Journal of Materials Processing Technology最新文献

{"title":"Chatter-free milling of aerospace thin-walled parts","authors":"Xuebing Li ,&nbsp;Jing Ni ,&nbsp;Xianli Liu ,&nbsp;Caixu Yue ,&nbsp;Shuming Yang ,&nbsp;Xia Ji ,&nbsp;Steven Y. Liang ,&nbsp;Lihui Wang","doi":"10.1016/j.jmatprotec.2025.118903","DOIUrl":"10.1016/j.jmatprotec.2025.118903","url":null,"abstract":"<div><div>The milling process of aerospace thin-walled parts requires extremely high geometric precision and surface quality, as these factors significantly influence aircraft performance and operational reliability. Milling chatter not only severely compromises machined surface integrity and accelerates tool wear, but also induces catastrophic production failures and significant economic losses. Over recent decades, the machining community has dedicated substantial efforts to investigating milling chatter mechanisms and developing corresponding control strategies. Remarkable progress has been made in terms of chatter stability prediction, online condition monitoring, and active/passive suppression techniques, with the ultimate objective of achieving chatter-free milling operations. However, compared with conventional milling processes,</div><div>thin-walled part machining presents distinctive challenges due to their inherent characteristics such as low structural rigidity, poor machinability, and complex dynamics involved during milling operations (including time-varying behaviors, modal coupling, and position-dependent effects). These combined factors pose significant obstacles to effective chatter control. This paper consequently concentrates on recent advancements in milling chatter research for aerospace thin-walled parts: (i) Establishing dynamic models that accurately characterize actual milling processes by incorporating force-induced deformation and tool wear effects; integrating dynamic parameter updating techniques with probabilistic stability lobe diagram (SLD) solution approaches to provide risk-aware chatter prediction results. (ii) Leveraging multi-signal fusion and statistical analysis/artificial intelligence (AI) to realize real-time chatter condition monitoring; exploring effective measures to improve monitoring model generalization capabilities under limited sample sizes and variable operational conditions. (iii) Evaluating passive and active chatter suppression strategies systematically, combined with digital twin technology to enable seamless integration of chatter monitoring, suppression, and process optimization. (iv) Discussing milling chatter-induced part surface/sub-surface defects, with related indexes to quantify the effect of chatter marks on surface integrity. Through critical analysis of cutting-edge research and industrial applications, we further evaluate current research limitations and present promising future directions. These include innovations in chatter mechanism modeling, uncertainty quantification, physics-AI hybrid methodologies, edge-cloud-fog monitoring systems, novel materials development, metaverse-enabled human-computer interfaces, and collaborative control technologies of shape accuracy-surface integrity.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118903"},"PeriodicalIF":6.7,"publicationDate":"2025-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144071770","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":"Regulating electric field with electrode rotation to enhance surface quality in sinking electrochemical milling of groove","authors":"Xiaolei Chen ,&nbsp;Zixian Deng ,&nbsp;Juchen Zhang ,&nbsp;Zhisen Ye ,&nbsp;Yongjun Zhang","doi":"10.1016/j.jmatprotec.2025.118898","DOIUrl":"10.1016/j.jmatprotec.2025.118898","url":null,"abstract":"<div><div>This research introduces a method of regulating electric field with electrode rotation to enhance surface quality in sinking electrochemical milling of groove. A tube electrode with partial insulation on sidewall is employed, when the exposed part of tube electrode’s sidewall faces the machining area, the power supply is activated for material dissolution and then switched off if the exposed part rotates to already machined area, reducing stray corrosion. Based on the correlation between electrode rotation angle and power supply state within one full rotation, four regulation modes were developed. In mode 1, power supply keeps switch-on during a full rotation of electrode, and the on-time ratio is 100 % (360°/360°). The ratio is 50 % (180°/360°) in mode 2, as the power supply is switched on in half of rotation. It’s 40 % (144°/360°) in mode 3, and 30 % (108°/360°) in mode 4. Simulations revealed that the already machined area suffered from pulse current density with peak gradually decreased in mode 1, exposing it to low current density. This issue was effectively eliminated in other