Journal of Materials Processing Technology最新文献

{"title":"Heterogeneous liquid–solid melt pools in EB-PBF of porous inconel 625/BNi-2: A general strategy for strength–permeability synergy in mixed-melting powder systems","authors":"Yifan Wang ,&nbsp;Houqin Wang ,&nbsp;Binggang Zhang ,&nbsp;Chenghui Jiang ,&nbsp;Yu Qiu ,&nbsp;Bo Gong ,&nbsp;Yi Peng ,&nbsp;Aoxing Li ,&nbsp;Huakang Bian ,&nbsp;Yuxin Liu","doi":"10.1016/j.jmatprotec.2025.119065","DOIUrl":"10.1016/j.jmatprotec.2025.119065","url":null,"abstract":"<div><div>To enhance tensile strength and functionality while maintaining porosity for transpiration cooling, this study introduces NiCrSiB (BNi-2) powder into the electron beam powder bed fusion (EB-PBF) process. By integrating beam defocusing, porous Inconel 625 alloys with uniform, interconnected micron-scale pores were fabricated. Comprehensive analyses of morphology, porosity, microstructure, mechanics, and permeability were conducted, with comparisons to BNi-2-free and powder metallurgy (PM) counterparts. BNi-2 improved pore uniformity, approaching PM quality. Lower line energy increased pore density and spatial uniformity. A quantitative multi-scale link between porosity, pore shape, and tensile strength was established, revealing that \"low beam current + high scan speed\" defines a highly sensitive and efficient process window, where small parameter changes can trigger functional shifts. Melt pool calculations revealed a stable heterogeneous state with liquid–solid coexistence, forming four zones: unmelted and partially melted powder zone (UMP/PMP), melted BNi-2 zone (MBZ), melted Inconel 625 zone (MIZ), and mixed MBZ&amp;MIZ zone (MIX), driven by heterogeneous melting and Cr, Mo, Si, B segregation. BNi-2 raised tensile strength to 166 MPa at 27 % porosity (277 % higher than EB-PBF baseline), and 80 MPa at 33 % porosity—142 % and 33 % higher than BNi-2-free and PM samples. Isotropic permeability reached 4.32–4.55 d (124 % of PM). This study achieved bidirectional optimization of structure and performance, and established a novel mechanism identification pathway and parameter design criterion applicable to the EB-PBF fabrication of porous metals. It provides a valuable and generalizable reference for structure–function synergistic regulation across different alloy systems.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119065"},"PeriodicalIF":7.5,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044827","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 high-strength joining with superior metallurgical bonding in tungsten/steel via in-situ element-selective directional diffusion","authors":"Huaqi Xu ,&nbsp;Wenjing Zhang ,&nbsp;Xiaonan Qi ,&nbsp;Wanjing Wang ,&nbsp;Ji-Chao Wang ,&nbsp;Ye Jiao ,&nbsp;Kailun Li ,&nbsp;Shubo Zhang ,&nbsp;Mingshen Li ,&nbsp;Yuping Xu ,&nbsp;Haishan Zhou ,&nbsp;Ming-Hsien Lee ,&nbsp;Wei Liu ,&nbsp;Guangnan Luo","doi":"10.1016/j.jmatprotec.2025.119064","DOIUrl":"10.1016/j.jmatprotec.2025.119064","url":null,"abstract":"<div><div>To address the weak metallurgical bonding at interfaces in traditional tungsten (W)/steel joints with copper (Cu) interlayers, this study proposes a strategy of in-situ element-selective directional diffusion, achieving high-strength metallurgical transition bonding at both W/Cu and Cu/steel interfaces. Specifically, by introducing a Cu-Ge interlayer at the W/steel interface, multi-physics-driven forces (gravity and temperature fields) were utilized to enable the selective directional diffusion of Fe and Cr from the steel across the Cu-based interlayer. These elements migrated through the Cu interlayer, forming an Fe-rich deposition layer at the W/Cu interface, realizing a metallurgically bonded W/Fe/Cu transition. Furthermore, compared to the brittle Fe₂W phase typically formed at conventional W/Fe interfaces, this study achieved in-situ toughening of the Fe₂W phase through lattice distortion and stacking faults engineering. Simultaneously, the entire distribution of Cu along steel grain boundaries formed a discontinuous reticulate Cu/steel heterostructure, effectively addressing the low bonding strength of conventional Cu/steel interfaces. Ultimately, an unprecedented shear strength of 380 MPa was attained. This work elucidates the mechanisms of interfacial metallurgical bonding, strengthening, and in-situ modification of brittle phases in dissimilar metal joints with significant thermophysical property differences. It provides a novel pathway for high-strength metallurgical joining of dissimilar metals in harsh service environments and offers new insights into the modification and toughening of brittle phases at welded interfaces.