Journal of Materials Processing Technology最新文献

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Mechanistic optimization of wide-gap ultrafast laser quartz glass welding with plasma dynamics 等离子体动力学下宽间隙超快激光石英玻璃焊接机理优化
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-04-02 DOI: 10.1016/j.jmatprotec.2025.118840
Ning Jiang, Rundong Qian, Huize Yin, Chenyi Ni, Yayun Liu, Haiyu Qiao, Chuanyang Wang
{"title":"Mechanistic optimization of wide-gap ultrafast laser quartz glass welding with plasma dynamics","authors":"Ning Jiang,&nbsp;Rundong Qian,&nbsp;Huize Yin,&nbsp;Chenyi Ni,&nbsp;Yayun Liu,&nbsp;Haiyu Qiao,&nbsp;Chuanyang Wang","doi":"10.1016/j.jmatprotec.2025.118840","DOIUrl":"10.1016/j.jmatprotec.2025.118840","url":null,"abstract":"<div><div>Ultrafast lasers have the advantages of high speed, small heat-affected zones, and non-contact processing. They can achieve fine welding in the field of microelectronic packaging, improve product quality, and reduce losses. However, ultrafast laser glass welding under wide-gap conditions faces challenges such as insufficient filling and an unstable molten pool, which limit its operability in practical applications. In this study the factors influencing welding strength are investigated by studying the interaction mechanism between the laser and glass, plasma density evolution, and temperature field analysis. First, the principle of irreversible expansion occurring in large gaps during welding was analyzed, and the welding results under different conditions were explained according to this principle. Avalanche ionization and photoionization are key mechanisms of plasma-induced irreversible expansion. Second, to obtain the optimal process parameters for use in the experiment, the plasma density and temperature field were numerically simulated, which reduced the experimental group and improved the experimental efficiency. Finally, the relationships between the process parameters, cavity shape, and welding strength were verified in an experiment involving ultrafast laser welding of quartz glass. The revealed plasma–cavity interaction mechanism and predictive modeling framework are applicable to a broad class of transparent dielectrics, offering a transferable scientific basis for precision laser joining. This work provides foundational insights into laser–matter interaction under wide-gap conditions and supports future extensions to heterogeneous material systems, complex interface geometries, and high-integration photonic manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118840"},"PeriodicalIF":6.7,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143768025","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}
引用次数: 0
Laser powder bed fusion: Defect type influences critical porosity re-growth during reheating after hot isostatic pressing 激光粉末床熔合:缺陷类型影响热等静压后再加热时临界孔隙度的再生长
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-04-01 DOI: 10.1016/j.jmatprotec.2025.118839
Jakob Schröder , Tobias Fritsch , Bruno Ferrari , Mika León Altmann , Giovanni Bruno , Anastasiya Toenjes
{"title":"Laser powder bed fusion: Defect type influences critical porosity re-growth during reheating after hot isostatic pressing","authors":"Jakob Schröder ,&nbsp;Tobias Fritsch ,&nbsp;Bruno Ferrari ,&nbsp;Mika León Altmann ,&nbsp;Giovanni Bruno ,&nbsp;Anastasiya Toenjes","doi":"10.1016/j.jmatprotec.2025.118839","DOIUrl":"10.1016/j.jmatprotec.2025.118839","url":null,"abstract":"<div><div>Despite the remarkable product design flexibility offered by additive manufacturing (AM) techniques, such as laser powder bed fusion, AM processes are susceptible to the formation of defects. In this context, the control of process parameters and the application of post-processing treatments, such as hot isostatic pressing (HIP), are of paramount importance to achieve the desired mechanical properties. The present study investigates the effectiveness of HIP as a function of process parameters in laser powder bed fused Ti-6V-4Al (PBF-LB/Ti64) using X-ray computed tomography. The process parameters are modified to obtain reference samples with low porosity, lack of fusion defects, or keyhole porosity. In all instances, subsurface keyhole porosity was observed