modes. Experiments showed a significant reduction of corrosion pits on already machined surface from mode 1 to mode 4, with surface roughness decreased from 2.78 μm to 1 μm. Oxygen content in the already machined area also decreased. Further analysis indicated that uneven breakdown of oxide films at low current density led to poor surface quality of already machined area, and mode 4 effectively prevented this, enhancing surface quality. This research advances sinking electrochemical milling for high-quality manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118898"},"PeriodicalIF":6.7,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070089","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":"Exploring of the effects of thermal ablation and plasma expansion on structure formation during ultrafast laser processing of Ti6Al4V alloy","authors":"Guangzhi He ,&nbsp;Jiaqun Li ,&nbsp;Haoze Han ,&nbsp;Jianfeng Yan ,&nbsp;Jiawang Xie ,&nbsp;Ma Luo ,&nbsp;Yuzhi Zhao ,&nbsp;Yanhai Cheng ,&nbsp;Ming Qiao","doi":"10.1016/j.jmatprotec.2025.118902","DOIUrl":"10.1016/j.jmatprotec.2025.118902","url":null,"abstract":"<div><div>Ultrafast laser processing has opened possibilities for surface modification of Ti6Al4V alloy, endowing them with enhanced and controllable properties. The interaction between ultrafast laser and metals is a complex process with energy transfer, material state evolution and mechanical dynamic at different spatial and temporal scales. However, the knowledge about material response of metals is still necessary to explore due to the complex ablation processes. Here, we study metal structure response induced by ultrafast laser thermo-mechanical ablation in a multi-scale perspective of micro-to-nanometer and femto-to-nanosecond region. Recast surface structure, dense crack, and nano oxidation layer are observed due to the thermal ablation after ultrafast laser processing. Hydrodynamic disturbance indued by plasma expansion contributes to the outwards ejection and recasting of molten materials to form extrusion craters and self-organized grooves. The mechanical effect induced by plasma expansion reconstructs internal structures with grain refinement and dislocation multiplication. Surface hardness is increased by multi-scale structure modification due to the thermo-mechanical ablation. Our work provides insights into the thermo-mechanical effects incurred by ultrafast laser pulse, which benefits the optimal laser conditions for precision processing, micro/nano fabrication, and surface engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118902"},"PeriodicalIF":6.7,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948448","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":"pH-driven interfacial bond dynamics enable high-efficiency low-damage polishing of fused silica with CeO2 based slurries","authors":"Fukun Li ,&nbsp;Yang Bai ,&nbsp;HaiXiang Hu ,&nbsp;Guanbo Qiao ,&nbsp;Lingzhong Li ,&nbsp;Feng Zhang ,&nbsp;Xuejun Zhang","doi":"10.1016/j.jmatprotec.2025.118896","DOIUrl":"10.1016/j.jmatprotec.2025.118896","url":null,"abstract":"<div><div>Achieving atomic-level surface integrity while maintaining a high material removal rate (MRR) remains a fundamental challenge in the polishing of fused silica due to its high hardness and brittleness. This study establishes a novel mechanistic framework for understanding how pH-driven interfacial bond dynamics govern chemo-mechanical polishing processes. By integrating multiscale experimental characterization (XPS, FTIR, Raman spectroscopy) with ReaxFF molecular dynamics simulations, we demonstrate for the first time that the dynamic equilibrium between the formation and rupture of Ce–O–Si interfacial bonds directly control removal efficiency and surface quality. Alkaline conditions enhance OH^– activity, facilitating Si–O bond hydrolysis and stable Ce–O–Si linkage formation, resulting in the highest MRR (397.6 nm/min). Acidic environments promote citrate-mediated Ce³⁺ complexation and nanocluster dispersion, enabling a rolling mechanism that achieves ultra-smooth surfaces (Sq = 0.086 nm). In contrast, neutral pH conditions suffer from PEG adsorption blocking active sites, leading to a 62 % reduction in MRR relative to alkaline systems. A 12.2-fold increase in MRR compared to SiO₂ abrasives (32.67 nm/min) confirms that chemical interfacial dynamics, rather than mechanical abrasion alone, are critical to material removal. This fundamental advancement provides a broadly generalizable theoretical basis for designing efficient, low-damage precision polishing processes across oxide-based optical materials and beyond.