Journal of Materials Processing Technology最新文献

{"title":"Surface alloying of Ti-20Nb-6Ta with Cu and Ag: The critical role of laser processing in microstructure and crack formation","authors":"Silmara Mota Cardoso ,&nbsp;Guilherme de Lucena Pires ,&nbsp;Marcio Sangali ,&nbsp;Kaio Niitsu Campo","doi":"10.1016/j.jmatprotec.2025.119037","DOIUrl":"10.1016/j.jmatprotec.2025.119037","url":null,"abstract":"<div><div>Postoperative infections remain a major concern in implantology, often leading to severe complications such as osteomyelitis and implant failure. To address this issue, a surface modification strategy was developed to impart antibacterial properties to a Ti-20Nb-6Ta (wt%) alloy by incorporating Cu and Ag via laser surface alloying. Cu and Ag were first deposited onto the substrate using electrodeposition and galvanic replacement, respectively, followed by surface melting using a laser under varying power levels and scanning speeds. The effects of processing parameters on the layer composition, microstructure, and defect formation were evaluated. The modified layers primarily exhibited a β-Ti structure, with fine Ti₂(Cu,Ag) intermetallic precipitates forming in samples with higher Cu and Ag contents. Crack density decreased with increasing energy density and the application of multiple laser scans. This was attributed to a reduced thermal gradient and stress. Lower Cu and Ag concentrations were also associated with lower crack densities. A nearly crack-free sample was obtained with average Cu and Ag levels of 3.4 and 0.6 wt%, respectively. In this condition, thermodynamic calculations predicted – and experimental results confirmed – the formation of the antibacterial Ti₂Cu phase upon post-heat treatment. Additionally, the presence of Cu and Ag in solid solution within the β phase suggests potential antibacterial ion release. The results highlight the complex interplay of several processing parameters in tailoring Ti-based surfaces for biomedical applications through laser surface alloying.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119037"},"PeriodicalIF":7.5,"publicationDate":"2025-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144889264","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":"Double enhancement in porosity suppression and penetration depth during laser welding Al–Mg alloy via high-frequency outward-spiral scanning mode","authors":"Xiaojian Xu,&nbsp;Haichao Cui,&nbsp;Chendong Shao,&nbsp;Yaqi Wang,&nbsp;Fenggui Lu","doi":"10.1016/j.jmatprotec.2025.119035","DOIUrl":"10.1016/j.jmatprotec.2025.119035","url":null,"abstract":"<div><div>Achieving substantial penetration while suppressing keyhole-induced porosity remains challenging during laser welding of Al–Mg alloys. Current studies primarily address keyhole porosity by utilizing the stirring effect of the scanning laser beam on the molten pool, which reduces energy density. Herein, we developed a high-frequency outward-spiral scanning laser mode, where the laser beam within a single keyhole moves reciprocally, eliminating wall convexity. Results demonstrated that this mode effectively suppressed keyhole collapse and pore formation while maintaining higher central energy density. Specifically, the keyhole collapse frequency decreased dramatically from 137.8 Hz with a conventional laser to 8.5 Hz using the high-frequency outward-spiral scanning laser. Under scanning laser welding condition, the keyhole walls remained flat and smooth, without swelling capillary waves and humps. Concurrently, the homogenized laser energy deposition on the keyhole wall and effectively mitigated the impact of locally vaporized Mg, preventing keyhole closure and pore formation. Additionally, the elevated central energy density ensured sufficient penetration, increasing the penetration depth by approximately 30 % compared to stirring modes. In contrast with conventional laser liner welded joint, the optimal outward-spiral scanning laser welded joint exhibited superior strength-ductility synergy, and the tensile strength reaching 371 ± 2 MPa (21.0 % enhancement) with an elongation of 9.8 ± 0.3 % (69.0 % increase).