in the as-built parts. Moreover, it was found that the efficacy of pore closure is dependent on the specific defect type. In the case of low porosity and keyhole pores, HIP resulted in effective closure. Conversely, larger lack of fusion defects were not closed due to their interconnectivity and the entrapment of argon gas. Subsequent heat treatments above the β-transus temperature allowed the investigation of the impact of defect type on porosity re-growth. For the first time, we reveal that lack of fusion defects are affected by considerable pore re-growth during post-HIP heat treatments of PBF-LB/Ti64. Such phenomenon is driven by the increasing internal pore pressure and local creep deformation at high temperatures. In contrast, re-growth is limited in samples with low porosity or keyhole pores.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118839"},"PeriodicalIF":6.7,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800439","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Evolution of surface and subsurface properties of Zr-4 alloy under the combined effects of laser heat treatment and laser gas nitriding: Microscopic morphology, chemical composition, and mechanical behavior 激光热处理和激光气体氮化复合作用下Zr-4合金表面和亚表面性能的演变:微观形貌、化学成分和力学行为
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-29 DOI: 10.1016/j.jmatprotec.2025.118833
Puhong Xu , Yongfeng Qian , Hong An , Haolin Guo , Zhiyu Zhang , Minqiang Jiang , Hu Huang , Jiwang Yan
{"title":"Evolution of surface and subsurface properties of Zr-4 alloy under the combined effects of laser heat treatment and laser gas nitriding: Microscopic morphology, chemical composition, and mechanical behavior","authors":"Puhong Xu ,&nbsp;Yongfeng Qian ,&nbsp;Hong An ,&nbsp;Haolin Guo ,&nbsp;Zhiyu Zhang ,&nbsp;Minqiang Jiang ,&nbsp;Hu Huang ,&nbsp;Jiwang Yan","doi":"10.1016/j.jmatprotec.2025.118833","DOIUrl":"10.1016/j.jmatprotec.2025.118833","url":null,"abstract":"<div><div>Zr-4 alloy, extensively employed as cladding in nuclear reactor fuel rods, stands as the foremost line of defense for reactor safety. Given its susceptibility to defects such as micro-pores during casting and its long-term exposure to extreme conditions during practical service processes, enhancing the surface and subsurface properties of Zr-4 alloy is essential. Herein, a nanosecond pulsed laser is used to irradiate the Zr-4 alloy in a nitrogen environment to investigate the evolution of its surface and subsurface properties under the combined effects of laser heat treatment and laser gas nitriding. The experimental results reveal a remarkable augmentation in surface hardness and scratch resistance of the Zr-4 alloy after laser irradiation. Notably, the hardness of the laser-irradiated surface obtained with a laser power of 23.0 W and a scanning speed of 150 mm/s reaches 19.10 GPa, which is more than 7 times higher than that of the untreated surface (2.37 GPa). These improvements are attributed to the synergistic effects of the introduction of hard ZrN phase, the reduction of subsurface porosity, and grain refinement. This study demonstrates a promising approach for significantly improving the mechanical properties of Zr-4 alloy, holding considerable practical significance for its applications in the nuclear energy industry and other relevant fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118833"},"PeriodicalIF":6.7,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143746689","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}
引用次数: 0
Study on element mixing of titanium-stainless steel dissimilar metal welding pool and its effect on joint properties in nanosecond laser welding 钛-不锈钢异种金属熔池元素混合及其对纳秒激光焊接接头性能影响的研究
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-29 DOI: 10.1016/j.jmatprotec.2025.118836
Xiang Wang , Rui-Hua Qiao , Yu-Ruo Zhang , Jun Ma , Che-Ping Liang , Lin-Jie Zhang , Suck-Joo Na
