Journal of Materials Processing Technology最新文献

{"title":"Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction","authors":"Jhoan Guzman ,&nbsp;Kaue C. Riffel ,&nbsp;Martin McDonnell ,&nbsp;Jeffrey Bunn ,&nbsp;Andrew Payzant ,&nbsp;Doug Kyle ,&nbsp;Antonio J. Ramirez","doi":"10.1016/j.jmatprotec.2026.119198","DOIUrl":"10.1016/j.jmatprotec.2026.119198","url":null,"abstract":"<div><div>Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119198"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145903991","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":"Liquid-bridge regulation in femtosecond laser-assisted meniscus-confined electrodeposition","authors":"Wanfei Ren ,&nbsp;Hao Jiang ,&nbsp;Wanfei Ren ,&nbsp;Zhaoqiang Zou ,&nbsp;Ningqian Tang ,&nbsp;Pingmei Ming","doi":"10.1016/j.jmatprotec.2026.119237","DOIUrl":"10.1016/j.jmatprotec.2026.119237","url":null,"abstract":"<div><div>Complex metal microstructures hold significant application potential in aerospace and biomedical engineering, yet their fabrication is hindered by critical challenges, particularly in achieving ultra-precision machining and realizing precise regulation of structural contours and surface morphologies at the micrometer scale. To address these issues, this study proposes an innovative femtosecond laser-assisted liquid-bridge regulation strategy for the high-quality and regulable fabrication of metal microstructures via electrodeposition. The core scientific advantage of this approach lies in its utilization of the femtosecond laser-induced photothermal effect, which enables active and non-contact regulation of the liquid-bridge contour a key breakthrough for precise regulation over the dimensions of deposited structures. Leveraging this regulable liquid-bridge regulation strategy, a variety of complex three-dimensional (3D) metal microstructures have been successfully fabricated. Microscopic characterization confirms that the fabricated microstructures possess dense interiors free of macroscopic defects; furthermore, the in-situ formation of nanocrystals and nanotwins endows these structures with excellent mechanical properties. This work provides a novel technical route for the dynamic regulation of electrodeposited structure dimensions, thereby substantially advancing the manufacturing capacity for complex metal microstructures and offering valuable insights for the broader research community in related fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119237"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074200","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":"Direct preparation of laser-induced doped graphite films on glass surfaces under domain-limiting effect for photonic debonding","authors":"Wenxue Dai ,&nbsp;Fangcheng Wang ,&nbsp;Ping He ,&nbsp;Huijuan Liu ,&nbsp;Chenghao Ma ,&nbsp;Qiang Liu ,&nbsp;Mingqi Huang ,&nbsp;Guoping Zhang ,&nbsp;Bingpu Zhou ,&nbsp;Rong Sun","doi":"10.1016/j.jmatprotec.2026.119214","DOIUrl":"10.1016/j.jmatprotec.2026.119214","url":null,"abstract":"<div><div>Constructing doped carbon-based multifunctional films with stable structures and excellent adhesion on glass substrates represents a core challenge and research focus in contemporary materials processing. Traditional high-temperature fabrication processes often suffer from aging and agglomeration of dopant particles, leading to reduced film structural uniformity and severely limiting their application potential in broad-spectrum light absorption and efficient thermal management. Here, we propose an in situ preparation method for laser-induced doped graphite films (LDGF) based on the domain-limiting effect, enabling the one-step construction of multifunctional release layers on glass surfaces. This approach utilizes the localized transient thermal field and non-equilibrium dynamics induced by ultraviolet lasers to promote the formation of stable interlayer bridging structures between metal ions and heteroatoms within the defective carbon matrix. The photothermal shock resistance of the LDGF film stems from the interfacial adhesion established through local substrate re-deposition and is further enhanced by the mechanical reinforcement imparted by metal ion bridges. Meanwhile, LDGF exhibits outstanding optical absorption performance (200–1200 nm, &gt;91.99 %), coupled with extremely low light transmittance (&lt;0.01 %). Experiments further demonstrate that LDGF reduces the photonic debonding threshold for identical bonding pairs by approximately 41 %, significantly broadening the applicability and operational window of photonic debonding processes. This laser-induced doping graphitization strategy provides an innovative and feasible material preparation pathway for photothermal conversion layers required in wafer-level and panel-level photonic debonding technologies for advanced packaging.