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119064"},"PeriodicalIF":7.5,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027594","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":"Chemical mechanical polishing of powder bed fusion – laser beam processed 316 L stainless steel","authors":"Rasmus Gunnerek ,&nbsp;Gowtham Soundarapandiyan ,&nbsp;Tatiana Mishurova ,&nbsp;Jakob Schröder ,&nbsp;Giovanni Bruno ,&nbsp;Joshua Boykin ,&nbsp;Agustin Diaz ,&nbsp;Uta Klement ,&nbsp;Eduard Hryha","doi":"10.1016/j.jmatprotec.2025.119055","DOIUrl":"10.1016/j.jmatprotec.2025.119055","url":null,"abstract":"<div><div>Additive manufacturing via powder bed fusion – laser beam (PBF-LB) enables the fabrication of complex geometries but suffers from inherently rough surfaces and surface tensile residual stresses, both of which can compromise structural integrity, particularly under fatigue loading. To address these limitations, this study investigates chemical mechanical polishing (CMP) as a surface finishing method for improving surface quality and modifying the residual stress state in PBF-LB 316 L stainless steel. The work uniquely examines how scan rotation (0° vs. 67° rotation) and contour parameters influence CMP effectiveness in material removal, surface smoothing, and subsurface stress redistribution. With a targeted material removal of 110 µm, CMP reduced surface roughness (<em>Sa</em>) by up to 94 %, achieving values as low as 0.7 µm. Microstructural analysis revealed no grain refinement but identified a thin, plastically deformed surface layer. This plastic deformation resulted in the transformation of tensile surface stresses (340 MPa) into beneficial compressive stresses (−400 MPa), as confirmed by synchrotron X-ray diffraction, which also showed a shift toward isotropic strain distribution. Further, these findings demonstrate that the initial scan strategy influences CMP performance and that CMP can enhance both surface integrity and mechanical reliability without altering the underlying microstructure. This study advances the understanding of how process induced microstructure and surface features affect CMP outcomes, enabling more informed design of post-processing strategies for improved surface integrity and mechanical performance in additively manufactured metals.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119055"},"PeriodicalIF":7.5,"publicationDate":"2025-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010794","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":"Pulsed/steady electromagnetic field modulation of melt viscosity and solidification in rare earth-aluminum alloys: Mechanistic insights beyond La-ZL114","authors":"Jiahui Zhang ,&nbsp;Qingwei Bai ,&nbsp;Wentao Guo ,&nbsp;Yang Liu ,&nbsp;Kaihua Zhang ,&nbsp;Oleksandr Bushma","doi":"10.1016/j.jmatprotec.2025.119048","DOIUrl":"10.1016/j.jmatprotec.2025.119048","url":null,"abstract":"<div><div>Regulating the magnetohydrodynamic behavior of molten metals during solidification stands as a high-quality, high-efficiency material manufacture strategy in the context of global carbon neutrality and lightweight materials development. Magnetic viscosity exerts a significant influence on mold filling capacity, defect formation, and microstructure evolution by modulating thermal, mass, and momentum transfer processes. This paper investigates how pulsed and steady magnetic fields regulate the viscosity of rare earth-containing Al-Si alloy melts (with 0.4 wt% La) to control both their casting fluidity and solidification microstructures, employing an electromagnetic field high-temperature viscometer, electromagnetic field confocal laser scanning microscope and the electromagnetic casting physic simulation. The results shown that the melt viscosity at 650 °C increases from 0.08 Pa·s to 0.092 Pa·s under a 60 mT steady magnetic field, while the casting fluidity length decreases by 19.34 %. This can be attributed to the magnetic damping effect. Under a pulsed magnetic field, the alloy casting fluidity length increases 23.74 %, Concurrently, both α-Al phases and rare earth phases are uniformly distributed and refined, with the α-Al grain refinement reaching 20.57 %. It is worth noting that the molten oscillation induced by the Lorentz force leads to the formation of dispersed microporosity / blowholes. In contrast, a stable magnetic field is effective in removing blowholes as most of them are concentrate in the upper part of the melt. A quantitative relationship between magnetic viscosity, temperature, and magnetic flux density is established, unlocking new potential for the precise tailoring of additive manufacturing and complex casting components through the coupled regulation of electromagnetic and solidification parameters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119048"},"PeriodicalIF":7.5,"publicationDate":"2025-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106285","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":"Fundamental investigation on damage evolution and material removal anisotropic mechanism in monocrystal sapphire","authors":"Xingyu Wang,&nbsp;Xiaoyu Bao,&nbsp;Wen Zheng,&nbsp;Sheng Wang,&nbsp;Qingliang