{"title":"Study on element mixing of titanium-stainless steel dissimilar metal welding pool and its effect on joint properties in nanosecond laser welding","authors":"Xiang Wang ,&nbsp;Rui-Hua Qiao ,&nbsp;Yu-Ruo Zhang ,&nbsp;Jun Ma ,&nbsp;Che-Ping Liang ,&nbsp;Lin-Jie Zhang ,&nbsp;Suck-Joo Na","doi":"10.1016/j.jmatprotec.2025.118836","DOIUrl":"10.1016/j.jmatprotec.2025.118836","url":null,"abstract":"<div><div>During the melting welding of titanium-stainless steel dissimilar metals, intermetallic compounds typically form within the weld seam, significantly compromising its mechanical properties. This study firstly used nanosecond pulse laser achieved effective welding of thin wall titanium and stainless steels by adjusting the mixing ratio of metal elements in the weld seam. A computational fluid dynamics (CFD) calculation model for thin-walled stainless steel titanium nanosecond pulse laser welding was established, and the physical mechanism of element mixing behavior was revealed. The effects of varying heat inputs on fluid flow, mixing of elements, and the evolution of microstructure in the weld pool were investigated. Regardless of whether the melting pool penetrates the titanium thin wall, titanium elements easily accumulate along the edges of the melting pool on the stainless steel side. When the melting pool fully penetrates the titanium sheet, the average titanium content in the weld seam exceeds 23 at%. Conversely, when the bottom of the melting pool is situated at the center of the titanium thin wall, the average titanium content within the weld seam is approximately 9.99 at%. No intermetallic compounds were found in the weld seam the strength of the weld can be increased about twice. Controlling the average content of Ti element in the weld seam to not exceed 10 at% is a key factor in obtaining excellent mechanical properties of welded joints, and it providing new welding strategies for titanium-stainless steel metal welding.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118836"},"PeriodicalIF":6.7,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800437","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}
引用次数: 0
Property enhancement in 6D10 aluminum alloy welds: A comparative study of CMT+P and oscillating laser welding techniques with novel Al-Si-Cu-Mg-Zn filler wire 6D10铝合金焊缝性能增强:新型Al-Si-Cu-Mg-Zn钎料CMT+P和振荡激光焊接技术的对比研究
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118830
Xianwei Jiang , Shuncun Luo , Meng Cao , Xiaonan Wang , Hiromi Nagaumi , Zengrong Hu
{"title":"Property enhancement in 6D10 aluminum alloy welds: A comparative study of CMT+P and oscillating laser welding techniques with novel Al-Si-Cu-Mg-Zn filler wire","authors":"Xianwei Jiang ,&nbsp;Shuncun Luo ,&nbsp;Meng Cao ,&nbsp;Xiaonan Wang ,&nbsp;Hiromi Nagaumi ,&nbsp;Zengrong Hu","doi":"10.1016/j.jmatprotec.2025.118830","DOIUrl":"10.1016/j.jmatprotec.2025.118830","url":null,"abstract":"<div><div>To solve the issue of weld softening encountered when welding high-strength aluminum alloy with conventional commercial welding wires, this study uses two welding techniques, Cold Metal Transfer Plus Pulse (CMT+P) and Oscillating Laser Welding with Filler Wire (OLWFW), to weld 6D10 aluminum alloy with a novel Al-Si-Cu-Mg-Zn wire. The porosity, microstructure, and mechanical properties of the welded joints are compared. Results show that minimum porosity is 0.42 % in the CMT+P process and 0.11 % in the OLWFW process. Metallurgical pores mainly affect yield strength and ultimate tensile strength, with less impact on elongation. CMT+P produces β'' and θ' strengthening phases (lower number density, larger size) in the weld seam when using Al-Si-Cu-Mg-Zn filler wire, while OLWFW (higher cooling rate) produces finer cellular sub-structures and higher density of smaller β''+ θ'+Q′ strengthening phases. Mechanical properties show that CMT+P joints have 284.5 MPa ultimate tensile strength in the weld seam and 252.5 MPa in the heat-affected zone, which increase to 311.5 MPa and 301.5 MPa respectively with OLWFW. Strengthening mechanisms quantified via dislocation shearing and Orowan mechanisms indicate that OLWFW exhibits greater precipitation strengthening than CMT+P, explaining the strength difference. This study discovered that filling with Al-Si-Cu-Mg-Zn welding wire can precipitate a significant amount of strengthening phase in the weld seam without post-weld heat treatment, especially when using the OLWFW welding technique with a higher cooling rate. This provides a new strategy for welding high-strength aluminum alloys: using novel multi-alloyed filler wires and high-cooling-rate welding techniques can improve both the strength of the weld seam and the welding coefficient, facilitating the broader application of high-strength aluminum alloys in vehicle manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118830"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760286","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}
