Journal of Materials Processing Technology最新文献

{"title":"Study on enhanced bonding performances and fracture mechanisms of vacuum hot-forged Ti/steel clad plates with Nb+Ni dual-interlayers","authors":"He Xiao ,&nbsp;Shaofei Ren ,&nbsp;Weifeng Liu ,&nbsp;Sheng Liu ,&nbsp;Bin Xu ,&nbsp;Mingyue Sun","doi":"10.1016/j.jmatprotec.2025.118861","DOIUrl":"10.1016/j.jmatprotec.2025.118861","url":null,"abstract":"<div><div>Ti/steel clad plate holds promising prospects in a wide range of corrosive environments, particularly in marine engineering and petrochemical industry. However, directly bonded Ti/steel clad plates typically suffer from inadequate interfacial strength due to the formation of detrimental Fe-Ti intermetallic compounds (IMCs). This study proposes the implementation of Nb+Ni dual-interlayers of varying thicknesses to suppress IMCs and enhance the bonding performances, with the bonding mechanisms and fracture mechanisms systematically unveiled. The analysis of the interfacial microstructure indicated that the initial thickness of the dual-interlayers influenced the bonding mechanism and phase distribution, thereby affecting the mechanical properties of the clad plates. The clad plate with 30 μm Nb + 50 μm Ni interlayers exhibited the highest average shear strength of 302 MPa, confirming the effectiveness of Nb+Ni dual-interlayers in overcoming the inability of directly bonded Ti/steel clad plates through hot-forging. The fracture mechanism, elucidated by the fracture observation and the interrupted tensile tests, indicated that the interfacial Ni₃Nb layer is closely related to the mechanical properties. Appropriate dual-interlayer thickness ensures the attenuation of Ni₃Nb layer and its superior deformation resistance ability is the key factor in enhanced bonding performances. These findings emphasise the critical role of Nb+Ni dual-interlayers with appropriate thickness in enhancing the mechanical properties of clad plates, offering novel insights for enhancing dissimilar metal bonding in industrial applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118861"},"PeriodicalIF":6.7,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143845260","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 dissolution behavior on electrochemical jet machining of SiCp/Al metal matrix composite","authors":"Weidong Liu ,&nbsp;Suyu Miao ,&nbsp;Min Gao ,&nbsp;Yu Zhao ,&nbsp;Yunfei Wang ,&nbsp;Yonghua Zhao","doi":"10.1016/j.jmatprotec.2025.118863","DOIUrl":"10.1016/j.jmatprotec.2025.118863","url":null,"abstract":"<div><div>Silicon carbide particle-reinforced aluminum matrix composites (SiC_p/Al) are advanced materials with challenging machinability for traditional techniques. Electrochemical jet machining (EJM), an emerging variant of electrochemical machining, offers a promising alternative for machining SiC_p/Al. Previous studies on EJM of SiC_p/Al have observed anomalous W-shaped removal profiles contradicting classical EJM theory. However, the underlying mechanisms remain unclear. This study investigates this unique phenomenon through an innovative method integrating electrochemical analysis and multiphysics simulation. Electrochemical analysis reveals special current efficiency characteristics of SiC_p/Al dissolution, which are sensitive to not only current density but also flow velocity. Additionally, a product-transport-related mechanism is proposed to elucidate the dependence of current efficiency on electric and hydraulic conditions. Increasing current density or decreasing flow velocity promotes the accumulation of electrolytic products between undissolved SiC particles, impeding matrix dissolution and reducing current efficiency. Furthermore, a multiphysics model considering the electro- and hydro-dynamics governed dissolution behavior is developed to simulate EJM of SiC_p/Al. Results indicate substantially low current efficiencies in the machined central region are induced by the synergistic effects of high current density and low flow velocity herein, thereby slowing the dissolution despite high current densities. Consequently, a central protrusion forms in the machined region, producing the observed W-shaped removal patterns. These findings provide in-depth insights into the EJM mechanism for metal matrix composites, aiding in material removal mechanism-driven machining process development.