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119214"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034849","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":"Synchronous multidirectional extrusion based on uniaxial load assembled toggle-arm mechanisms: A case study on 2195 Al-Li alloy","authors":"Peng Jia ,&nbsp;Xusheng Chang ,&nbsp;Xiaoyu Shen ,&nbsp;Zhuoxun Yi ,&nbsp;Yushi Qi ,&nbsp;Gang Chen ,&nbsp;Qiang Chen","doi":"10.1016/j.jmatprotec.2026.119221","DOIUrl":"10.1016/j.jmatprotec.2026.119221","url":null,"abstract":"<div><div>Synchronous extrusion from independent directions for each port is a potential approach for manufacturing multidirectional structural components (MDSCs). However, its universality and flexibility are limited by the need for specific forming devices, and the accuracy constraints of these devices may lead to folding defects and non-uniform microstructures. To address these challenges, this study proposes a synchronous multidirectional extrusion (SMDE) method based on uniaxial load. The uniaxial load is synchronously decomposed and redirected into multiple independent movements by toggle-arm mechanisms. This method allows excellent flexibility in manufacturing MDSCs since almost arbitrary load direction is available by adjusting the angle and size of the toggle-arm. Moreover, the load synchrony will be easier enabled by the rigidity of toolsets rather than the accuracy of the devices. The feasibility of SMDE was demonstrated by manufacturing an MDSC with square ports and orthogonal ribs using 2195 aluminum-lithium alloy. The investigations in material flow and microstructures at different forming stages revealed non-uniform forming mechanisms influenced by the nonlinear kinematic characteristics and multidirectional discrepancies. Results show that the progressive reduction in horizontal velocity, combined with additional compression, reduces inter-directional variations in height of thin-walled ports, improving the dimensional accuracy. Meanwhile, the active control of nonuniform deformation with additional compression promotes uniform dynamic recrystallization and grain refinement, leading to uniform microstructures and near-isotropic properties across the ports. The average yield strength, ultimate tensile strength, and elongation were tested to be 487.4 MPa, 529.4 MPa and 8.2 %, respectively. Moreover, the strength heterogeneity of the tested ports was calculated to below 1.39 %. This work provides theoretical and experimental guidance for optimizing of multidirectional load paths and actively controlling nonuniform deformation, and offers a novel and efficient method for the precision forming of MDSCs with arbitrary orientations.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119221"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035333","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":"Cathode jet and columnar grain suppression in oscillating arc-wire directed energy deposition of titanium alloy","authors":"Kang Sun ,&nbsp;Xiao Xiao ,&nbsp;Shigeaki Uchida ,&nbsp;Pengkang Zhao ,&nbsp;Dongsheng Wu ,&nbsp;Hisaya Komen ,&nbsp;Ning Ma ,&nbsp;Keke Zhang ,&nbsp;Manabu Tanaka ,&nbsp;Huijun Li","doi":"10.1016/j.jmatprotec.2026.119215","DOIUrl":"10.1016/j.jmatprotec.2026.119215","url":null,"abstract":"<div><div>As titanium is a thermionic cathode material, strong cathode jet can easily be caused by gas metal arc welding (GMAW)-based directed energy deposition (DED) of titanium alloys. Additionally, during the DED process, coarse columnar grains are prone to form, which severely affects the performance of the deposited titanium components. Therefore, it remains a challenge to fabricate high-performance titanium alloy components using GMAW-based DED. In this work, these obstacles can be overcome using an oscillating arc. Additionally, the influencing mechanisms of the oscillating arc on the cathode jet, droplet transfer, molten pool flow, microstructure, and mechanical properties were