Journal of Materials Processing Technology最新文献

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Residual stress engineering for highly loaded rolling-sliding contacts: Finding the sweet spot for maximum durability by hard turning and deep rolling 高负荷滚动滑动接触的残余应力工程:通过硬车削和深轧找到最大耐用性的最佳点
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-12 DOI: 10.1016/j.jmatprotec.2025.119027
Simon Dechant , Henke Nordmeyer , Florian Pape , Bernd Breidenstein , Gerhard Poll , Max Marian
{"title":"Residual stress engineering for highly loaded rolling-sliding contacts: Finding the sweet spot for maximum durability by hard turning and deep rolling","authors":"Simon Dechant ,&nbsp;Henke Nordmeyer ,&nbsp;Florian Pape ,&nbsp;Bernd Breidenstein ,&nbsp;Gerhard Poll ,&nbsp;Max Marian","doi":"10.1016/j.jmatprotec.2025.119027","DOIUrl":"10.1016/j.jmatprotec.2025.119027","url":null,"abstract":"<div><div>The durability of highly loaded rolling-sliding contacts, such as those in rolling bearings, is critically determined by subsurface microstructure and residual stresses engineered during manufacturing. This study systematically investigates the interplay between thermal and mechanical process parameters during deep rolling, using bearing inner rings as a representative example, to identify optimal conditions for maximizing fatigue life. By isolating the effects of process temperature (20–400 °C) and deep rolling pressure (200–400 bar), we demonstrate that moderate mechanical loading at room temperature can more than double bearing life through beneficial compressive residual stresses, while excessive pressure or thermal input above 200 °C sharply reduces durability. Notably, we reveal a previously unrecognized mechanism of hidden thermal degradation that limits lifetime, even when conventional hardness or microstructural metrics remain unchanged. These results define a process window for residual stress engineering in bearing steels and provide generic guidelines for hybrid manufacturing of rolling-sliding components subjected to severe tribological loading. The findings advance fundamental understanding of process-induced fatigue mechanisms and offer a framework for the rational design of subsurface-optimized, durable, and sustainable machine elements.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119027"},"PeriodicalIF":7.5,"publicationDate":"2025-08-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144842373","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
Towards understanding the ultrasonic vibration-assisted diamond cutting of ZnO crystals: Surface integrity and tool wear mechanism 超声振动辅助金刚石切割ZnO晶体:表面完整性和刀具磨损机理
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-11 DOI: 10.1016/j.jmatprotec.2025.119026
Weihai Huang, Takeshi Hashimoto, Jiwang Yan
{"title":"Towards understanding the ultrasonic vibration-assisted diamond cutting of ZnO crystals: Surface integrity and tool wear mechanism","authors":"Weihai Huang,&nbsp;Takeshi Hashimoto,&nbsp;Jiwang Yan","doi":"10.1016/j.jmatprotec.2025.119026","DOIUrl":"10.1016/j.jmatprotec.2025.119026","url":null,"abstract":"<div><div>Zinc oxide (ZnO) is a promising material for optics and optoelectronics. However, its machining methods are limited, with polishing being virtually the only available technique, which restricts the fabrication of complex shapes. In this study, for the first time, ultraprecision diamond cutting of single-crystal ZnO was explored. Conventional cutting (CC) and ultrasonic vibration-assisted cutting (UVC) experiments were performed in dry and oil mist lubrication environments. It was found that under dry conditions, both CC and UVC resulted in surface fractures owing to the oxidation-induced chemical tool wear. Using oil mist lubrication significantly reduced tool wear, particularly for UVC. As a result, surface roughness was reduced to 1.9 nm Sa. Cutting in the [11−20] direction was more likely to achieve crack-free surfaces on ZnO than cutting in the [1−100] direction under CC; however, the machinability in cutting in the [1−100] direction was improved by applying UVC. Both CC and UVC processes activated basal and pyramidal slip systems in the subsurface region, accompanied by a high density of dislocations located immediately beneath the surface. UVC further promotes polycrystallization and pyramidal slip activity in the subsurface. A microlens array was fabricated with a surface form error of less than 49 nm peak-to-valley and a surface roughness of less than 2.2 nm Sq by integrating slow tool servo diamond turning with ultrasonic vibration assistance under oil mist lubrication. This study reveals the fundamental cutting characteristics of ZnO, provides guidance for ultraprecision cutting of brittle oxide crystals, and validates a potential solution for fabricating micro-structures on ZnO surfaces.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119026"},"PeriodicalIF":7.5,"publicationDate":"2025-08-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144852507","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
