Journal of Materials Processing Technology最新文献

{"title":"A novel end-to-end integrated process paradigm for fatigue life improvement in nickel-based superalloy hole structures","authors":"Lv-Yi Cheng ,&nbsp;Kai-Shang Li ,&nbsp;Run-Zi Wang ,&nbsp;Xue-Lin Lei ,&nbsp;Jia-Sheng Chen ,&nbsp;Ning Yao ,&nbsp;Cheng-Cheng Zhang ,&nbsp;Xian-Cheng Zhang ,&nbsp;Shan-Tung Tu","doi":"10.1016/j.jmatprotec.2024.118694","DOIUrl":"10.1016/j.jmatprotec.2024.118694","url":null,"abstract":"<div><div>The premature fatigue failure of hole structures poses a critical challenge in aviation components. This study introduces an end-to-end integrated paradigm, utilizing the cold expansion process (CEP) as a technological carrier to simultaneously improve both fatigue life and stability in the IN718 hole structures. Integrated process technology gains better performance than the isolated ones, where IP-CEP achieves a 2.76-fold improvement in fatigue life. This paradigm further advances to a 4.87-fold fatigue life improvement with reduced dispersions by actively integrating drilling, reaming, cold expansion, reaming, and polishing, breaking through the upper limits of CEP-series. The fatigue life improvement mechanisms are elucidated through advanced surface integrity analysis and fatigue fracture characterization. The results show that the cold expansion process induces substantial maximum compressive residual stress (CRS) and gradient plastic deformation layer, while reaming and polishing effectively improve the surface quality of cold expansion holes. Finally, a clear link between surface integrity and high-temperature fatigue life is established. The consistent enhancement in the fatigue life of the hole structure was primarily attributed to the synergistic effects of CRS, the plastic deformation layer, and superior surface quality. This study proposes an active anti-fatigue paradigm with flexible stages, providing a unified framework to balance multiple objectives for high-temperature structural applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118694"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169449","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":"Localized heating assisted laser shock peening without coating enhances mechanical properties of Ti6Al4V alloys","authors":"Qingyun Zhu ,&nbsp;Zhengxin Lu ,&nbsp;Hui Li ,&nbsp;Yaowu Hu","doi":"10.1016/j.jmatprotec.2024.118681","DOIUrl":"10.1016/j.jmatprotec.2024.118681","url":null,"abstract":"<div><div>Room-temperature laser shock peening without coating (RT-LSPwoC) is the mainstream method for surface strengthening, yet it induces tensile residual stress on the surface during rapid heating and cooling. Warm LSPwoC, combining the benefits of dynamic strain aging and LSPwoC, exhibits higher performance than RT-LSPwoC. However, overall high-temperature is time- and resource-consuming, and it is prone to causing thermal stress relaxation during processing, making it unsuitable for large-scale applications. In this paper, a novel localized heating assisted LSPwoC (LHA-LSPwoC) method, utilizing a continuous wave laser for local heating, is proposed. Additionally, the deep physics-informed neural network model, embedded with physical formulas, is designed for process optimization. It enables rapid and accurate responses for an extensive number of cases (40 cases with an average deviation below 1 %), overcoming the drawbacks of traditional numerical simulations that are time-consuming and difficult to efficiently handle numerous cases. Compared to RT-LSPwoC, LHA-LSPwoC samples have higher dislocation density and higher grain refinement, demonstrating higher hardness and residual stress, particularly superior fatigue performance. The mechanism of LHA-LSPwoC is discussed, and thermally coupled finite element simulations and molecular dynamics calculations are conducted to provide theoretical support. The proposed method is cost-effective and flexible, showing outstanding potential for industrial applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118681"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169441","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":"Bridging behavior of molten pool and its effect on defects formation in ultra-thin sheets edge welding by micro-plasma arc","authors":"Yuxiang Hong ,&nbsp;Jiaxing Gao ,&nbsp;Kai Lin ,&nbsp;Shengyong Li ,&nbsp;Baohua Chang ,&nbsp;Dong Du","doi":"10.1016/j.jmatprotec.2024.118696","DOIUrl":"10.1016/j.jmatprotec.2024.118696","url":null,"abstract":"<div><div>The molten pool behavior and weld formation in ultra-thin (thickness ≤ 0.3 