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118896"},"PeriodicalIF":6.7,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948447","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 evolution mechanism and strengthening mechanism of the second phase in pulsed laser welded joints of rare earth magnesium alloy","authors":"Xiaobin Zhang ,&nbsp;Bangfu Zhang ,&nbsp;Tingqu Li ,&nbsp;Yunbo Qian ,&nbsp;Xiaoxu Zheng ,&nbsp;Weifeng Xie","doi":"10.1016/j.jmatprotec.2025.118899","DOIUrl":"10.1016/j.jmatprotec.2025.118899","url":null,"abstract":"<div><div>Magnesium alloy welded joints face significant challenges in terms of high tensile properties, and behind these high tensile properties lies fundamental research on microstructure. In this paper, aiming at the problem of the second phase that is difficult to control during the welding process of magnesium alloys, pulsed laser welding was successfully carried out on Mg-5Al-2Gd-0.5Mn magnesium alloy plates. The combined technology of zonal Scanning electron microscope (SEM), transmission electron microscope (TEM) and electron backscatter diffraction (EBSD) was adopted, aiming to study the mechanism and strengthening mechanism of the entire process of the evolution of the second phase from the nanometer scale to the micrometer scale during the welding process. So as to achieve the purpose of regulating the generation of the second phase to improve the performance of the joint. The research results show that within the crystal, there are mainly circular sub-micron-sized Al₂Gd phases and rod-shaped Al₂Gd phases combined with self-phase. At the same time, there are also a small amount of post-generated ones combined with Al₈Mn₄Gd phases and Al₂Gd phases. At the grain boundary (GB), there are mainly nano-scale Al₈Mn₄Gd phases, along with a small amount of nano-scale Mg₁₇Al₁₂ and Al₁₂Mn phases. There are also clusters of sub-micron polycrystalline phases newly formed by combining Al₈Mn₄Gd phases with other phases. The average hardness and ultimate tensile strength (UTS) of the joint are 68.9 HV and 261.7 MPa, respectively. Because during the formation process of the rare earth (RE) phase with similar orientation characteristics to Mg, a large number of dislocations are absorbed, reducing the degree of plastic deformation of the material. In the magnesium alloy, the Mg₁₇Al₁₂ phase is replaced by the RE phase that is stuck within the grains and at the GB. The RE phase forms a conconsistent phase boundary with the Mg matrix, hindering the movement of dislocations. The contribution rate of the second phase strengthening is 47.7 %. At the same time, the formation of the RE phase promotes the formation of GB. The grains were refined, the contribution rate of grain boundary strengthening is 37.6 %, and the RE phase significantly improved the mechanical properties of the joint. The research result provides the necessary basic theory for regulating the complex second phase of magnesium alloys to improve the mechanical properties of magnesium alloy joints.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118899"},"PeriodicalIF":6.7,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143941836","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":"Sonotrode design and spatial-temporal configuration strategy of ultrasonic vibration for aluminum/steel resistance spot welding","authors":"Baokai Ren ,&nbsp;Kang Zhou ,&nbsp;Ping Yao ,&nbsp;Gang Wang ,&nbsp;Wenxiao Yu","doi":"10.1016/j.jmatprotec.2025.118897","DOIUrl":"10.1016/j.jmatprotec.2025.118897","url":null,"abstract":"<div><div>Exploring the rational and effective spatial-temporal configuration strategy of ultrasonic vibration for the ultrasonic longitudinal vibration-assisted resistance spot welding (UA-RSW) is significant important for the manufacture of high-strength and reliable aluminum/steel welded joints. However, systematic sonotrode design methods, spatial configurations (electrode-sonotrode geometric coupling, vibration application position), and temporal configuration (vibration duration) have been severely neglected in related work. This work proposes a systematic method for sonotrode design in UA-RSW process, achieving frequency matching between the ultrasonic excitation system and sonotrode. The effects of ultrasonic vibration application position and electrode-sonotrode combination on the macro-morphology and mechanical performance of aluminum/steel UA-RSW joints were systematically investigated. Experimental results revealed that directing ultrasonic vibrations toward the steel sheet increased energy transfer efficiency, which enhances sheet melting rate and thermal conductivity, ultimately increasing aluminum nugget diameters. Further studies demonstrated that the application of a radius-truncated electrode-sonotrode combination promoted radial Joule heat transfer and inhibited thickness reduction of the aluminum alloy sheet, achieving an average tensile-shear strength of 6.14 kN. The study on ultrasonic temporal