Zhao","doi":"10.1016/j.jmatprotec.2025.119052","DOIUrl":"10.1016/j.jmatprotec.2025.119052","url":null,"abstract":"<div><div>Monocrystal sapphire curved surface optical components are widely used in various fields such as optical engineering, aerospace, and scientific research due to their superior optical performance and reliable mechanical properties. However, the processing of curved components involves multiple crystal planes of sapphire (including the A, M, N, C, and R planes), and the anisotropic characteristics of material removal and damage evolution on each crystal plane have become an issue that urgently needs to be addressed. In this study, for the first time, single-abrasive scratch experiments were systematically performed on all sapphire crystal planes (A, M, N, C, R), and the crystal-orientation dependence of material removal was directly revealed through analysis of scratch morphology and force. An innovative analytical approach was developed that combines elastic stress field modeling with slip/twinning and cleavage activation probabilities to evaluate the anisotropic characteristics of damage evolution in monocrystal sapphire. Finally, transmission electron microscopy was used to characterize subsurface damage within the scratch grooves, and, based on the relationship between dislocations and cracks, the orientation dependence of damage evolution was further elucidated. We developed an innovative analytical approach that combines elastic stress field modeling with slip/twinning and cleavage activation probabilities to quantitatively assess the anisotropic characteristics of damage evolution in monocrystalline sapphire. The results indicate that the anisotropy in the material removal form of sapphire occurs during the brittle removal stage, with significant anisotropic characteristics manifested in the differences in brittle spalling shape and brittle spalling area. Furthermore, the distribution of the elastic stress field indicates that median cracks are induced by tensile stress during the loading process, while radial and lateral cracks are caused by tensile stress during the unloading process. Simultaneously, the degree of brittle fracture induced by scratching force, the stress field, and the probability of cleavage fracture activation follow the sequence R &lt; N &lt; C &lt; M &lt; A, whereas plasticity exhibits an inverse relationship with the activation probability of slip/twinning. The scratching of R plane is more conducive to the ductile machining due to its lower elastic stress and higher dislocation density. These findings provide valuable scientific insights and a solid theoretical foundation for advancing the processing of sapphire curved surface components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119052"},"PeriodicalIF":7.5,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145010795","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 high strength and defect suppression in CFRP/aluminum alloy single-sided friction riveted joints via novel threaded rivets","authors":"Feilong Yu ,&nbsp;Han Tang ,&nbsp;Bowen Zhang ,&nbsp;Hailang Wan ,&nbsp;Feng Zhu ,&nbsp;Weilun Zheng ,&nbsp;Hongbo Xia ,&nbsp;Yongbing Li ,&nbsp;Yunwu Ma","doi":"10.1016/j.jmatprotec.2025.119054","DOIUrl":"10.1016/j.jmatprotec.2025.119054","url":null,"abstract":"<div><div>In the single-sided joining of thermoset carbon fiber-reinforced polymer (CFRP) and aluminum alloy, the complete penetration of the workpieces is typically required, which can lead to challenges such as difficulty in drilling through stacked layers, damage to the joint, and potential safety concerns during service. This study employs the single-sided friction riveting (SSFR) process to achieve a reliable joining between CFRP and aluminum alloy, with an emphasis on elucidating the intrinsic differences in microstructural characteristics and mechanical properties of the joints induced by threaded structures of rivets. The external threaded rivet reduces heat generation, thereby inhibiting crack formation at the thread tips and expanding the process window for defect-free joints. A systematic comparative analysis of internal and external threaded rivets on joint mechanical performance was conducted, and the key load-bearing areas were identified. Cracks in defective joints prevent the aluminum alloy filled in the thread from effectively bearing the load during tensile-shear tests. The tensile-shear failure mode of internal threaded joints was primarily characterized by the plastic deformation of the load-bearing side aluminum alloy, leading to rivet pull-out, while external threaded joints failed mainly due to tearing of the load-bearing side aluminum alloy, causing rivet pull-out. The peak tensile-shear force of defect-free internal threaded joints is 7.0 kN, with a failure displacement of 6.4 mm, which is 6.1 % and 52.4 % higher than that of external threaded joints, respectively. This work demonstrates that optimizing the rivet thread design and process parameters can effectively improve the forming quality and enhance the mechanical performance of SSFR joints.