investigated. Experimental and simulation results indicated that the metal vapor near the welding wire in conventional GMAW-based DED was primarily composed of Ti ion (Ti Ⅱ) particles, while the cathode jet was mainly composed of Ti atom (Ti Ⅰ) particles. The oscillating arc reduced the molten pool temperature and caused the cathode jet to move away from the droplet. It also shifted the peak intensity of Ti atom particles from the molten pool to the welding wire, while promoting the ionization of a large number of Ti atom particles into Ti ion particles in the cathode jet region. The oscillating arc also promoted convection in the molten pool and altered the flow patterns, which increased the cooling rate and thereby refining the β and α grains. Oscillating cold metal transfer (CMT)-based DED significantly improved the mechanical properties of Ti6Al4V alloy. This work provides new perspectives and guidance for the engineering applications of GMAW-based DED of titanium alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119215"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146035332","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":"Fast shot speed–dependent defect evolution in high-pressure die casting: Coupled roles of externally solidified crystals and cavity-formed α-Al","authors":"Lei Liu ,&nbsp;Guantao Wang ,&nbsp;Kai Zhao ,&nbsp;Kaiyang Li ,&nbsp;Yanqiang Li ,&nbsp;Huanyue Zhang ,&nbsp;Tao Zhang ,&nbsp;Ying Fu ,&nbsp;Zhirou Zhang ,&nbsp;Enyu Guo ,&nbsp;Huijun Kang ,&nbsp;Zongning Chen ,&nbsp;Jianru Fang ,&nbsp;Tongmin Wang","doi":"10.1016/j.jmatprotec.2026.119228","DOIUrl":"10.1016/j.jmatprotec.2026.119228","url":null,"abstract":"<div><div>Microstructural inhomogeneity and associated mechanical property fluctuations are inherent challenges in high-pressure die casting (HPDC), with origins difficult to elucidate due to coupled solidification and melt flow. In this study, the microstructural response of an HPDC AlSi10MnMg alloy to varying fast shot speeds was investigated using a TiB₂-assisted strategy to modify nucleation behavior in the shot sleeve and die cavity, enabling decoupling of the roles of externally solidified crystals (ESCs) and cavity-formed α-Al ((α-Al)_II) in defect formation. The results show that ESCs exhibit opposite responses to increasing fast shot speed. When ESCs nucleate near the shot sleeve wall, higher fast shot speed reduces ESCs content and size, whereas when ESCs are more uniformly dispersed in the melt, increasing fast shot speed promotes their transport into the die cavity, resulting in increased ESCs content. Under thermal-gradient-dominated solidification in die cavity, increasing fast shot speed leads to an inward shift and widening of segregation bands, accompanied by a reduced porosity volume fraction and increased pore number density. In contrast, when heterogeneous nucleation in the die cavity is promoted by TiB₂ addition, segregation-band position remains stable with band widening, while both porosity volume fraction and pore number density decrease, even though ESCs content increases. These defect evolutions are associated with systematic variations in strength and ductility. This work presents a process-based perspective for defect control in HPDC by decoupling microstructural variables under coupled melt flow and solidification, which may extend to other forming processes where flow and solidification are coupled.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119228"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034900","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":"In situ surface rejuvenation and plasticity enhancement of Zr-based bulk metallic glass by high-speed cutting","authors":"Feng Ding ,&nbsp;Pingjun Tao ,&nbsp;Tao Zhang ,&nbsp;Zijian Lai ,&nbsp;Hongye Wu ,&nbsp;Jun Wang ,&nbsp;Lijuan Zheng ,&nbsp;Xi Shen ,&nbsp;Chengyong Wang","doi":"10.1016/j.jmatprotec.2026.119232","DOIUrl":"10.1016/j.jmatprotec.2026.119232","url":null,"abstract":"<div><div>Zirconium-based (Zr-based) bulk metallic glasses (BMGs) are promising structural materials, but their application is hindered by their intrinsic brittleness, which arises from shear localization. This work presents an <em>in situ</em> surface engineering strategy that simultaneously shapes and functionally enhances Zr-based BMGs by harnessing the strong thermomechanical coupling associated with high-speed cutting. It is demonstrated