</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119035"},"PeriodicalIF":7.5,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144880197","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 external magnetic field on microstructure and mechanical properties in resistance spot welding of microstructurally inhomogeneous high-pressure die casting aluminum alloy","authors":"Yuhao Wang ,&nbsp;Zhuoran Li ,&nbsp;Huihong Liu ,&nbsp;Zhenke Teng ,&nbsp;YuJun Xia ,&nbsp;Yongbing Li","doi":"10.1016/j.jmatprotec.2025.119034","DOIUrl":"10.1016/j.jmatprotec.2025.119034","url":null,"abstract":"<div><div>High-pressure die casting (HPDC) aluminum alloys are widely used in lightweight automotive body-in-white structures. In addition to large single-piece castings, segmented HPDC components joined by resistance spot welding (RSW) remain common, offering cost and manufacturing flexibility for high-volume production. However, the microstructural inhomogeneity inherent in HPDC aluminum alloys presents substantial challenges to RSW. To address this, this study employs a novel multi-pulse magnetically assisted resistance spot welding (MPMA-RSW) process, which combines multi-pulse (MP) scheduling with an external magnetic field (EMF) to enhance the weld quality of 2.5 mm AlSi7MnMg sheet joints. The results indicate that repeated melting and solidification of a microstructurally inhomogeneous base material (BM) lead to the formation of thick and low-hardness partially melted zones (PMZ) within the nugget. Cracks and low-hardness PMZ influence the fracture path of AlSi7MnMg sheet joints. The EMF creates a three-dimensional composite flow pattern inside the nugget, which interrupts the growth of columnar grain zones (CGZ), transforms directional solidification into nearly simultaneous solidification, thereby suppressing hot crack formation in the nugget, and promotes the development of high-hardness equiaxed grain zones (EGZ) that extend to the edge of the nugget. Ultimately, the MPMA-RSW process increases nugget diameter by 26.6 %, peak lap-shear force by 23.2 %, and peak energy absorption by 58.1 %. These findings validate the weldability of the new material and provide a theoretical basis for process optimization.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119034"},"PeriodicalIF":7.5,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902198","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":"Advanced laser directed energy deposition of Q690D high-strength steel using flux-cored wire: Microstructure evolution and mechanical performance","authors":"Lingyun Feng ,&nbsp;Hangbiao Mi ,&nbsp;Shinong Liao ,&nbsp;Pengcheng You ,&nbsp;Qingyong Liu ,&nbsp;Jian Wang ,&nbsp;Jinzhong Lu ,&nbsp;Wei Guo ,&nbsp;Binyan He","doi":"10.1016/j.jmatprotec.2025.119029","DOIUrl":"10.1016/j.jmatprotec.2025.119029","url":null,"abstract":"<div><div>High humidity and corrosive marine environments present substantial challenges to the durability and repair of high-strength steels. In this study, a structurally sound and defect-free repair of offshore-grade Q690D high-strength low-alloy steel was successfully achieved using a combination of flux-cored wire and laser wire-directed energy deposition technology. The repaired region was predominantly composed of lath martensite in both the deposition zone and the heat-affected zone. During the deposition process, the flux-cored wire facilitated the in-situ formation of nanoscale Ti₂C and TiC precipitates with core-shell structures through metallurgical reactions with the surrounding matrix. The repaired specimens exhibited a tensile strength of approximately 807 MPa, comparable to that of the base metal, along with a significantly enhanced flexural strength of ∼1626 MPa, primarily due to the synergistic interaction between nano-precipitates, lath martensite structures, and dislocation movement. However, Charpy impact energy at −20 ℃ decreased to approximately 52.4 % of the base material, owing to the embrittling effects of lath martensite and oxide inclusions, which facilitate void nucleation and crack propagation. These results validate the application potential of flux-cored wire assisted laser wire-directed energy deposition technology for repairing high-strength steels in marine-relevant environments, and reveal a coupled strengthening and embrittlement mechanism. This provides both mechanistic insight and practical guidance for the restoration of other structural alloys with similar service demands.