strategy revealed that extending ultrasonic vibration duration from 350 ms to 550 ms effectively promoted grain refinement in both the aluminum melting zone and the heat-affected zone with the average grain size at the center region of the aluminum melting zone reduced by 54.3 %. Additionally, the regulation effect of ultrasonic vibration on the joint microstructure was significantly diminished after the solidification of the aluminum alloy. The experimental results demonstrated that ultrasonic vibration delayed by 100 ms post-current removal can effectively balance the IMC layer growth and grain distribution. These systematic investigations can provide both theoretical guidance and practical methodology for aluminum/steel UA-RSW in automotive applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118897"},"PeriodicalIF":6.7,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948446","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":"Understanding cutting-induced reduction in sheet metal formability: An in-situ investigation of microstructural effects","authors":"Kyung-Shik Kim ,&nbsp;Can Okuyucu ,&nbsp;Narayan S. Pottore ,&nbsp;Hong Zhu ,&nbsp;Cemal Cem Tasan","doi":"10.1016/j.jmatprotec.2025.118894","DOIUrl":"10.1016/j.jmatprotec.2025.118894","url":null,"abstract":"<div><div>Cracking during forming processes near shear-cut edges has been a major issue for the forming of advanced high strength steel sheets. The current understanding is limited by the complexity of the problem, which involves complex microstructures, stress states, and strain paths. In this work, to overcome these challenges, we have systematically investigated two quenching &amp; partitioning (QP) steel grades, focusing on the microstructural evolution during cutting and forming, using various advanced characterization techniques, including novel in-situ scanning electron microscopy and synchrotron X-ray diffraction tests. We have investigated various factors including cutting-induced roughness, sub-surface damage, austenite stability, and phase constitution. These investigations shed light on why some higher strength QP steels can exhibit better cut-edge failure resistance compared to lower strength QP grades. More specifically, it was observed that the presence of the soft ferrite phase plays a critical role in heterogeneity of micro-strain evolution, surface roughness development, damage nucleation, and the overall cut-edge behavior. In contrast, a higher strength QP steel with the larger proportion of tempered martensite and bainite has exhibited more favorable deformation characteristics following shearing. This finding thus provides a key microstructural design guideline that can be applied to various other advanced high strength steels, for alleviating the edge cracking phenomenon during forming operations.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118894"},"PeriodicalIF":6.7,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143935983","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":"Highly efficient damage recovery in MgO: Insights from plasma-enabled atomic-scale reconstruction","authors":"Yuxi Xiao ,&nbsp;Yongjie Zhang ,&nbsp;Wenjing She ,&nbsp;Zejin Zhan ,&nbsp;Jun Yang ,&nbsp;Liang Guo ,&nbsp;Hui Deng","doi":"10.1016/j.jmatprotec.2025.118886","DOIUrl":"10.1016/j.jmatprotec.2025.118886","url":null,"abstract":"<div><div>Single-crystal MgO has been extensively used in electronic devices, optical windows, and thin-film growth. However, its high hardness and brittleness pose significant challenges to efficiently obtaining a smooth and low-damage surface through conventional chemical mechanical polishing and high-temperature annealing, limiting its further industrial applications. Here, we propose a plasma-enabled atomic-scale reconstruction (PEAR) strategy to overcome these bottlenecks, enabling rapid damage recovery and achieving atomic-scale smoothness in single-crystal MgO. The damage recovery process exhibits anisotropic material flow, governed by the interplay between crystal structure and damage characteristics—a previously unreported mechanism in PEAR. Additionally, by inducing atoms’ migration and rebonding within the damaged region according to crystal properties, PEAR not only recovers micro-scale grooves with depths of 200–300 nm within 25 min of Ar plasma irradiation, but also enhances the surface and crystal quality of MgO, resulting in an atomic-scale smooth surface with an <em>S</em>a roughness of less than 0.1 nm (1 μm × 1 μm). Moreover, PEAR demonstrates crystal plane-agnostic repairability, successfully recovering laser-induced grooves on the (100), (110) and (111) crystal planes, highlighting its broad applicability in surface smoothing. This universal recovery behavior, achieved despite the crystallographic anisotropy of MgO, suggests a paradigm shift in atomic-scale processing of hard brittle oxides. Our findings establish PEAR as a transformative methodology for surface engineering of wide-bandgap single-crystal transparent materials requiring atomic-scale precision.