Journal of Materials Processing Technology最新文献_第7页

A novel flexible-structured saw blade for bone cutting: reducing ploughing and promoting chip evacuation 一种用于骨切割的新型柔性结构锯片：减少犁耕和促进切屑的排出

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-08-05 DOI: 10.1016/j.jmatprotec.2025.119000

Han Wang, Urara Satake, Toshiyuki Enomoto

{"title":"A novel flexible-structured saw blade for bone cutting: reducing ploughing and promoting chip evacuation","authors":"Han Wang, Urara Satake, Toshiyuki Enomoto","doi":"10.1016/j.jmatprotec.2025.119000","DOIUrl":"10.1016/j.jmatprotec.2025.119000","url":null,"abstract":"<div><div>Oscillating bone sawing is widely employed in orthopedic surgery due to its ability to achieve precise bone resection with minimal damage to surrounding soft tissues. However, conventional saw blades with large negative rake angles often induce excessive ploughing forces, elevated temperatures, poor chip evacuation, accelerated tooth tip wear, and crack formation in bone tissue. While trajectory and vibration-assisted strategies have been explored, their reliance on complex mechanical systems limits clinical adoption. In this study, a novel saw blade with an embedded flexible structure is proposed, which passively adjusts the depth of cut through elastic deformation of the flexible structure. This design offers two key advantages: (1) when cutting with a negative rake face, the flexible tooth adaptively reduces the actual depth of cut, thereby reducing ploughing forces; and (2) when cutting with a positive rake face, periodic elastic deformation induces passive low-frequency vibrations, promoting shear crack formation and transforming continuous, spiral-like chips into fine, needle-like fragments, thereby improving chip evacuation. Multi-tooth sawing experiments confirmed that the proposed blade reduced sawing forces by 56.4 % in the feed direction and 36.7 % in the oscillation direction, suppressed peak cutting temperature to 43.3 °C (below the 47 °C threshold for cell damage), and significantly decreased tooth tip wear and groove wall cracking. These results demonstrate the effectiveness of the proposed structure as a compact, mechanically simple solution that complements motion-based strategies, enhancing cutting performance and adaptability in bone cutting applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119000"},"PeriodicalIF":7.5,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144771019","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

A novel phosphorescence-based thermometry technique for the measurement of tool temperature distribution in metal cutting 基于磷光的金属切削刀具温度分布测量新技术

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-08-05 DOI: 10.1016/j.jmatprotec.2025.119004

Henrik Feuk , Mattias Richter , Filip Lenrick , Rachid M'Saoubi , Volodymyr Bushlya

{"title":"A novel phosphorescence-based thermometry technique for the measurement of tool temperature distribution in metal cutting","authors":"Henrik Feuk , Mattias Richter , Filip Lenrick , Rachid M'Saoubi , Volodymyr Bushlya","doi":"10.1016/j.jmatprotec.2025.119004","DOIUrl":"10.1016/j.jmatprotec.2025.119004","url":null,"abstract":"<div><div>Precise knowledge of the temperature during cutting processes is of high interest as the temperature of a cutting tool dictates the performance, and for the workpiece it controls the quality and integrity of the generated surface. For the first time, in this study, a novel technique has been developed utilizing phosphor thermometry for 2D surface temperature measurement of a cutting tool in metal cutting. More specifically, lifetime-based phosphor thermometry was used as it has several advantages in accuracy over pyrometry-based methods, including being independent of emissivity and absolute optical signal intensity. The phosphor material, ruby (Al<sub>2</sub>O<sub>3</sub>:Cr), was coated on zirconia toughened alumina (ZTA) tools and used in orthogonal machining of hardened AISI 1045 (HRC 38). 2D surface temperature measurements with varying cutting speed, feed, and offset were performed to investigate their impact on the temperature. The phosphor thermometry results were also compared to infrared thermography measurements, and the results demonstrate issues for infrared thermography with the emissivity being temperature dependent and dynamically changing across the tool surface and time. Hence, phosphor thermometry offers a highly accurate alternative, yet at the cost of higher experimental complexity.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119004"},"PeriodicalIF":7.5,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144852508","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

Dual-channel welding torch with CO2 regulation for high-strength Ti/Fe joints: Weld formation and microstructure control 用于高强度Ti/Fe接头的CO2调节双通道焊枪：焊缝形成与显微组织控制

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-08-05 DOI: 10.1016/j.jmatprotec.2025.119006

Yujie Tao , Yibo Liu , Zuyang Zhen , Yue Liu , Qi Sun , Qingjie Sun

{"title":"Dual-channel welding torch with CO2 regulation for high-strength Ti/Fe joints: Weld formation and microstructure control","authors":"Yujie Tao , Yibo Liu , Zuyang Zhen , Yue Liu , Qi Sun , Qingjie Sun","doi":"10.1016/j.jmatprotec.2025.119006","DOIUrl":"10.1016/j.jmatprotec.2025.119006","url":null,"abstract":"<div><div>A dual-channel welding torch was innovatively employed in this work to enable separate delivery of Ar shielding gas and CO<sub>2</sub> active gas flows. By rotating the torch body, four distinct CO<sub>2</sub> incorporation modes relative to the molten pool were achieved: front-side, backside, 304SS-side, and TC4-side modes. The CO<sub>2</sub> gas served dual functions of arc ionization and surface oxidation, each of which significantly affected molten pool behaviors. A CO<sub>2</sub> gas flow of 1.0 L/min was determined as the threshold for effective arc ionization, promoting inward Marangoni flow and substantially improving joint back reinforcement. Surface oxidation of TC4 and 304SS happened at flow rates of 0.5 L/min and 1.5 L/min, respectively. Due to the differing oxidation resistances of Ti and Fe, the molten pool exhibited asymmetric spreading across the substrates, resulting in joint inclination. The inclination phenomenon caused uneven heat distribution across the joint, leading to excessive dissolution of Ti or Fe. Among the four incorporation modes, the front-side mode optimized the benefits of CO<sub>2</sub> ionization for molten pool regulation while minimizing oxidation risks. This configuration produced optimal weld formation and homogeneous microstructure, achieving a remarkable tensile strength of 525.5 MPa—a 183 % increase compared to pure Ar shielding under identical welding parameters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 119006"},"PeriodicalIF":7.5,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144780528","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