mm) sheets edge welding is extremely sensitive to the variation of thermodynamic conditions, due to its unique heat transfer conditions and molten pool dynamics caused by special joint form and extremely small molten pool size. In this paper, micro-plasma arc source was applied to join the edge joint composed of two 0.12 mm thickness 304 stainless steel diaphragms. The typical molten pool bridging behavior was observed by a high-speed microphotography system. In addition, the formation mechanism of lack of fusion (LOF) defects was analyzed. The experimental results showed that common disturbances could affect the continuity and symmetry of melting process. Due to the instability raised by this melting process, the liquid bridge fails to form or to maintain, which is the major cause for undesirable weld and defects. Unlike sound weld formation process, the molten pool behaviors in LOF defects formation process could be classified into three states: temporarily discontinuous bridging (TDB), cyclically discontinuous bridging (CDB), and not only cyclically discontinuous but asymmetric bridging (CDAB). Comparing the TDB state, the backflow of molten pool under the CDB state tends to be more intense, leading to the occurrence of defects in succession. During the CDAB process, the molten pool is subject to lateral misalignment due to the gravitational component, resulting in asymmetric weld with defects. This study offers a comprehensive insight into molten pool behavior and weld formation process, which can enhance the understanding of ultra-thin sheets edge welding.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118696"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169454","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 electromagnetic self-pierce upsetting riveting with flat die for joining ultra-high strength steel and aluminum structures","authors":"Jiageng Jin ,&nbsp;Yuxuan Liao ,&nbsp;Jiachang Qin ,&nbsp;Yuanna Xu ,&nbsp;Guangyao Li ,&nbsp;Junjia Cui ,&nbsp;Hao Jiang","doi":"10.1016/j.jmatprotec.2024.118691","DOIUrl":"10.1016/j.jmatprotec.2024.118691","url":null,"abstract":"<div><div>Ultrahigh-strength steel (UHSS) is a promising material that can decrease sheet thickness and increase automobile safety. However, joining UHSS with aluminum alloys poses significant challenges to existing joining processes, such as self-piercing riveting (SPR), which often leads to rivet upsetting owing to the high strength of UHSS. This study proposes a novel joining process called electromagnetic self-pierce-upsetting riveting (ESP-UR). This method combines the piercing of a semi-hollow rivet leg in SPR with the upsetting of a rivet shank in traditional riveting, utilizing a novel rivet designed for high-strength and low-ductility steel. The effectiveness of the ESP-UR process was validated through riveting experiments involving 1.5-mm-thick 22MnB5 UHSS and 2.0-mm-thick 5052 aluminum sheets. A numerical experimental analysis and microstructural characterization were performed to characterize the joint formation mechanism. The results indicated that small protrusions created by the short rivet leg embedded in the lower sheet were compensated for by rivet cavities, resulting in a flat bottom surface of the joint. Furthermore, the hole diameter positively influenced the strength of the ESP-UR joint, with joints featuring a hole diameter of 5.8 mm exhibiting an 8.5 % increase in shear strength compared to those with a 5.6-mm diameter under a stroke of 5.0 mm. Additionally, the failure modes were analyzed and discussed. These findings provide theoretical guidance for optimizing stroke and hole diameter designs in future engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"336 ","pages":"Article 118691"},"PeriodicalIF":6.7,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169458","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":"Meshfree simulation and prediction of recrystallized grain size in friction stir processed 316L stainless steel","authors":"Lei Li ,&nbsp;David Garcia ,&nbsp;Tianhao Wang ,&nbsp;Julian D. Escobar ,&nbsp;Mayur Pole ,&nbsp;Kathy Nwe ,&nbsp;David M. Brown ,&nbsp;Kenneth A. Ross ,&nbsp;Matthew J. Olszta ,&nbsp;Keerti S. Kappagantula ,&nbsp;Donald R. Todd ,&nbsp;Neil J. Henson ,&nbsp;Erin I. Barker ,&nbsp;Eric Smith ,&nbsp;Ayoub Soulami","doi":"10.1016/j.jmatprotec.2025.118751","DOIUrl":"10.1016/j.jmatprotec.2025.118751","url":null,"abstract":"<div><div>Friction stir processing (FSP) is a promising solid-phase microstructural modification technique that can repair and enhance damaged stainless steel surfaces