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118886"},"PeriodicalIF":6.7,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143935984","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":"Submerged arc additive manufacturing of duplex stainless steel: Effect of intrinsic heat treatment on microstructure, mechanical properties and pitting resistance","authors":"Fangjie Cheng ,&nbsp;Manye Xue ,&nbsp;Bo Zhang ,&nbsp;Shuai Yan ,&nbsp;Shaojie Wu","doi":"10.1016/j.jmatprotec.2025.118885","DOIUrl":"10.1016/j.jmatprotec.2025.118885","url":null,"abstract":"<div><div>In the additive manufacturing of duplex stainless steel (DSS), thermal cycle and material mismatch frequently result in the imbalance between austenite and ferrite and properties deterioration. Due to the limitations of heat input and forming conditions during the wire arc additive manufacturing (WAAM) process, the improvement of the deposition efficiency faces significant challenges. In this study, submerged arc additive manufacturing (SAAM) with high deposition efficiency is utilized for the fabrication of 2209 DSS with heat inputs of 1.3 kJ/mm, 1.5 kJ/mm, 2.0 kJ/mm and 2.4 kJ/mm. The unique intrinsic heat treatment (IHT) inherent to SAAM is investigated, revealing its significant impact on the microstructure, mechanical properties, and corrosion resistance. Under the high heat input and large width-to-thickness ratio of SAAM, the deposited metal undergoes two remelting processes and multiple reheating processes. This IHT induced nitrogen loss and austenite transformation in the deposited metal, resulting in the formation of interlayer and intralayer zones with different austenite morphology. As the heat input increases, nitrogen loss intensifies and the change of travel speed alters the molten pool morphology, resulting in an increase in cooling rate. These lead to a reduction in austenite content, reaching its lowest value of 63.7 % at the heat input of 2.0 kJ/mm. Subsequently, further increases in heat input result in an increase in austenite content. The yield strength of these components is all higher than the 2205 DSS hot-rolled plates. The pitting corrosion resistance of these components decreases as heat input increases, but remains superior to that of 2205 DSS hot-rolled plates.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"341 ","pages":"Article 118885"},"PeriodicalIF":6.7,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143911567","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":"Effects of a new dual-beam oscillating laser welding technique for aluminum alloy joints: Microstructure, properties, and formation mechanism","authors":"Libo Wang ,&nbsp;Tianyu Xu ,&nbsp;Zhengwu Zhu ,&nbsp;Lin Zhang ,&nbsp;Gaoyang Mi ,&nbsp;Xiuquan Ma","doi":"10.1016/j.jmatprotec.2025.118883","DOIUrl":"10.1016/j.jmatprotec.2025.118883","url":null,"abstract":"<div><div>To optimize the welding process and joint performance of laser-welded aluminum alloys, a novel dual-beam oscillating laser welding technique was employed in this study. Specifically, by adjusting the power ratio of the composite beams and integrating the temperature field simulation, an intrinsic relationship was established among the composite beam process, microstructure, and joint performance. The results indicated that the primary laser beam ensured the welding efficiency and molten pool stability. The oscillation of the auxiliary laser achieved an orderly agitation within the molten pool, collectively refining the grains, destabilizing the grain growth, and establishing new orientations. Such a disruption led to the formation of fragmented fine grains with large grain misorientation angles and high geometrically necessary dislocation densities, as well as regulated temperature gradients in the central region and tiny equiaxed grains with dispersed orientations. Moreover, the power ratio between the primary and auxiliary beams was identified as a critical factor affecting the strength and ductility of the weld. A low power ratio induced keyhole instability, increased defects, and reduced joint performance, whereas a balanced power ratio refined the microstructure and enhanced the joint strength. With an optimal ratio of 950 W (primary) to 450 W (auxiliary), consistent penetration and stable internal oscillations were achieved, thereby improving the overall weld quality.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118883"},"PeriodicalIF":6.7,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143903871","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}