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119054"},"PeriodicalIF":7.5,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027595","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":"Synergistic enhancement of weld stability and mechanical performance in laser welding of titanium alloy by coupling ring-shaped mode and beam oscillation","authors":"Peiqing Yang ,&nbsp;Laihege Jiang ,&nbsp;Tengyi Yu ,&nbsp;Suning Zhao ,&nbsp;Geng Li ,&nbsp;Ming Gao","doi":"10.1016/j.jmatprotec.2025.119053","DOIUrl":"10.1016/j.jmatprotec.2025.119053","url":null,"abstract":"<div><div>Oscillating laser and ring-shaped laser modes have been proven effective in enhancing the process stability and joint quality of laser welding. However, their combined effects, along with the mechanisms of spatter suppression and microstructural regulation, remain largely unexplored. To address this, a novel ring-shaped mode oscillating laser welding (RMOLW) process was developed by integrating both beam modes. The influence of this novel process on the stability and microstructural characteristics of TC4 titanium alloy welds was investigated through comparative analysis. Results show that the proposed process improves the uniformity of energy density distribution along the welding path, thereby reducing undercut severity. The significant reduction in spatter is attributed to the ring-shaped laser enlarging the keyhole opening area to 0.76 mm², while beam oscillation induces stable vortex flow in the molten pool. Together, these effects effectively suppress spatter formation caused by keyhole collapse due to molten metal squeezing and covering the keyhole. The synergy between ring-shaped laser and beam oscillation reduced both the temperature gradient and cooling rate, leading to the formation of distinct microstructures in the weld zone. Due to the reduced undercut depth, the presence of strengthening basket weave microstructures, and a high fraction of high-angle grain boundaries, the welded joints produced by this novel process exhibit enhanced tensile strength and elongation. This study proposes a novel approach to enhance welding stability and microstructural characteristics, providing a foundation for advancing beam shaping strategies in laser welding.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119053"},"PeriodicalIF":7.5,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145005262","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":"Distortion suppression mechanism of laser directed energy deposition on thin sheets based on ultrasonic rolling prestressing","authors":"Chenglong Yang ,&nbsp;Yanle Li ,&nbsp;Tingyu Ge ,&nbsp;Hai Gong ,&nbsp;Shaoqi Song ,&nbsp;Heng Chen ,&nbsp;Fuzhen Han ,&nbsp;Fangyi Li","doi":"10.1016/j.jmatprotec.2025.119051","DOIUrl":"10.1016/j.jmatprotec.2025.119051","url":null,"abstract":"<div><div>Laser directed energy deposition (LDED) on thin sheet enables the fabrication of both overall geometric shape and local functional features. However, the warping and distortion of the sheet triggered by the high-energy input is the bottleneck that restricts its large-scale industrial promotion. Traditional stress regulation methods (like scan path optimization and heat treatment) have limitations in terms of high fabrication costs and low efficiency, and lack rapid distortion suppress methods based on stress neutralization. This study proposes an active distortion suppression method for laser directed energy deposition on thin sheets based on ultrasonic rolling (UR) pretreatment and establishes a multi-physics finite element model for LDED of UR prestressed sheets. Three processing strategies were designed depending on the combination mode of UR and LDED: CG (conventional group without UR), OSP (opposite side processing of UR sheets with LDED), and SSP (same side processing of UR sheets with LDED). Experimental results show that, compared with CG, the OSP strategy greatly suppressed the sheet distortion by 61.8 %, while the SSP strategy had the reverse effect. The suppression of sheet distortion essentially stems from two aspects: stress neutralization and improved material properties. Specifically, the stress coupling simulation results of OSP strategy show that due to the pre-compressive stress on the surface layer of the rolled sheet, the tensile stress of the sheet parallel to the laser scanning direction is significantly reduced, which predominates in suppressing distortion of sheet. Furthermore, microstructural observation demonstrated that the geometrically necessary dislocations density was increased for the surface layer of ultrasonic rolled sheets, and the proportion of low angle grain boundaries also increased from 5.2 % to 31.6 %. The bending strength, yield strength, and elastic modulus were improved, enhancing the resistance of the sheet to distortion, which is another significant factor in suppressing distortion. The proposed processing strategy is reliable for suppressing distortion in LDED, and provides novel insights for precision control of large parts built by additive manufacture.