exposed to harsh environments. The quality of the repaired material is closely correlated to the recrystallized grain size in the stir zone (SZ), which is influenced by the thermomechanical conditions dictated by FSP process parameters. Thus, establishing a reliable relationship between these parameters and recrystallized grain size in the SZ is crucial for optimizing repair quality. However, existing experimental approaches often rely on indirect temperatures measured far from the SZ, along with rough strain rate estimations, which are imprecise and time-consuming. Meanwhile, existing mesh-based modeling methods usually face numerical challenges when dealing with the large material deformations inherent in FSP. To address these issues, this study introduces a meshfree process model for FSP based on the smoothed particle hydrodynamics (SPH) method, aimed at predicting process conditions under different parameters. The model is validated using experimental data from 11 combinations of tool traverse and rotation speeds on 316 L stainless steel. Correlations between process parameters, material flow, temperature, strain, strain rate, and recrystallized grain size are revealed through SPH simulations and electron backscatter diffraction (EBSD) imaging. The results show that <em>in situ</em> SZ temperatures range from 1071 to 1322°C, which exceed the tool temperature by over 300°C. Furthermore, SZ temperature, strain rate, and grain size increase monotonically with higher tool temperature and faster traverse speed. A relationship is then established between the model-predicted Zener-Hollomon parameter and the recrystallized grain size based on EBSD data, expressed as <span><math><mrow><mi>ln</mi><mrow><mrow><mfenced><mrow><mi>d</mi></mrow></mfenced></mrow><mo>=</mo><mtext>-</mtext><mn>0.364</mn><mi>ln</mi><mrow><mfenced><mrow><mi>Z</mi></mrow></mfenced></mrow><mtext>+</mtext><mn>14.673</mn></mrow></mrow></math></span>. This relationship exhibits satisfactory accuracy with errors of less than 26.9% in predicting grain sizes at various SZ locations, which offers valuable insights for optimizing FSP repair processes for 316 L stainless steel.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118751"},"PeriodicalIF":6.7,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175409","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":"Nano/microstructures and thermoelectric properties of silicon germanium manufactured using laser powder bed fusion","authors":"Ryan Welch,&nbsp;Sumner Gubisch,&nbsp;Saniya LeBlanc","doi":"10.1016/j.jmatprotec.2025.118749","DOIUrl":"10.1016/j.jmatprotec.2025.118749","url":null,"abstract":"<div><div>Silicon germanium alloys are high-temperature thermoelectric materials that convert heat to electricity at ∼1000 °C. Yet, the current application of silicon germanium-based thermoelectric devices is limited to niche areas due to unwieldy manufacturing processes that limit the shape of thermoelectric materials to simple cuboids and thus limit power generation potential. Laser powder bed fusion of thermoelectric materials offers the potential to fabricate freeform shapes and induce nano- and microstructures favorable for thermoelectric energy conversion. Here, we successfully fabricated undoped Si₅₀Ge₅₀ and Si₈₀Ge₂₀ parts using laser powder bed fusion and investigated the resulting structure and properties. The undoped Si₈₀Ge₂₀ alloy had a maximum thermoelectric figure of merit, <em>ZT</em>, of 0.06 at 400 °C. The laser manufactured parts exhibited p-type behavior with a measured Seebeck coefficient that changed based on the stoichiometry. Si₅₀Ge₅₀ reached a Seebeck coefficient of 588 µV/K at 50 °C while Si₈₀Ge₂₀ reached 513 µV/K at 400 °C. Oxidation during processing contributed to balling and lack-of fusion defects and was alleviated in single melt lines by washing the powder in hydrofluoric acid prior to laser processing. Processing related defects remained in bulk samples fabricated with acid treated powder, suggesting that the processing atmosphere is a primary cause of processing-induced defects. This work advances the processing of silicon germanium alloys for thermoelectric devices by uncovering the structures and thermoelectric properties of silicon germanium processed via laser-based additive manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118749"},"PeriodicalIF":6.7,"publicationDate":"2025-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174390","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 current density on electrochemical machining process of laser powder bed fusion manufactured