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118863"},"PeriodicalIF":6.7,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855552","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":"Bidirectional electromagnetic impact hydroforming for improved forming accuracy and material flow control in aluminum alloys","authors":"Wang Zhang ,&nbsp;Limeng Du ,&nbsp;Shaowei Ouyang ,&nbsp;Zihao Shao ,&nbsp;Xinhui Zhu ,&nbsp;Zhipeng Lai ,&nbsp;Xiaotao Han ,&nbsp;Liang Li ,&nbsp;Quanliang Cao","doi":"10.1016/j.jmatprotec.2025.118860","DOIUrl":"10.1016/j.jmatprotec.2025.118860","url":null,"abstract":"<div><div>Impact hydroforming technology has emerged as a promising approach for enhancing the forming performance of lightweight components. However, all existing methods in this area are constrained by unidirectional loading, which leads to critical challenges such as excessive thinning and low forming accuracy, particularly when forming complex geometries with large drawing ratios and curvatures. To overcome these limitations, this study introduces an innovative bidirectional electromagnetic impact hydroforming method for shaping aluminum alloy sheet metals, which combines axial and radial pulsed Lorentz forces to achieve remarkable control over material flow and forming accuracy. Comprehensive mechanical analyses reveal that the radial magnetic pressure optimizes wall thickness and deformation uniformity by reducing radial tensile stress and enhancing circumferential compressive stress in the flange. This approach results in a remarkable 44 % improvement in the maximum forming height of sheet metals in a free bulging process under the test conditions, compared to conventional unidirectional methods. Furthermore, the proposed method is successfully applied to form concave-bottomed cylindrical components, where radial magnetic pressure significantly suppresses localized thinning, mitigates necking, and prevents cracking. Notably, the maximum die-fitting gap is reduced from 8 mm to just 0.3 mm, while maintaining a thinning rate below 20 %, demonstrating good forming performance. These results highlight that the novel process, which integrates high strain rate loading, liquid medium, and highly controllable electromagnetic characteristics, offers a new forming method for achieving high accuracy, low-thinning ratio, and high-efficiency manufacturing of complex thin-walled components. This method holds significant potential for applications in industries such as aerospace, automotive, and advanced manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118860"},"PeriodicalIF":6.7,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143881637","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":"Impact of beam shaping on melt pool behavior in laser processing of stainless steel 316L: Thermal analysis using multispectral imaging","authors":"Ruihang Dai,&nbsp;Bicheng Yang,&nbsp;Katrin Wudy","doi":"10.1016/j.jmatprotec.2025.118835","DOIUrl":"10.1016/j.jmatprotec.2025.118835","url":null,"abstract":"<div><div>In Laser-based Powder Bed Fusion of Metals (PBF-LB/M), melt pool temperature distributions directly impact process dynamics and final part quality. While ring-shaped laser beam profiles promise improved melt pool stability, their effect on melt pool temperature remains unclear due to inaccurate absolute temperature measurements. To address this, we employ an in-house off-axial Multispectral Imaging (MSI) system (mean relative error less than 1.6%) to enable in-situ measurement of absolute melt pool temperatures and thermal gradients in 316L stainless steel. Comparing Gaussian and ring-shaped beams, we find that the Gaussian beam creates a concentrated heat zone with linearly increasing peak temperatures with increasing power under conduction mode. In contrast, the ring-shaped beam induces surface melting at lower power and full melting at higher power, resulting in a half-moon-shaped temperature distribution. Thermal gradient (indicative of Marangoni flow) reveals that the Gaussian beam generates stronger gradients (4–25 <span><math><mrow><mi>K</mi><mo>/</mo><mi>μ</mi><mi>m</mi></mrow></math></span>), driving circular Marangoni flow and bowl-shaped melt pools. The ring-shaped beam produces weaker gradients (2–18 <span><math><mrow><mi>K</mi><mo>/</mo><mi>μ</mi><mi>m</mi></mrow></math></span>), leading to flatter melt pools at low power and semi-elliptical melt pools at high power. This study provides critical insights into optimizing beam shaping strategies, broadening application possibilities, and deepening the understanding of melt pool dynamics in PBF-LB/M.