Single-step reductive sintering for sustainable additive manufacturing of as-water-atomized steel powders 水雾化钢粉的单步还原烧结可持续增材制造
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-10 DOI: 10.1016/j.jmatprotec.2025.119023
Mingzhang Yang , Mohsen K. Keshavarz , Mihaela Vlasea
{"title":"Single-step reductive sintering for sustainable additive manufacturing of as-water-atomized steel powders","authors":"Mingzhang Yang ,&nbsp;Mohsen K. Keshavarz ,&nbsp;Mihaela Vlasea","doi":"10.1016/j.jmatprotec.2025.119023","DOIUrl":"10.1016/j.jmatprotec.2025.119023","url":null,"abstract":"<div><div>Steel additive manufacturing (AM) has traditionally relied on highly refined powders that underwent energy-intensive pre-processing to remove impurities and achieve the targeted bulk composition. This study presents an innovative, resource-efficient, and economically viable approach to binder jet additive manufacturing (BJAM) of steel. By directly utilizing low-cost, as-water-atomized steel powders, this method achieves in-situ chemical refinement and bulk densification via a single-step reductive sintering process, streamlining production while minimizing environmental impact and costs. Key factors include maintaining low H<sub>2</sub> partial pressure to prevent excessive decarburization, while leveraging higher temperatures to reduce stable oxides and triggering supersolidus liquid-phase sintering (SLPS), thus achieving densification &gt; 99.7 % solid. In-situ thermal and off-gassing analyses, combined with ex-situ chemical analysis, revealed the underlying reductive sintering mechanisms, particularly the dominant role of CO-based redox reaction in driving deoxidation and decarburization after the BCC→FCC transformation.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119023"},"PeriodicalIF":7.5,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829877","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
High-efficiency electrical arc machining of tantalum–tungsten alloy: Mechanism, microstructural evolution, and surface modification for precision finishing 钽钨合金的高效电弧加工:机理、显微组织演变及精密精加工的表面改性
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-10 DOI: 10.1016/j.jmatprotec.2025.119025
Jianping Zhou , Yinan Zhao , Shengsheng Zhang , Yu Ren , Jiayang Huang , Yue Zhao , Yan Xu
{"title":"High-efficiency electrical arc machining of tantalum–tungsten alloy: Mechanism, microstructural evolution, and surface modification for precision finishing","authors":"Jianping Zhou ,&nbsp;Yinan Zhao ,&nbsp;Shengsheng Zhang ,&nbsp;Yu Ren ,&nbsp;Jiayang Huang ,&nbsp;Yue Zhao ,&nbsp;Yan Xu","doi":"10.1016/j.jmatprotec.2025.119025","DOIUrl":"10.1016/j.jmatprotec.2025.119025","url":null,"abstract":"<div><div>Tantalum–tungsten (Ta–W) alloys are widely used in extreme environments due to their exceptional thermal stability, mechanical strength, and corrosion resistance. However, their high hardness and melting point make them extremely difficult to machine. To overcome the limitations of traditional mechanical—which often suffer from low efficiency and poor process stability—this study pioneers the application of high-efficiency electrical arc machining (EAM) to the rough machining and surface modification of Ta–W alloys. A coupled thermo-mechanical model is developed to correlate discharge energy with the depth of the heat-affected zone (HAZ), grain size evolution, and surface hardness degradation. Real-time arc dynamics are captured via high-speed imaging, and microstructural transformations are systematically analyzed using electron backscatter diffraction (EBSD), transmission electron microscopy (TEM) and nanoindentation techniques, revealing evident recrystallization, grain coarsening, and thermal softening. Experimental results show that under 30 V, a maximum material removal rate (MRR) of 11,869.88 mm³ /min is achieved, while the relative electrode wear ratio (REWR) is reduced to 1.86 %. Meanwhile, the surface hardness in the HAZ decreases by over 60 %, dropping from 2.4–2.9 GPa in the base material to 0.84 GPa. Friction and wear testing further indicate that the arc-modified surface exhibits improved machinability, providing a favorable foundation for subsequent precision processing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119025"},"PeriodicalIF":7.5,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829876","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-assisted machining of SiCp/Al composites: Preheating history driven microstructure evolution and its role in material removal 激光辅助加工SiCp/Al复合材料:预热历史驱动的微观组织演变及其在材料去除中的作用
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-10 DOI: 10.1016/j.jmatprotec.2025.119024
Feijie Cui , Hang Zhang , Minghui Yang , Ben Deng , Xiaowei Tang , Rong Yan , Fangyu Peng