Inconel 718","authors":"Pengfei Guo ,&nbsp;André Martin ,&nbsp;Changshuai Zhai ,&nbsp;Zuo Li ,&nbsp;Xufei Lu ,&nbsp;Jun Yu ,&nbsp;Xin Lin ,&nbsp;Inger Odnevall ,&nbsp;Michael Gibbons ,&nbsp;Andreas Schubert","doi":"10.1016/j.jmatprotec.2025.118748","DOIUrl":"10.1016/j.jmatprotec.2025.118748","url":null,"abstract":"<div><div>Electrolytic jet machining (EJM) has been widely recognized as one of the effective methods for the surface post-processing of the laser powder bed fusion (LPBF)-components. However, this concept remains challenging due to the limited machining allowance of the LPBF-components and the complexed anodic dissolution behavior, which determine the dimensional accuracy and surface quality of the machined workpiece, respectively. In this work, high current densities ( ≥ 100 A/cm²) are novelly employed to investigate the leveling ratio and transpassive dissolution behavior of LPBF-Inconel 718 for the first time. Compared to 100 A/cm², 200 A/cm² improves the leveling ratio to 58.9 % from 57.1 % when the surface roughness is less than 1 µm. However, the high current density up to 200 A/cm² still cannot inhibit the selective dissolution of the inhomogeneous microstructure, which limits further reduction of the surface roughness. A high current density leads to a rougher micro-surface on horizontal section than low current density, caused by more Nb oxides attached on the horizontal section at high current density generate from continuously distributed Nb-segregation γ phase along the machining depth direction. In addition, the local fine dendrites on vertical section result in a smooth EJM-surface, owing to the relatively uniform dissolution. This investigation provides systematic understanding of leveling process and transpassive dissolution behavior under high current density with complex surface and microstructure, which can further promote synergetic improvements of the surface integrity and dimensional tolerance through controlling the EJM parameters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118748"},"PeriodicalIF":6.7,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143173924","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on the machining mechanism and quality of an ice-coated drilling method for thin-walled parts","authors":"Huaixin Lin ,&nbsp;Gang Jin ,&nbsp;Xiaofan Deng ,&nbsp;Zhanjie Li ,&nbsp;Yuanhao Ma ,&nbsp;Guangyu Wang ,&nbsp;Feifan Hou ,&nbsp;Shaokun Luo","doi":"10.1016/j.jmatprotec.2025.118743","DOIUrl":"10.1016/j.jmatprotec.2025.118743","url":null,"abstract":"<div><div>The drilling of thin-walled parts often encounters serious issues, such as low machining dimensional and geometric accuracy, thus compromising the integrity of the hole wall surface and subsurface layer. These issues are major constraints in achieving high-quality and high-precision manufacturing in aerospace and other industries. This study proposes an innovative ice-coated drilling (ICD) method for thin-walled parts and delves into the discussion of its machining mechanism. Four typical aerospace materials with thin-walled parts were selected as the research objects. The influence of different processing methods on machining quality was comprehensively evaluated by comparing and analyzing the performance of traditional drilling (TD) and ICD in terms of the flatness, parallelism, roundness, diameter error, axial force, torque, hole wall, and chip morphology of the hole. Results show that ICD remarkably improves the flatness and parallelism of the four thin-walled parts through the cooling effect and auxiliary support function of the ice layer, and it optimizes the roundness and diameter error of the hole. Moreover, the hole wall is smooth without defects, the height of the outlet burr is greatly reduced, and the overall machining quality is remarkably improved. In addition, the presence of the ice layer not only reduces axial forces and torque but also enhances residual compressive stress. The effects of different machining methods on cutting temperature were further analyzed, and the mechanism of ICD to suppress the heat-affected zone (HAZ) was elucidated. This study provides a novel and efficient solution to the challenges of machining thin-walled parts in manufacturing fields, such as aerospace.