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118835"},"PeriodicalIF":6.7,"publicationDate":"2025-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143845258","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-isothermal forming limits of press-hardening steels during hot stamping","authors":"Pedram Samadian ,&nbsp;Ryan George ,&nbsp;Constantin Chiriac ,&nbsp;Cyrus Yau ,&nbsp;Clifford Butcher ,&nbsp;Michael J. Worswick","doi":"10.1016/j.jmatprotec.2025.118857","DOIUrl":"10.1016/j.jmatprotec.2025.118857","url":null,"abstract":"<div><div>The development of modern lightweight vehicles necessitates the use of press-hardening steels (PHSs) that can enhance occupant safety while reducing fuel consumption due to their exceptional strength and energy-absorption capabilities. The objective of this study is to develop a methodology to determine the hot formability of PHSs during non-isothermal hot-stamping processes and to gain insights that can be broadly applied across different material systems. The work is focused on an Al-Si coated PHS grade with 1800 MPa tensile strength in the hot-formed condition, designated as PHS1800. The hot formability tests were performed <em>via</em> the Marciniak test setup with a quenching carrier blank using in-situ stereo digital image correlation (DIC) strain measurements. The dependence of formability on the hot-stamping conditions was systematically examined by altering the initial forming temperature, punch speed, and cooling rate within the ranges of 600–750 °C, 10–40 mm/s, and 20–50 °C/s, respectively. To predict the non-isothermal forming-limit curves (FLCs), a numerical modeling scheme based on the Marciniak-Kuczyński (MK) theory was established that incorporates the evolution of temperature and strain rate during hot forming. A process-dependent function was proposed for the initial imperfection factor to predict the FLCs for a wide range of hot-stamping conditions beyond those considered in the model calibration. The Marciniak test procedure provided approximately linear strain paths within a strain-state range from uniaxial drawing to equibiaxial stretching. The measured limit strains revealed that the formability increases with the initial forming temperature and is reduced with increases in the forming speed and cooling rate. The predicted FLCs were in close agreement with the measured limit strains as functions of the initial forming temperature, speed, and cooling rate. The developed numerical scheme provides a predictive tool to calculate variations in the non-isothermal limit strains of press-hardening steels during elevated-temperature forming, which is crucial for optimizing tooling design and process parameters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118857"},"PeriodicalIF":6.7,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855551","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":"Review of vibration texturing","authors":"Peiyuan Ding ,&nbsp;Pingfa Feng ,&nbsp;Kaiyue Wu ,&nbsp;Jiahui Liu ,&nbsp;Qilin Li ,&nbsp;Jianfu Zhang ,&nbsp;Yaoke Wang ,&nbsp;Jianjian Wang","doi":"10.1016/j.jmatprotec.2025.118851","DOIUrl":"10.1016/j.jmatprotec.2025.118851","url":null,"abstract":"<div><div>Driven by engineering demands and human curiosity, over the past two decades, functional surface micro/nanostructures have emerged as a popular research direction to regulate the interaction between objects and their environment. With the gradual development of micro/nanostructure design, manufacturing technology has become a bottleneck restricting their application, stemming from their small scale and low machining efficiency. Vibration texturing technique has shown significant promise because of its capability to effectively address the challenges of scale and efficiency in micro/nanostructure fabrication. The scientific challenge for vibration texturing lies in comprehensive understanding of the formation mechanism and achieving the desired micro/nanostructures through the rational matching and precise control of process parameters to meet the demands of various structural geometries across different application fields. However, systematic reviews on vibration texturing with respect to the latest research developments and prospects are still lacking. This review presents the recent progress in vibration texturing, in particular, advances over the past decade, focusing on the structural formation mechanism and process design. The existing vibration texturing processes are categorized into five main types; namely, dimpling, chiseling, indenting, scribing, and grooving, based on the formation mechanisms of structure. Finally, the applications and future perspectives of vibration texturing are summarized and discussed.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118851"},"PeriodicalIF":6.7,"publicationDate":"2025-04-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143845261","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":"Interlayer time as a robust, geometry-agnostic predictor of microstructural and mechanical properties evolution in PBF-LB/M Ti6Al4V alloy","authors":"A.E. Medvedev ,&nbsp;S. Brudler ,&nbsp;S. Piegert ,&nbsp;T. Illston ,&nbsp;M. Qian ,&nbsp;M. Brandt","doi":"10.1016/j.jmatprotec.2025.118858","DOIUrl":"10.1016/j.jmatprotec.2025.118858","url":null,"abstract":"<div><div>Process optimisation during laser-based powder bed fusion of metals (PBF-LB/M) has in the past been shown to offer a large amount of control over microstructure and mechanical properties of materials, especially in the ability to utilise the <em>in-situ</em> thermal treatments, facilitated by heat accumulation during the fabrication process. Interlayer time (<span><math><mi>ILT</mi></math></span>) in PBF-LB/M of Ti6Al4V titanium alloy was previously shown to play a significant role in controlling the final microstructure, however, was also prone to occasional impurity pick-up facilitated by an increase in part temperature during the fabrication. However, a systematic understanding of the interplay between <span><math><mi>ILT</mi></math></span>, process parameters, build size, heat accumulation and impurity pick-up was lacking. Here, we evaluated the effect of <span><math><mi>ILT</mi></math></span> in a wide range (10 – 73 s) as well as part geometry on the evolution in microstructure, mechanical properties and residual stresses generated in PBF-LB/M Ti6Al4V. This study confirms that <span><math><mrow><mi>IL</mi><mi>T</mi></mrow></math></span> &lt; 40 s is linked to dramatic heat accumulation, significant microstructure coarsening as well as reduction in strength and residual stresses, while further reduction to as low as <span><math><mrow><mi>IL</mi><mi>T</mi></mrow></math></span> ≈ 10 s led to sample glow, surface discoloration and impurity pick-up with consequent increase in hardness and embrittlement, manifesting a crucial limitation on the <em>in-situ</em> heat treatment implementation through <span><math><mi>ILT</mi></math></span> control. We further demonstrate that this limitation can be overcome by reducing the cumulative track length per unit volume (via using thicker powder layers and/or wider hatch spacing), which, despite achieving higher overall average temperatures, acquired less impurities due to fewer melting/exposure cycles during fabrication of identical size parts. Further, by virtue of minimising the number of expansion/contraction cycles per part, this approach was shown to be highly effective in reducing the magnitude of residual stress generated in parts. Most importantly, this work demonstrated that the effect of <span><math><mi>ILT</mi></math></span> on the microstructure and mechanical properties of PBF-LB/M Ti6Al4V is largely agnostic to the global part geometry and/or a number of parts in a build, even for vastly different process parameter combinations. This indicates a significant potential for the future development of a new <span><math><mi>ILT</mi></math></span>-derived process optimisation metric for direct and informed design of microstructure and properties in PBF-LB/M Ti6Al4V.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118858"},"PeriodicalIF":6.7,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143824076","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":"Macroscopic and microscopic deformation mechanism of cup-shaped part made of difficult-to-deform metal during the current-assisted flow spinning process","authors":"Can Chen ,&nbsp;Gangfeng Xiao ,&nbsp;Qinxiang Xia ,&nbsp;Junhao Zhang ,&nbsp;Sizhu Cheng","doi":"10.1016/j.jmatprotec.2025.118859","DOIUrl":"10.1016/j.jmatprotec.2025.118859","url":null,"abstract":"<div><div>Cup-shaped parts with different thin-walled thickness structures are an essential transmission component for the harmonic reducer in aerospace and intelligent robotics engineering. However, those cup-shaped parts are usually prepared from a difficult-to-deform metal with high deformation resistance and poor plasticity at room temperature. This paper explores a current-assisted flow spinning (CAFS) method to reduce deformation resistance, improve plasticity, and promote grain refinement through electroplasticity. To reveal the mechanism of pulse current on macroscopic and microscopic deformation mechanism, a finite element model coupled with the electroplasticity effect is constructed; an experimental platform for the current-assisted flow spinning is set up, and a series of process experiments are carried out. The results show that the current density of the cup-shaped blank is concentrated near the contact area of the roller, so the softening region, due to the electroplasticity effect, highly overlaps with the deformation region of the cup-shaped blank. Thus, as the current intensity increases, the stress and the dangerous area of the cup-shaped part decreases, improving the forming quality of the spun workpiece. In addition, the gradual decrease of the current density along the axial direction from the mouth to the bottom makes the grain refinement accelerated by the electroplasticity effect at the mouth higher than that at the middle, which partially eliminates the uneven microstructure along the axial direction caused by the uneven deformation. The tensile strength and hardness of the spun workpiece under pulse current conditions increase by 8.49 % and 7.42 %, respectively. These findings provide an important theoretical basis for the current-assisted forming process to prepare high-performance and high-precision complex components made of difficult-to-deform metal.