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"345 ","pages":"Article 119051"},"PeriodicalIF":7.5,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144997671","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 strategy for improving the formability of surface arrayed micro-grooves by constructing dual-gradient microstructures","authors":"Jiajia Wang ,&nbsp;Zhenhai Xu ,&nbsp;Shaoxi Xue ,&nbsp;Debin Shan ,&nbsp;Jie Xu ,&nbsp;Bin Guo","doi":"10.1016/j.jmatprotec.2025.119049","DOIUrl":"10.1016/j.jmatprotec.2025.119049","url":null,"abstract":"<div><div>Uniform grain refinement has been widely recognized as a strategy for enhancing the formability of surface arrayed micro-grooves by increasing the number of grains involved in the filling process. However, excessive grain refinement impeded the efficient formation of micro-grooves due to increased flow stress. In order to address this dilemma, a new strategy for constructing dual-gradient (DG) microstructures was proposed, to improve the formability of micro-grooves. This unique dual-gradient microstructure, featuring both grain size and dislocation density gradients, exhibited a soft surface (∼200 HV) and a hard core (∼350 HV). In addition, the effect of dual-gradient microstructure on the formability of micro-grooves in 316 L stainless steel was investigated by micro-rolling, in comparison with homogeneous coarse-grained (CG) and fine-grained (FG) sheets. The experimental results showed that the micro-grooves in the DG sheet achieved comparable surface quality to that of the FG sheet, while exhibiting significantly greater forming heights. Smaller differences in the surface quality and greater increases in forming heights were observed with increasing reduction or micro-groove width. Microstructural analysis revealed that the surface quality was governed by grain size, while the forming height was influenced by both the surface grain structure and through-thickness dual-gradient structure. The synergistic effect of initially favorable grain orientation of the surface grains, as well as intensified localized stress concentrations near the micro-grooves induced by the through-thickness dual-gradient structure, facilitated dislocation slip within the transverse direction-normal direction plane, thereby contributing to greater forming heights. This study offers promising a practical approach for micro-forming applications in stainless steels and other metallic materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119049"},"PeriodicalIF":7.5,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144996348","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":"Microstructural refinement and mechanical strengthening mechanism of the thin Al-Mg-Si alloy ribbons enhanced via melt spinning","authors":"Mingwei Xu ,&nbsp;Taili Chen ,&nbsp;Zihan Yang,&nbsp;Yuge Luo,&nbsp;Xiangyu An,&nbsp;Xin Luo,&nbsp;Jin Zhang,&nbsp;Zhilin Liu","doi":"10.1016/j.jmatprotec.2025.119047","DOIUrl":"10.1016/j.jmatprotec.2025.119047","url":null,"abstract":"<div><div>Effects of melt spinning process on the surface quality, microstructural evolution, phase formation, and mechanical strengthening of Al-Mg-Si alloy was investigated thoroughly. Experimental results show that the optimal nozzle diameters, nozzle-wheel gap, and wheel speed for preparing Al-Mg-Si alloy ribbons were 0.2–0.6 mm, 0.2–0.8 mm, and 1000–1400 rpm, respectively. The rapid cooling rate can be able to reach the level of 2.51 × 10⁴ K/s ∼ 1.1 × 10⁶ K/s during ribbon solidification. The average grain size of Al-Mg-Si alloy ribbon was refined to less than 10 μm. The coarsening Mg₂Si and Fe-enriched intermetallic compounds were refined to sub-micron or even nanometer scale. With the increase of wheel speeds, the size of second-phase particles became smaller and uniformly dispersed in metal matrix. The maximum microhardness of Al-Mg-Si alloy ribbon is 152 Hv, nearly 3.75 times of the conventional cast Al-Mg-Si alloy. Then, the fundamental mechanisms, responsible for the relationship between cooling rates, grain structure, texture variation, precipitates, and mechanical properties, were revealed accordingly by mathematic modelling together with multiscale characterization, and micro-nano hardness testing. This work provides some insights in preparing high-quality ribbons to architecture the bulk Al-Mg-Si alloys, which is essential for manufacturing the high precision optical and electronic components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119047"},"PeriodicalIF":7.5,"publicationDate":"2025-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144925823","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}