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118743"},"PeriodicalIF":6.7,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143173919","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":"Electromagnetic hydraulic blanking flanging integrated process","authors":"Ziqin Yan ,&nbsp;Wei Wen ,&nbsp;Hanpeng Wang ,&nbsp;Chuan Zhou ,&nbsp;Guang Yang ,&nbsp;Rui Li ,&nbsp;Lihua Zhan ,&nbsp;Xiaohui Cui ,&nbsp;Ang Xiao","doi":"10.1016/j.jmatprotec.2025.118745","DOIUrl":"10.1016/j.jmatprotec.2025.118745","url":null,"abstract":"<div><div>Electromagnetic forming is a high strain rate forming method, which can significantly increase the forming limit of aluminium alloy. However, there are two problems in the process of hole flanging: (1) sheet needs prefabricated holes, which usually obtained by blanking process. (2) Different shapes of parts need different coil structures; Therefore, the forming process is complicated and the cost is high. Hence, this paper introduces an high strain rate forming method called electromagnetic hydraulic blanking flanging (EMHBF) integrated process. This process combines blanking and flanging in one device, can meet the flanging parts of various shapes and sizes under the condition of not replacing the coil, simplifying the process and reducing the production cost. A multi-physical field coupling model, encompassing electromagnetic and fluid-solid interactions, is also developed to explore changes in liquid flow patterns and the stress state of sheet metal. The influence of die structure (by changing the angle parameters of the die structure, the liquid flow direction can be regulated), discharge voltage, sheet thickness, and flanging part shape on EMHBF forming results is investigated. Variations in die structure lead to differing distributions of liquid pressure on the sheet’s upper and lower surfaces, altering liquid flow patterns and enhancing the sheet’s forming accuracy. An increase in voltage increases the sheet thickness shear stress and blanking velocity, consequently decreasing the blanking burr height. The simulated maximum forming height error was less than 9.0 %, and the maximum thickness error was less than 5.3 %. The EMHBF can meet the needs of different thicknesses and flanging part shapes for a discharge voltage of 8.5 kV. Therefore, this article provides reference rules for designing an EMHBF process. The flanging parts with high forming accuracy can be obtained in the EMHBF device by optimizing the process parameters. The essence of the EMHBF process is guiding the high-pressure and high-speed fluid movement on demand by changing the die structure and discharge voltage. In the future, EMHBF will not be limited to blanking and flanging. The blanking and other sheet deformation behavior can be achieved if the die is designed reasonably.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118745"},"PeriodicalIF":6.7,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143175408","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 double ignition strategy for enhanced efficiency in atmospheric plasma machining","authors":"Junqi Zhang ,&nbsp;Zhixian Chen ,&nbsp;Zejin Zhan ,&nbsp;Yongjie Zhang ,&nbsp;Bing Wu ,&nbsp;Yinhui Wang ,&nbsp;Hui Deng","doi":"10.1016/j.jmatprotec.2025.118746","DOIUrl":"10.1016/j.jmatprotec.2025.118746","url":null,"abstract":"<div><div>Due to the advantages of high efficiency, low cost and versatile operation, atmospheric plasma machining has drawn significant attention in the field of semiconductor and optical fabrication. Nevertheless, for conventional atmospheric plasma machining sources feature low temperature, the machining efficiency is limited due to the low gas ionization rate. This paper presents a novel double ignition strategy based on coupled coupling plasma (CCP) for enhanced radical concentration and machining efficiency. The double ignition plasma jet (DIPJ) enhances electron concentration and promotes the dissociation of fluorine radicals compared to single ignition plasma jet (SIPJ), exhibiting higher removal efficiency. Afterwards, the jet characteristics are significantly affected by regulating the electric field distribution of DIPJ through adjusting the structural parameters, which further promotes the ignition strength and radical generation. With the optimization of ignition configuration and process parameters, a Gaussian removal function can be obtained and the material removal rate (MRR) can be reached over 0.4 mm³/min at a full width at half maximum (FWHM) of 4.8 mm. The form error of a 100 × 50 mm² Si planar mirror can be reduced from 150.41 nm to 19.36 nm RMS within 7.9 min after one iteration of figuring, which demonstrates the high processing efficiency optical manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118746"},"PeriodicalIF":6.7,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143173922","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}