引用次数: 0
Magnetic pulse welding of high-strength aluminum alloy with enhanced Lorentz force via novel hollow field shaper 利用新型空心场成形器增强洛伦兹力的高强度铝合金磁脉冲焊接
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118829
Junjia Cui , Wanting You , Hao Sun , Guangyao Li , Peng Wang , Qing Wang , Chenling Zheng , Chong Wang , Hao Jiang
{"title":"Magnetic pulse welding of high-strength aluminum alloy with enhanced Lorentz force via novel hollow field shaper","authors":"Junjia Cui ,&nbsp;Wanting You ,&nbsp;Hao Sun ,&nbsp;Guangyao Li ,&nbsp;Peng Wang ,&nbsp;Qing Wang ,&nbsp;Chenling Zheng ,&nbsp;Chong Wang ,&nbsp;Hao Jiang","doi":"10.1016/j.jmatprotec.2025.118829","DOIUrl":"10.1016/j.jmatprotec.2025.118829","url":null,"abstract":"<div><div>Magnetic pulse welding (MPW) has been widely applied to join metallic tubes in the automotive and aerospace fields. However, low energy utilization of the device limits the Lorentz force and the application to high-strength alloys. A novel hollow field shaper structure is proposed to expand the range of potentially applicable materials. Topology optimization was employed to trade off the efficiency and the strength of the device. The welding of 6061-T6 aluminum-alloy tube and 1020 steel tube was realized. The joint strength has increased threefold. The results showed that under the enhanced Lorentz force, the element was diffused into each other. The numerical study found that the Lorentz force from the novel design was enhanced by 56 %. The radial deformation in the free deformation experiment increased by 243.3 %, validating the improvement of the force. By creating an analytical model, it was analyzed that the increase in force was due to the decrease in current division on the sloping surface of the hollow field shaper. Besides, the efficiency increased by 66.7 % implying lower energy costs. Thus, the proposed structure was validated to expand the materials range of MPW.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118829"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739861","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}
引用次数: 0
Unveiling the mechanism behind high formability in ultrafine-grained Cu with low ductility 揭示了低延展性超细晶铜高成形性的机理
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118828
Huimin Liu , Yao Jiang , Wen Yang , Zhonghua Liu , Junyu Ke , Saiyang Li , Fan Liu , Xinping Zhang , Jing Tao Wang
{"title":"Unveiling the mechanism behind high formability in ultrafine-grained Cu with low ductility","authors":"Huimin Liu ,&nbsp;Yao Jiang ,&nbsp;Wen Yang ,&nbsp;Zhonghua Liu ,&nbsp;Junyu Ke ,&nbsp;Saiyang Li ,&nbsp;Fan Liu ,&nbsp;Xinping Zhang ,&nbsp;Jing Tao Wang","doi":"10.1016/j.jmatprotec.2025.118828","DOIUrl":"10.1016/j.jmatprotec.2025.118828","url":null,"abstract":"<div><div>To explore the formability of ultrafine-grained (UFG) materials, hemispherical spinning tests are conducted on the UFG Cu for the first time. The limit half-cone angle of spinning for UFG Cu is experimentally determined to be 15.2°, slightly higher than the 7.84° for coarse-grained (CG) Cu, despite UFG Cu exhibiting significantly lower tensile ductility than the latter. The exceptional formability of UFG Cu is primarily attributed to the mechanism of deformation-induced dynamic recovery during spinning, which promotes dislocation absorption via grain boundary migration and releases the strain/strain concentration at grain boundaries. Finite element method (FEM) simulations confirm that fracture in both UFG and CG materials predominantly occurs in the cone wall region due to its biaxial tensile stress state. In contrast, the spinning deformation zone exhibits a triaxial compressive stress state, which serves as an optimal constraint for accommodating large plastic strains within large ranges of strain rates. By adjusting key processing parameters, such as feed ratio and rotational speed, the extent of dynamic recovery can be effectively activated and enhanced. These findings provide new insights into the plastic forming behavior of UFG Cu and expand its potential for engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118828"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143746690","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}