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119029"},"PeriodicalIF":7.5,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144880196","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":"Binder rheology and printability in direct ink writing: A framework for hierarchically porous structures","authors":"Havva E. Aysal ,&nbsp;Eduardo M. Sosa ,&nbsp;Rakesh K. Gupta ,&nbsp;Brian Paul ,&nbsp;Chih-Hung Chang ,&nbsp;Konstantinos A. Sierros","doi":"10.1016/j.jmatprotec.2025.119033","DOIUrl":"10.1016/j.jmatprotec.2025.119033","url":null,"abstract":"<div><div>Model single and dual-binder metal inks are developed and studied for direct ink writing (DIW) of hierarchical porous metal parts. This study establishes a generalized framework for tuning ink rheology in metal DIW by linking binder molecular conformation to shear-thinning behavior, printability, and hierarchical porosity formation. These aqueous-based ink formulations leverage the unique properties of xanthan gum (XG) and hydroxyethyl cellulose (HEC), both serving as binders and viscosity modifiers with distinct conformational structures, combined with stainless-steel micro particles. A novel printability assessment methodology is introduced, integrating rheological modeling with a figure of merit and processing maps to define effective printing windows. Helical-concentrated inks (XG) exhibit stronger shear-thinning behavior and limited effective printability regions due to increased shear rate dependence than their linear counterparts (HEC). After partial sintering at 1100°C, printed parts achieve 20–34 % porosity with pore areas ranging from 3–6 µm², which are present within the struts of the printed scaffold. The resulting scaffolds feature hierarchical porosity, with open millimeter-scale lattice pores and micropores in struts, achieving total porosity of 52–80 %. Experimental investigations show tensile elastic moduli of 3.84–5.13 GPa and compression moduli of 0.06–0.97 GPa. These findings provide fundamental insights into DIW ink formulation and hierarchical porosity development, offering a transferable strategy for processing porous metallic and ceramic scaffolds in biomedical and structural applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119033"},"PeriodicalIF":7.5,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902199","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-accuracy and high-surface-quality electrical discharge machining using bipolar hybrid pulses","authors":"Hang Dong,&nbsp;Ruixiang Li,&nbsp;Qingsong Zhang,&nbsp;Jianping Zhou","doi":"10.1016/j.jmatprotec.2025.119028","DOIUrl":"10.1016/j.jmatprotec.2025.119028","url":null,"abstract":"<div><div>Electrical discharge machining (EDM) predominantly employs a single machining polarity. Generally, machining with one polarity achieves relatively high efficiency, but the accuracy and surface quality are poor. Conversely, machining with the opposite polarity can improve machining accuracy and surface quality to some extent, but it significantly reduces machining efficiency and has limited applicability in engineering. Hence, single-polarity EDM struggles to simultaneously achieve high accuracy, excellent surface quality, and good machining efficiency. This study proposes a novel bipolar EDM method that compounds positive and negative EDM via bipolar hybrid pulses. For the first time, the electrical parameters of positive and negative pulses are independently controllably adjusted, fully leveraging the polarity effects of EDM to enhance machining performance comprehensively. The mechanism of bipolar EDM is disclosed, and the influences of electrical parameters on machining performance are investigated. Results show that the compound of positive and negative pulses enables the discharge gap of bipolar EDM to be larger than that of negative EDM. This larger discharge gap facilitates the timely removal of machining debris, enhancing machining stability and further improving accuracy and surface quality. Therefore, compared with negative EDM that exhibits better accuracy and surface quality in single-polarity EDM, bipolar EDM reduces the included angle by 6.7°, surface roughness by 19.2 % and recast layer thickness by 74.8 %. Moreover, few significant pores or cracks are observed on the machined surface, and the material removal rate increases by 1.5 times. The proposed bipolar EDM method has promising applications in precision machining.