{"title":"Laser-assisted machining of SiCp/Al composites: Preheating history driven microstructure evolution and its role in material removal","authors":"Feijie Cui ,&nbsp;Hang Zhang ,&nbsp;Minghui Yang ,&nbsp;Ben Deng ,&nbsp;Xiaowei Tang ,&nbsp;Rong Yan ,&nbsp;Fangyu Peng","doi":"10.1016/j.jmatprotec.2025.119024","DOIUrl":"10.1016/j.jmatprotec.2025.119024","url":null,"abstract":"<div><div>SiCp/Al composites are typical difficult-to-machine materials, and laser-assisted machining (LAM) is an effective approach to address their poor machinability. However, the intrinsic softening mechanism of material under the laser action is still unclear. The preheating history of LAM in which the workpiece temperature first rises and then decreases has also gone unnoticed. Understanding the interaction between laser preheating and the microstructure of SiCp/Al composites is beneficial to enhance the advantages of LAM. In this study, a novel molecular dynamics (MD) simulation model of SiCp/Al composites considering the laser preheating history is performed to analyze the dynamic evolution of microstructure from three perspectives: heating, cooling and cutting. The grain growth phenomenon in the Al matrix is identified by XRD and laser scanning (LS) experiments, and the degree of grain growth is controlled by the combination of scanning speed and laser power. The MD simulation indicates that the grain growth of Al matrix is achieved through disordering and recrystallization. In addition, it is observed in TEM experiments that high temperature arising from laser heating contributes to the annihilation of dislocations within the Al matrix. Ultimately, the nanoindentation experiments verify the material softening under the laser annealing effect. It is worth emphasizing that different preheating histories induce various microstructure, which in turn affects the softening degree of the material. The LAM experiments and simulation of SiCp/Al composites are performed, and the results demonstrate that different softening degree of the material leads to variation in the removal behavior, as reflected in the cutting forces and shear angles. This study is conducive to enhancing the comprehension of the material softening mechanism under the laser action and the material removal behavior under different preheating histories, which provides theoretical support for the rational control of LAM parameters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119024"},"PeriodicalIF":7.5,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829875","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
Effect of tool face geometry on additive friction stir deposition of Al-Mg-Si alloy: Process modeling and validation in correlation with mechanical properties 刀具面几何形状对Al-Mg-Si合金搅拌摩擦沉积的影响:与力学性能相关的过程建模和验证
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-08 DOI: 10.1016/j.jmatprotec.2025.119007
Nimesh Fernando, R. Sarvesha, James Caudill, I.S. Jawahir
{"title":"Effect of tool face geometry on additive friction stir deposition of Al-Mg-Si alloy: Process modeling and validation in correlation with mechanical properties","authors":"Nimesh Fernando,&nbsp;R. Sarvesha,&nbsp;James Caudill,&nbsp;I.S. Jawahir","doi":"10.1016/j.jmatprotec.2025.119007","DOIUrl":"10.1016/j.jmatprotec.2025.119007","url":null,"abstract":"<div><div>Additive Friction Stir Deposition (AFSD) is a solid-state additive manufacturing process that deposits material layer by layer through shear-based plastic deformation. A critical challenge in AFSD is understanding how tool face geometry governs material flow, heat generation, and microstructure evolution, factors that directly influence the mechanical performance of the build. To address this, we propose a novel and integrated approach focused on: (i) developing high-fidelity analytical-numerical models to capture spatial variations in material flow, strain rate, and temperature; (ii) designing nature-inspired tool face geometries to actively control material flow and thermal conditions; and (iii) experimentally evaluating the influence of these geometries on microstructure and mechanical properties during AFSD of an Al-Mg-Si alloy. Three tool designs, a flat tool, a four-protrusion tool, and a vortex tool are employed to investigate how tool geometry affects process behavior. Simulations are used to predict how localized flow and heat generation can be tailored through geometry design, particularly by enhancing build direction material motion and reducing thermal losses. Tensile tests on both heat-treated and non-heat-treated samples, supported by SEM, EBSD, and TEM analyses, are used to establish the link between tool-induced strain conditions and resulting microstructural features, such as grain refinement and precipitate distribution. Overall, this study highlights the critical role of tool face geometry in modulating material flow, thermal profiles, and mechanical properties during AFSD.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119007"},"PeriodicalIF":7.5,"publicationDate":"2025-08-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144861241","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
Pulsed laser texturing of brazed diamond grinding wheels with orderly arranged abrasive grains and their grinding performance on WC/Co composites 脉冲激光磨粒有序钎焊金刚石砂轮的织构及其对WC/Co复合材料的磨削性能
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-07 DOI: 10.1016/j.jmatprotec.2025.119022
