser welding technique with multiscale thermal management to address these critical issues in Zr-N36/IN718 joints. Through a series of experiments with dynamic heat input redistribution, temperature gradient optimization, and multi-stage residual stress mitigation, a quantitative correlation between thermal process and joint strengthening mechanism is established. Results indicate that reducing heat input by 42 % effectively alleviates excessive Ni/Cr/Fe elemental diffusion, decreasing IMCs layer thickness from 39 μm to 17 μm. The thermal management strategy (300 W preheating +360 W in-situ heat treatment) results in a 23.5 % reduction in small-angle grain boundaries (55.4–31.9 %) and 30 % decrease in kernel average misorientation (KAM) indicating substantial residual stress release. The joint tensile strength is enhanced from 23.73 MPa to 103 MPa, with the fracture mode transitioning from intergranular brittle to ductile dimple-dominated failure. Microstructural analysis demonstrates a γ-(Ni, Cr, Fe) matrix reinforced by nano-Ni₃Nb precipitates in the fusion zone, while gradient-distributed NiZr₂ and σ-FeCr phases at the reaction layer effectively mitigate thermal expansion mismatch.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118975"},"PeriodicalIF":6.7,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144587625","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"From high cooling rates to high creep performance: Role of metastable beta in in-situ alloyed Ti64-TiAl alloys fabricated by laser powder bed fusion","authors":"Hatem A. Soliman ,&nbsp;Ali Ghasemi ,&nbsp;Mohamed Elbestawi ,&nbsp;Swee Leong Sing","doi":"10.1016/j.jmatprotec.2025.118957","DOIUrl":"10.1016/j.jmatprotec.2025.118957","url":null,"abstract":"<div><div>This study employs a novel processing approach using laser powder bed fusion (L-PBF). It leverages rapid cooling to develop a metastable microstructure that can retain or revert to suit both room and high-temperature applications. This approach is paired with a cost-effective blending strategy to fabricate novel alloys with microstructures that integrate ductile and hard phases. The study demonstrates the effectiveness of this approach in significantly enhancing the creep performance of Ti-6Al-4V (wt%) through in situ alloying with Ti-48Al-2Cr-2Nb (at%) at weight fractions of 20 % and 40 % via L-PBF. A tailored microstructure was achieved, leading to crack free samples. X-ray diffraction (XRD) phase analysis identified a metastable microstructure comprising the ductile β phase alongside hard α/α′/α₂ phases. A significant presence of β phases was observed in the 40 % TiAl alloy, comprising 80 % of the scanned area according to electron backscatter diffraction (EBSD) analysis, demonstrating the influence of rapid cooling in retaining high-temperature phases. Results from transmission electron microscopy (TEM), energy dispersive spectroscopy (EDS), and selected area electron diffraction (SAED) indicated a high dislocation density within the α phase, which contributed to crack nucleation during mechanical testing. The heat-treated alloys, in which the β phase revert to α₂, exhibited creep lifetime that surpassed Ti64 by 380 % for the 20 % TiAl alloy and over 600 % for the 40 % TiAl alloy. The combination of β and α phases at room temperature contributed to a yield strength of 966 MPa for 20 % TiAl and 741 MPa for 40 % TiAl, along with elongation percentages of 6.8 % for 20 % TiAl and 3.2 % for 40 % TiAl, both of which surpassed those of TiAl. These results pave the way for processing other materials beyond these specific alloys, enabling a wide range of applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118957"},"PeriodicalIF":6.7,"publicationDate":"2025-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144557691","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}