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119028"},"PeriodicalIF":7.5,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144866230","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Integrated forming process of selective laser melting near-net-shaped preforms and hot gas bulging for complex-shaped AlSi10Mg alloy parts","authors":"Jiangkai Liang ,&nbsp;Gaoning Tian ,&nbsp;Shengtong Su ,&nbsp;Wei Du ,&nbsp;Yanli Lin ,&nbsp;Zhubin He","doi":"10.1016/j.jmatprotec.2025.119030","DOIUrl":"10.1016/j.jmatprotec.2025.119030","url":null,"abstract":"<div><div>To overcome the challenges associated with additive manufacturing of large-size, low-stiffness metal thin shells, specifically the difficulty in maintaining dimensional accuracy and the simultaneous occurrence of wrinkling, cracking, and thinning during fluid pressure forming, an integrated forming process of selective laser melting near-net-shaped preform and hot gas bulging was proposed. This study systematically examined the hot formability and the pre-deformed microstructure and properties of selective laser melted AlSi10Mg alloy to determine the optimal process parameters and assess the viability of the proposed integrated forming process for fabricating complex thin-walled parts. Results show that: (1) The selective laser melted AlSi10Mg alloy preforms exhibit excellent microstructural characteristics and superior hot formability, and the feasibility of forming these preforms via hot gas bulging technique was successfully validated. (2) During hot gas bulging process, the precipitation and coarsening of the Si phase, coupled with enhanced dynamic recrystallization, as well as the formation of a uniform dislocation network and deformed twinned Si phase, synergistically contribute to a significant improvement of ductility in the formed parts. (3) Compared to the direct selective laser melting technique, the integrated forming process markedly improved the dimensional accuracy and density of the fabricated parts. The dimensional deviation was reduced from 1.62 mm to below 0.28 mm, while porosity decreased from 0.36 % to 0.07 %. Despite a reduction in tensile strength, the ductility at 25 ℃ and 230 ℃ increased to 18.5 % and 32.5 %, respectively, thereby making the material highly suitable for applications requiring enhanced ductility. The feasibility of selective laser melted preforms via the hot gas bulging process was systematically confirmed, thereby establishing a foundational basis for the prospective application of this integrated forming methodology. The methodologies and insights obtained from this study hold particular significance for the fabrication of large, complex thin-walled metal components, especially in the context of demanding aerospace applications and emerging next-generation transportation systems.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119030"},"PeriodicalIF":7.5,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144866229","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":"Fatigue resistance mechanisms and energy absorption capacity of twin-boundary designed sheet-based Gyroid lattice structures built by laser powder bed fusion","authors":"Xiang Liu ,&nbsp;Lei Yang ,&nbsp;Yunlong Ren ,&nbsp;Chunze Yan ,&nbsp;Yusheng Shi","doi":"10.1016/j.jmatprotec.2025.119032","DOIUrl":"10.1016/j.jmatprotec.2025.119032","url":null,"abstract":"<div><div>Aluminum triply periodic minimal surface (TPMS) lattice structures have numerous potential applications in industrial fields such as automotive, aerospace, and military. To enhance the energy absorption capacity, crack resistance, and fatigue performance of aluminum triply periodic minimal surface (TPMS) lattice structures under compressive and cyclic compressive loads, this study designed three sheet-based Gyroid lattice structures with different orientations by adding twin boundaries. The impact of twin-boundary design on the mechanical properties of the structures was investigated through quasi-static compression tests, finite element simulations, and compression-compression fatigue tests. The results show that while the three lattice structures exhibit similar overall compressive properties, their failure processes differ. The addition of twin boundaries delays structural failure, smooths stress fluctuations during compression, and effectively alters crack propagation direction, enhancing crack resistance. Furthermore, twin boundaries contribute to higher energy absorption capacity by controlling crack propagation. Among the three structures, the double orientation fourfold Gyroid (DFG) lattice structure demonstrates the highest energy absorption efficiency before fracture and excellent fatigue crack resistance. Although the fatigue life of the double orientation fourfold Gyroid (DFG) lattice is relatively short after initial damage, its cracks remain confined to the first layer, allowing it to retain relatively good load-bearing capacity. Post-fatigue analysis reveals that the double orientation fourfold Gyroid (DFG) lattice undergoes less grain fragmentation and deformation compared to the single orientation Gyroid (SG) lattice, highlighting its superior fatigue resistance. These findings provide valuable insights for optimizing the compressive and fatigue performance of lattice structures in engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119032"},"PeriodicalIF":7.5,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144866241","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 metric for design of microstructure and mechanical properties in PBF-LB/M Ti6Al4V alloy","authors":"A.E. Medvedev ,&nbsp;S. Brudler ,&nbsp;S. Piegert ,&nbsp;T. Illston ,&nbsp;J. Noronha ,&nbsp;M. Qian ,&nbsp;M. Brandt","doi":"10.1016/j.jmatprotec.2025.119031","DOIUrl":"10.1016/j.jmatprotec.2025.119031","url":null,"abstract":"<div><div>Traditionally, volumetric energy density (<em>VED</em>) metric has been the primary tool in design and evaluation of the effect of process optimisation on microstructure and mechanical properties in additively manufactured (AM) components. However, the literature strongly indicates that <em>VED</em> often fails to accurately evaluate this relationship, even for modified versions of <em>VED</em> incorporating materials-specific parameters, such as density or thermal conductivity. This limitation stems from the inability of various <em>VED</em> definitions to account for the heat accumulation in fabricated parts. To overcome this deficiency, we propose a novel metric, normalised energy input rate (<em>NEIR</em>), which incorporates the effect of interlayer time (<em>ILT</em>) on the <em>in-situ</em> heat accumulation during AM process to reflect the microstructural and mechanical properties evolution much more accurately than <em>VED</em>. Further, we demonstrate that <em>NEIR</em> could be used to enable informed site-specific microstructural and microhardness control in laser-based powder bed fusion of metals (PBF-LB/M) of Ti6Al4V alloy, even in extremely thin sections as small as 1 mm in diameter. <em>NEIR</em> has the potential to become the enabling metric for a straightforward design and fabrication of gradient metallic meta-materials with tuneable global response to mechanical loading.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119031"},"PeriodicalIF":7.5,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144880199","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":"Enhancing gap bridging in autogenous welding of butt joints with laser beam shaping using a deformable mirror","authors":"Yongcui Mi ,&nbsp;Luigi Angelastri ,&nbsp;Fredrik Sikström ,&nbsp;Pasquale Guglielmi ,&nbsp;Gianfranco Palumbo ,&nbsp;Isabelle Choquet ,&nbsp;Antonio Ancona","doi":"10.1016/j.jmatprotec.2025.119001","DOIUrl":"10.1016/j.jmatprotec.2025.119001","url":null,"abstract":"<div><div>This work presents a novel application of deformable mirror (DM)-enabled laser beam shaping to enhance gap bridging capability in autogenous butt joint welding of stainless steel sheets. Three distinct near-Gaussian beam geometries — circular (C), transverse elliptical (TE), and longitudinal elliptical (LE) – were experimentally evaluated for their influence on weld quality. The tests were conducted across constant joint gaps up to 0.6 mm in 2.0 mm-thick AISI 316 stainless steel. The investigation demonstrates that elliptical beam shapes, particularly those with the major axis aligned in the welding direction (LE), significantly improve gap-bridging performance and weld seam consistency. Metallographic analyses, in-process top-view weld pool imaging, and microhardness profiling collectively indicate that elliptical beam shapes reduce the sensitivity of the fusion zone geometry to gap variation, enabling bridging gaps up to 30% of sheet thickness, three times the typical 10% limit. The results further reveal that effective gap bridging is governed not solely by beam radius, but critically by the spatial distribution and gradients of power density across the gap, which modulate Marangoni-driven melt flow. These findings underscore the fundamental role of adaptive beam shaping in controlling weld pool dynamics and advancing process robustness without filler material. This study represents the first systematic exploration of DM-based elliptical beam shaping in autogenous butt welding and establishes a foundational methodology for real-time adaptive beam control in laser processing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119001"},"PeriodicalIF":7.5,"publicationDate":"2025-08-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144880198","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}