Zhen Zhang , Quanli Zhang , Qiwen Wang , Wentao Wang , Jiuhua Xu
{"title":"Pulsed laser texturing of brazed diamond grinding wheels with orderly arranged abrasive grains and their grinding performance on WC/Co composites","authors":"Zhen Zhang ,&nbsp;Quanli Zhang ,&nbsp;Qiwen Wang ,&nbsp;Wentao Wang ,&nbsp;Jiuhua Xu","doi":"10.1016/j.jmatprotec.2025.119022","DOIUrl":"10.1016/j.jmatprotec.2025.119022","url":null,"abstract":"<div><div>The brazed diamond grinding wheel with orderly arranged grains exhibits excellent performance in efficiently processing hard and brittle difficult-to-machine materials owing to its high exposure height, holding strength, and grinding ratio. However, there are many challenges in achieving high efficiency and precision dressing of brazed diamond grinding wheels and improving the grinding surface quality of hard and brittle materials. In this study, firstly, laser trimming experiments were conducted on a brazed diamond grinding wheel, and an evaluation method for abrasive high equivalence of the grinding wheel was proposed based on the global data acquisition and image processing, the exposure height distribution of abrasive grains of the brazed grinding wheel was analysed comprehensively. Subsequently, pulsed laser texturing experiments were performed on the diamond abrasive grains of the brazed diamond grinding wheel. By optimising the laser scanning trajectory, a low damage and uniformly arranged surface texture was fabricated on the abrasive grains. Finally, grinding experiments was conducted on WC/6Co cemented carbide using the abrasive textured brazed diamond grinding wheel, where the wear characteristics of the abrasive textured brazed diamond grinding wheel were investigated and the influence of different abrasive texture types on the grinding surface quality and grinding force of WC/6Co cemented carbide was compared and analysed. In this study, low-damage textures were fabricated on the surface of large-grain brazed diamond grinding wheels to regulate the material removal mechanism in WC/6Co cemented carbide, providing valuable insights for grinding efficiency and accuracy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119022"},"PeriodicalIF":7.5,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144858419","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
Obtaining ultra-fine grains by hot deformation without inducing secondary phase pinning grain boundaries in Ni-based superalloy 镍基高温合金在不产生二次相钉住晶界的情况下通过热变形获得超细晶粒
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-07 DOI: 10.1016/j.jmatprotec.2025.119020
Peiru Yang, Yuan Huang, Qianying Guo, Chong Li, Yongchang Liu
{"title":"Obtaining ultra-fine grains by hot deformation without inducing secondary phase pinning grain boundaries in Ni-based superalloy","authors":"Peiru Yang,&nbsp;Yuan Huang,&nbsp;Qianying Guo,&nbsp;Chong Li,&nbsp;Yongchang Liu","doi":"10.1016/j.jmatprotec.2025.119020","DOIUrl":"10.1016/j.jmatprotec.2025.119020","url":null,"abstract":"<div><div>To overcome the limitations of grain refinement via η-phase precipitation in Ni-based superalloys, this study establishes a precipitation-free hot deformation strategy within the γ single-phase region of Allvac 718Plus. By systematically varying temperature (1000–1150 °C) and strain rate (0.001–1 s<sup>-1</sup>), we decouple their effects and reveal an interplay between dislocation-driven dynamic recovery (DRV), dynamic recrystallization (DRX), and deformation twinning. DRX nucleation is primarily controlled by dislocation density, promoted under high strain rates, while grain growth is enhanced at elevated temperatures and low strain rates. Twinning plays a crucial role in twin-induced DRX (TDRX) and microstructural stabilization. A mechanism map is proposed to illustrate the transitions among DRV, DRX, and twinning across deformation regimes. The optimized condition (1150 °C, 0.1 s<sup>-1</sup>) achieves a uniform, ultra-fine (∼10 μm) grain structure with high hardness and no secondary phase formation. This framework offers a transferable approach to grain refinement in Ni-based and other FCC alloys without relying on precipitation control.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119020"},"PeriodicalIF":7.5,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829873","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
Defect-structure-property relationships in laser powder bed fusion processed NdFeB magnets: The dominant role of laser energy density 激光粉末床熔合加工钕铁硼磁体缺陷-结构-性能关系:激光能量密度的主导作用
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-06 DOI: 10.1016/j.jmatprotec.2025.119018
Hao Dong , Ketai He , Han Xu , Xiaowei Meng , Yangwei Du , Guoxuan Ming , Tianyan Ji , Kunjie Dai , Chaofang Dong