that even at cutting speeds up to1600 m/min, high-speed cutting kinetically suppresses crystallization while spontaneously inducing structural rejuvenation in the machined subsurface. Multiscale characterization reveals that this rejuvenated state, characterized by reduced atomic ordering and increased free volume, drives a fundamental transition in the mechanical deformation mechanism: the volume of the shear transformation zone is refined, promoting a shift from highly localized shear banding to more homogeneous plasticity. Consequently, the engineered subsurface exhibits dramatically enhanced damage tolerance, with both plastic instability strain and energy absorption capacity prior to failure doubled compared to the as-cast state. This study establishes clear process–structure–property relationships, demonstrating that high-speed cutting is a versatile in situ manufacturing platform for tailoring the functional surface properties of BMGs. This approach bridges geometric shaping with property engineering, offering an efficient route for fabricating high-performance BMG components for advanced engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119232"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074199","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":"Crack-free additive manufacturing of Ni-based superalloy IN713LC with enhanced performance via high-temperature thermal field assistance","authors":"Shuai Liu ,&nbsp;Xin Wen ,&nbsp;Changsheng Liu ,&nbsp;Zhikang Xia ,&nbsp;Yongqiang Wang ,&nbsp;Chao Yuan","doi":"10.1016/j.jmatprotec.2025.119174","DOIUrl":"10.1016/j.jmatprotec.2025.119174","url":null,"abstract":"<div><div>High-temperature thermal-field-assisted additive manufacturing (AM) has been applied to several γ′-rich Ni-based superalloys, yet a generalizable parameter selection scheme, quantitative defect regime mapping, and fundamental understanding of microstructural evolution remain elusive. Here, IN713LC is used as a representative alloy and fabricated via induction-heating-assisted laser directed energy deposition (IH-LDED) to address these gaps. Crack-free and dense builds were achieved at process temperatures between the γ′ precipitation threshold and the solidus, using 70–80 % of the theoretical melting energy density. A crack-type competition mechanism, governed by the coupling of temperature and energy density, was revealed. Elevated temperatures promoted γ′ homogenization and eliminated γ/γ′ eutectic, suppressing liquation cracking and preventing ductility-dip cracking. Strain-age cracking was dominated by notch effects, transformation stresses, or thermal stresses under different conditions. Low energy input caused local oxidation, whereas super-solidus temperatures triggered rapid semi-solid oxidation and a novel feedback loop, both leading to oxidation-induced cracking. As process temperature increased, solute-driven differential lattice expansion modified γ/γ′ misfit from 1.1 % at 1100°C to −4.1 % at 1200°C, strengthening the coherent strain field. This shifted γ′–dislocation interactions from long-range cooperative shearing to short-range shearing and Orowan bypass, enabling tailored strength–ductility combinations. These findings establish a generic process–defect–microstructure–performance framework, offering mechanistic and transferable insights into additive manufacturing of non-weldable superalloys (e.g., performance customization and quantitative defect analysis).</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119174"},"PeriodicalIF":7.5,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749018","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":"Role of laser beam shape and energy density in modulating surface quality, porosity, microstructure, and mechanical properties of PBF-LB/M Ti-6Al-4V","authors":"Abid Ullah ,&nbsp;Alexander E. Medvedev ,&nbsp;Dirk Herzog ,&nbsp;Andrey Molotnikov ,&nbsp;Tingting Liu ,&nbsp;Ingomar Kelbassa ,&nbsp;Milan Brandt","doi":"10.1016/j.jmatprotec.2026.119197","DOIUrl":"10.1016/j.jmatprotec.2026.119197","url":null,"abstract":"<div><div>Beam shaping has recently gained attention as a means to mitigate the thermal gradients and melt-pool instabilities associated with conventional Gaussian beams in laser powder bed fusion (PBF-LB/M), which often lead to surface roughness, defects, and microstructural inconsistency. This study examines the effects of different beam shapes