引用次数: 0
Tailoring microstructure and strengthening mechanism of anisotropic elastocaloric effect in NiTi shape memory alloys by laser directed energy deposition scanning strategy 激光定向能沉积扫描策略制备NiTi形状记忆合金各向异性弹热效应及其强化机理
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-26 DOI: 10.1016/j.jmatprotec.2025.118825
Shuyao Wang, Yongjun Shi, Xuejin Zhao, Kaijun Fan, Ying Li, Qin Wang
{"title":"Tailoring microstructure and strengthening mechanism of anisotropic elastocaloric effect in NiTi shape memory alloys by laser directed energy deposition scanning strategy","authors":"Shuyao Wang,&nbsp;Yongjun Shi,&nbsp;Xuejin Zhao,&nbsp;Kaijun Fan,&nbsp;Ying Li,&nbsp;Qin Wang","doi":"10.1016/j.jmatprotec.2025.118825","DOIUrl":"10.1016/j.jmatprotec.2025.118825","url":null,"abstract":"<div><div>The NiTi shape memory alloys (SMAs) with elastocaloric effect are applied to new solid-state refrigeration technologies with green and zero-global warming potential, and additive manufacturing technologies provide new opportunities to advance their development. In this study, four scanning strategies for laser directed energy deposition (LDED) additive manufacturing involving the direction change of adjacent hatch lines and the rotation of adjacent deposited layers were designed, and the NiTi SMAs were synthesized in situ from two metal powders, Ni and Ti. The microstructure evolutionary behaviors and reinforcement mechanisms of anisotropic elastocaloric effects were analyzed. The rotation of two adjacent deposited layers demonstrates the potential to inhibit the growth of Ti<sub>2</sub>Ni precipitation phase dendrite arms and to modulate their morphology and content, and to disperse the direction of the temperature gradient and reduce the stresses and deformations resulting from the thermal cycling process. The differences in microstructure evolution behaviors of different scanning strategies make NiTi SMAs exhibit anisotropy in stress-strain response behaviors and elastocaloric effects. The results of the analysis of the elastocaloric effect show that the temperature drop generated at the surface of the alloy is a linearly increasing function of the maximum compressive stress. The customized microstructure of “semicircular arc” shaped grains within the double cross-section was obtained by the simultaneous rotation of adjacent hatch lines and deposited layers, exhibiting a synergistic enhancement of phase strain and elastocaloric effects. The cooling effect up to −9.4 °C (unloaded at 1100 MPa) was increased by 224 % compared to the conventional strategy. This study provides a way to advance the rapid development of solid-state refrigeration technology by customizing the microstructure of NiTi SMAs and obtaining the desired elastocaloric effect via LDED additive manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118825"},"PeriodicalIF":6.7,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725319","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}
引用次数: 0
Stress interaction analysis and mitigation in multi-process bellows manufacturing using continuous finite element simulation 基于连续有限元模拟的多工序波纹管制造应力相互作用分析与缓解
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-26 DOI: 10.1016/j.jmatprotec.2025.118826
Yuanyang Gao , Yanhong Wei , Xiangbo Liu , Honghe Jia , Wenyong Zhao