{"title":"Defect-structure-property relationships in laser powder bed fusion processed NdFeB magnets: The dominant role of laser energy density","authors":"Hao Dong ,&nbsp;Ketai He ,&nbsp;Han Xu ,&nbsp;Xiaowei Meng ,&nbsp;Yangwei Du ,&nbsp;Guoxuan Ming ,&nbsp;Tianyan Ji ,&nbsp;Kunjie Dai ,&nbsp;Chaofang Dong","doi":"10.1016/j.jmatprotec.2025.119018","DOIUrl":"10.1016/j.jmatprotec.2025.119018","url":null,"abstract":"<div><div>This study investigates the challenges of microstructure control and defect mitigation in the fabrication of NdFeB permanent magnets via laser powder bed fusion (LPBF), systematically elucidating the influence of laser energy density on densification behavior, microstructural evolution, and magnetic properties. Experimental results demonstrate that increasing laser energy density under appropriate power levels enhances the relative density of samples to 95.8 %. However, excessive or insufficient power triggers vertical wide cracks, attributed to the synergistic effects of gradient thermal stress concentration, Nd-rich liquid film-induced grain boundary weakening, and insufficient volumetric melt feeding rate to compensate for solidification shrinkage and thermal deformation during solidification. Microstructural analysis reveals that the melt pool's rapid cooling rate promotes an increase in the volume fraction of the Nd<sub>2</sub>Fe<sub>14</sub>B main phase to 78.5 %, resulting in a 3.28-fold enhancement in magnetic energy product compared to samples produced by conventional processes. Electron backscatter diffraction characterization indicates a preferential &lt; 001 &gt; orientation along the laser scanning direction, yielding a 16.4 % higher magnetic energy product than that along the build direction. By establishing the multi-scale correlation of process parameters, microstructure, and magnetic properties, this research clarifies the mechanisms of crack initiation and propagation and the principles of magnetic performance regulation for developing high-performance additively manufactured permanent magnets.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119018"},"PeriodicalIF":7.5,"publicationDate":"2025-08-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144810474","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
Bi-cylindrical part formed by a combined spinning process 由复合纺丝工艺制成的双圆柱形零件
IF 7.5 2区 材料科学
Journal of Materials Processing Technology Pub Date : 2025-08-06 DOI: 10.1016/j.jmatprotec.2025.119008
Zixuan Li , Junkun Leng , Hongjie Jin , Haijie Xu , Pater Zbigniew , Xiaomiao Niu , Xuedao Shu
{"title":"Bi-cylindrical part formed by a combined spinning process","authors":"Zixuan Li ,&nbsp;Junkun Leng ,&nbsp;Hongjie Jin ,&nbsp;Haijie Xu ,&nbsp;Pater Zbigniew ,&nbsp;Xiaomiao Niu ,&nbsp;Xuedao Shu","doi":"10.1016/j.jmatprotec.2025.119008","DOIUrl":"10.1016/j.jmatprotec.2025.119008","url":null,"abstract":"<div><div>Bi-cylindrical parts are a type of cylindrical component featuring an inner boss shape, making them suitable as lightweight structural parts for aerospace and transportation applications. A shovel-conventional combined spinning process for the integrated formation of bi-cylindrical parts is proposed in this work, representing a significant advancement over traditional manufacturing methods that require multiple operations and joining processes. A mathematical model is developed to elucidate the relationship between the inner boss shape height, outer cylindrical part height, and shovel reduction ratio under different thickness conditions. Through numerical simulations and experimental methods, the deformation mechanisms and microstructural evolution during both processes are analyzed. Results demonstrate that as the shovel reduction ratio increased from 20 % to 40 %, the inner boss height increased significantly while the outer cylindrical part height decreased correspondingly. The shovel spinning process exhibits three distinct deformation stages (shovel-up, stable feed, and roller-closing) with the inner boss wall forming a knife-shaped top region, transitional middle region, and uniform straight wall bottom region. Microstructural analysis reveals distinct deformation mechanisms across different zones in shovel spinning, with grain size varying from 7.51 μm to 104.83 μm depending on local stress states. At 40 % shovel reduction ratio, dynamic recrystallization mechanisms significantly increase the proportion of high-angle grain boundaries to 51.6 % while reducing internal strain, resulting in substantial grain refinement and texture randomization. In contrast, multi-pass conventional spinning produces more uniformly refined grains with stable boundary distributions and lower strain heterogeneity, developing strong textures in critical regions. This combined spinning method represents a transformative approach to integrated manufacturing, enabling seamless weld-free fabrication of complex components with tailored microstructures, optimized mechanical properties, and superior structural integrity—eliminating traditional joining-related weaknesses while maintaining the dimensional accuracy and material continuity critical for high-performance applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119008"},"PeriodicalIF":7.5,"publicationDate":"2025-08-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829874","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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