and volumetric energy densities (VEDs) on the surface quality, porosity, microstructure, and mechanical response of Ti-6Al-4V. Cubic specimens were fabricated on an Aconity MIDI+ system using Gaussian, core-ring, and ring beam profiles over a VED range of 78–341 J/mm³ . The results show that beam shaping with optimized VED reduces porosity, refines microstructure, and enhances mechanical performance. The Gaussian beam performed well at low VEDs (≤130 J/mm³) but exhibited increased surface roughness and keyhole porosity at higher energy inputs (≥150 J/mm³), whereas the ring-based beams initially showed higher porosity at low VEDs but achieved ∼99.97 % relative density and smoother surfaces at higher VEDs. The ring beam promoted stable conduction-mode melting, continuous prior-β grain growth, refined α′ martensitic microstructures, and strong crystallographic texture. From a mechanical perspective, Vickers hardness values (370–400 HV) correlated with the observed microstructural features. In addition, the Gaussian beam exhibited higher indicative strength at low VEDs but deteriorated with increasing energy input, whereas the ring beam showed the opposite trend, reaching an ultimate tensile strength of 1192 MPa and ∼21 % ductility under optimal conditions. Beam behavior was further evaluated using areal energy density (AED) normalized to the melt-pool width, indicating that melt-pool stability and the resulting surface quality, porosity, and microstructural evolution are primarily influenced by the spatial distribution of laser energy rather than nominal energy metrics alone. These findings provide a physical basis for laser beam shaping as an effective approach to broaden the stable processing window and achieve defect-free, texture-controlled Ti-6Al-4V components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119197"},"PeriodicalIF":7.5,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145939266","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":"Fracture of ultrathin coating during micro-channel forming process of coated metallic sheet: Experiments and numerical prediction","authors":"Jilai Wang ,&nbsp;Chuanzheng Li ,&nbsp;Haotian Gong ,&nbsp;Zhutian Xu ,&nbsp;Yi Wan","doi":"10.1016/j.jmatprotec.2025.119164","DOIUrl":"10.1016/j.jmatprotec.2025.119164","url":null,"abstract":"<div><div>The coating-then-forming process offers a promising route to improve the manufacturing efficiency of metallic bipolar plates in proton exchange membrane fuel cells. However, fracture of ultrathin coatings during forming presents a formidable challenge to the corrosion resistance of coated metallic sheets. To provide theoretical guidance for addressing this issue, this work investigates the coating fracture behavior during the micro-channel forming process through experiments and numerical analysis. Coating cracks were revealed to be concentrated within the fillet and flat regions of the channel ridge, highly sensitive to local strain levels governed by both channel geometry and substrate microstructure. Therefore, a full-field simulation methodology was developed to predict the coating fracture during forming, balancing between computational efficiency with accuracy. Within this numerical framework, hybrid modeling of the metallic sheet substrate was employed, combining local implementation of crystal plasticity in the critical region with homogeneous materials elsewhere. For coating on the critical region, varying failure parameters correlated with substrate microstructure were determined by the microscopic fracture mechanism. Experimental validation confirms that the developed model can precisely predict both coating fractures and formed profiles, notably achieving an 80 % accuracy improvement in crack density compared to conventional approaches. Based on the simulation results, process windows were established to correlate coating fracture and channel geometry with forming parameters, thereby guiding optimization toward the minimization of crack density under geometrical constraints. Following parameter optimization, coating cracks were successfully eliminated at the flat region, demonstrating an effective strategy for maintaining the corrosion resistance after forming.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119164"},"PeriodicalIF":7.5,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693103","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}