{"title":"Stress interaction analysis and mitigation in multi-process bellows manufacturing using continuous finite element simulation","authors":"Yuanyang Gao ,&nbsp;Yanhong Wei ,&nbsp;Xiangbo Liu ,&nbsp;Honghe Jia ,&nbsp;Wenyong Zhao","doi":"10.1016/j.jmatprotec.2025.118826","DOIUrl":"10.1016/j.jmatprotec.2025.118826","url":null,"abstract":"<div><div>A major challenge in the bellows manufacturing process is the accumulation of complex stresses due to the multi-step forming and welding processes, which can significantly impact the bellows’ service life under varying and complex thermal/mechanical loads in engine fuel systems. This research focuses on the full process chain for 1Cr18Ni9Ti bellows and innovatively conducts a multi-process direct finite element analysis of the full process chain, including hydraulic forming (HF), end-corrugation flattening (ECF), resistance spot welding (RSW), and full circumferential welding (FCW). Firstly, finite element models (FEM) for four individual processes were established and were integrated into a continuous simulation model of the full process chain. Subsequently, the high reliability of the model was verified. The research further investigated the influence of each process on the stress distribution and evolution and concluded that the stress in the trough was mainly affected by HF and FCW. Corresponding optimization based on HF and FCW effectively reduced the stress level in the trough by 10.4 %. The significance of this research lies in providing critical insights for efficient multi-aspect process optimization and offering valuable references for simulating other complex manufacturing process chains.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118826"},"PeriodicalIF":6.7,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143706269","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}
引用次数: 0
In-situ bonding of horizontal bimetallic interface by laser offset during laser powder bed fusion of copper/nickel multi-material structures and underlying thermodynamic mechanisms 激光粉末床熔合铜/镍多材料结构时水平双金属界面激光偏移原位键合及其热力学机制
IF 6.7 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-03-26 DOI: 10.1016/j.jmatprotec.2025.118831
Lin Li , Qimin Shi , Shoufeng Yang
{"title":"In-situ bonding of horizontal bimetallic interface by laser offset during laser powder bed fusion of copper/nickel multi-material structures and underlying thermodynamic mechanisms","authors":"Lin Li ,&nbsp;Qimin Shi ,&nbsp;Shoufeng Yang","doi":"10.1016/j.jmatprotec.2025.118831","DOIUrl":"10.1016/j.jmatprotec.2025.118831","url":null,"abstract":"<div><div>Achieving robust bonding between dissimilar materials is crucial for both vertical and horizontal interfaces in multi-material structures fabricated via layer-by-layer laser powder bed fusion (LPBF). However, horizontal bonding has been less explored than vertical bimetallic interfaces, largely because of the limitations in the available equipment, process strategies, and research concepts. In this study, we propose a practical horizontal dissimilar laser offset strategy, wherein the laser spot is displaced outwards from the interface profile by a certain distance, to improve horizontal bonding in CuSn10/IN718 structures. A laser offset of 75 μm enhanced metallurgical bonding and reduced microcracks, resulting in a smoother surface. The laser offset area displayed interlocking macro-segregation peninsulas composed of CuSn10 or IN718. The diffusion behaviour between these segregated peninsulas, located at the boundary of the molten pool, was found to be more intense than that at the centre, driven by a steeper temperature gradient at the molten pool boundary (22.61 ×10<sup>6</sup> K·m<sup>−1</sup> at the boundary <em>vs</em> 18.03 ×10<sup>6</sup> K·m<sup>−1</sup> at the centre, representing a 25.4 % increase). Such material heterogeneity shows microstructural differences, characterised by fine columns, reticulations, and discrete pellets. Consequently, hardness and elastic modulus exhibited a smooth transition across the CuSn10/IN718 interface, which was enabled by the homogeneous material distribution obtained using the laser offset technique. The laser offset strategy provides a convenient laser scanning approach for LPBF and other laser-based multi-material AM processes. This study conducted a detailed analysis of segregation and interlocking at the interface, which may be beneficial for studying other material combinations.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118831"},"PeriodicalIF":6.7,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739862","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}
引用次数: 0
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