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118859"},"PeriodicalIF":6.7,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847962","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":"Stabilization mechanism of arc behavior and droplet transition in laser-arc hybrid welding of NS70 magnesium alloy","authors":"Yunhao Liu ,&nbsp;Xiaojie Cui ,&nbsp;Yanqiu Zhao ,&nbsp;Xiong Zhang ,&nbsp;Peng Li ,&nbsp;Peiyun Xia ,&nbsp;Xiaohong Zhan","doi":"10.1016/j.jmatprotec.2025.118856","DOIUrl":"10.1016/j.jmatprotec.2025.118856","url":null,"abstract":"<div><div>The welding stability for magnesium alloy presents a significant challenge owing to the inherent softness of the welding wire and the propensity for high vaporization rates. The arc behavior and droplet transition, serving as pivotal indicators of welding stability, are mainly concerned. This study conducted laser-arc hybrid welding experiments on NS70 magnesium alloy, a novel lightweight material. The welding process was monitored using multi-source information from infrared temperature measurement, spectroscopy, and high-speed camera imaging. A comparison was made between the droplet transition behaviors during laser- metal inert gas (MIG) and laser-cold metal transfer (CMT) welding processes. The variations in arc plasma morphology, molten pool temperature, and ionization intensity were synchronously detected and quantitatively analyzed. The study investigated the effects of welding current and laser power on arc characteristics and droplet transition behavior in the CMT arc mode. Optimal process parameters were determined based on the weld seam surface quality and porosity rate. The results indicate that the increase of welding current enlarges the arc area, but disturbs plasma morphology. At a current of <em>I</em>= 65 A, the droplet transition frequency increased by 60.4 % compared to that under <em>I</em>= 35 A, and the fish scale density increased by 99.2 %. Analysis of the droplet transfer behavior during the wire feeding and withdrawal phases reveals that a welding current of 35 A and a laser power of 1900 W mitigate the intense droplet impact on the molten pool and the issue of incomplete droplet transfer. These findings provide a reliable basis for industrial welding production of NS70 magnesium alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118856"},"PeriodicalIF":6.7,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143828507","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":"Study of viscous layer in friction welding of Fe/Al dissimilar metals: Formation, evolution and effect on joint properties","authors":"Shuai Gong ,&nbsp;Shuhai Chen ,&nbsp;Gaoyang Yu ,&nbsp;Guocheng Shao ,&nbsp;Jihua Huang ,&nbsp;Jian Yang ,&nbsp;Pishi Chen","doi":"10.1016/j.jmatprotec.2025.118850","DOIUrl":"10.1016/j.jmatprotec.2025.118850","url":null,"abstract":"<div><div>In friction welding of aluminum alloys to steel, an interlayer consisting of thermoplastic metal is formed at the interface. However, the current research on this interlayer is still insufficient. In this paper, two different welding control methods are designed using self-developed welding equipment, the control method of “Rotating and Separating after welding” and the control method of “Stopping immediately after welding”. Rotary friction welding of aluminum alloys to steel has been investigated by combining the two control methods. The results show that in rotary friction welding of aluminum alloys to steel, an interlayer consisting of thermoplastic aluminum is formed at the interface, which is called the viscous layer. The formation and evolution of the viscous layer are summarized and quantified by comparing the interface morphology obtained at different times and by different control methods. It was found that the viscous layer first formed at the 1/2–2/3 position of the friction interface, then spread across the interface and finally covered the entire friction interface. At the same time, the interface friction state was changed due to the formation of the viscous layer. The interface friction gradually changed from Coulomb friction between aluminum alloy and steel to adhesive friction between aluminum alloy and viscous layer. It was also found that the viscous layer had an important contribution to the formation of welded joints. The coverage area of the viscous layer, the metallurgical reaction between the viscous layer and the steel, and the microstructure of the viscous layer are the main factors affecting the strength of the joint.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118850"},"PeriodicalIF":6.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143824077","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}