Performance enhancement of laser powder bed fusion Ti6Al4V via a novel ultrahigh speed shock approach using two developed setups 激光粉末床熔合Ti6Al4V的超高速冲击性能增强

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-08-02 DOI: 10.1016/j.jmatprotec.2025.119003

Qinming Gu , Zhenyu Zhang , Hongxiu Zhou , Feng Zhao , Jianian Hu

{"title":"Performance enhancement of laser powder bed fusion Ti6Al4V via a novel ultrahigh speed shock approach using two developed setups","authors":"Qinming Gu , Zhenyu Zhang , Hongxiu Zhou , Feng Zhao , Jianian Hu","doi":"10.1016/j.jmatprotec.2025.119003","DOIUrl":"10.1016/j.jmatprotec.2025.119003","url":null,"abstract":"<div><div>Pores and residual tensile stress are inevitable in laser powder bed fusion (LPBF), degrading the overall properties of the fabricated components. To address these challenges, a novel ultrahigh speed shock (UHSS) approach is proposed, in which a projectile reaches a velocity of 2.35 km/s using two custom-developed setups. The approach involves additive manufacturing with a self-made LPBF machine, followed by shock treatment with a custom-made two-stage light gas gun system. The velocity was optimized through molecular dynamics simulations and theoretical calculations. After UHSS, the tensile strength of Ti6Al4V increased from 1182.9 to 1576.8 MPa, representing a 33.3 % improvement while maintaining ductility. Additionally, the friction coefficient and wear rate under a 5 N load decreased from 0.733 and 6.475 × 10<sup>–4</sup> mm<sup>3</sup>/N∙m to 0.562 and 4.471 × 10<sup>–4</sup> mm<sup>3</sup>/N∙m, corresponding to reductions of 23.3 % and 31.0 %, respectively. The electric resistance increased from 1.63 to 2.28 MΩ‧cm<sup>2</sup> under UHSS, representing a 39.9 % improvement. Micro-computed tomography revealed that porosity approached zero after UHSS. Moreover, electron backscatter diffraction revealed a 41.8 % reduction in average crystallite size from 1.22 to 0.71 μm after UHSS. The enhanced properties are attributed to grain refinement, pore reduction, and the introduction of compressive stress. The proposed UHSS approach and two developed setups offer a new route for fabricating Ti6Al4V with remarkable properties, potentially applicable in extreme environments.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 119003"},"PeriodicalIF":7.5,"publicationDate":"2025-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144757842","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

Achieving strength-plasticity breakthrough of rare-earth free Mg alloy with multi-scale framework fabricated via laser-cold metal transfer hybrid additive manufacturing 利用激光-冷金属转移复合增材制造技术实现了无稀土镁合金多尺度骨架的强度-塑性突破

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-31 DOI: 10.1016/j.jmatprotec.2025.119002

Jian Zhu , Mengmeng Xu , Yongxin Cheng , Shuai Wu , Yixuan Mao , Xidong Hui , Hongyu Zheng

{"title":"Achieving strength-plasticity breakthrough of rare-earth free Mg alloy with multi-scale framework fabricated via laser-cold metal transfer hybrid additive manufacturing","authors":"Jian Zhu , Mengmeng Xu , Yongxin Cheng , Shuai Wu , Yixuan Mao , Xidong Hui , Hongyu Zheng","doi":"10.1016/j.jmatprotec.2025.119002","DOIUrl":"10.1016/j.jmatprotec.2025.119002","url":null,"abstract":"<div><div>To overcome the drawbacks of low strength and poor plasticity of Mg alloys, this work innovatively employed laser-cold metal transfer (CMT) hybrid additive manufacturing technology to fabricate rare-earth free Mg alloy with outstanding mechanical properties. The laser multi-remelting effect significantly promoted grain refinement and intensified columnar-to-equiaxed transition. The average grain sizes of CMT-zone, laser-induced single remelting zone and laser-induced multi-remelting zone were 15.89 μm, 8.75 μm and 3.56 μm, respectively. The average size of substructure in the laser multi-remelting zone was 310 nm. Due to the synergistic effect of the laser and CMT heat source, a multi-scale framework composed of micro-nano grains and dispersed precipitates was formed. The framework notably enhanced crack resistance, facilitated grain boundary strengthening and activated non-basal slip systems, thereby achieving an exceptional breakthrough of strength and plasticity. The laser-CMT hybrid additive manufacturing Mg alloy exhibited a tensile yield strength (TYS) of 224.8 MPa, an ultimate tensile strength (UTS) of 322.6 MPa and a plastic elongation (PE) of 13.5 %, which reached the levels of deformed Mg alloys. This study introduced a novel and highly promising additive manufacturing approach for producing large-scale and high-performance components made of Mg alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 119002"},"PeriodicalIF":7.5,"publicationDate":"2025-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144757857","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

Forming behavior and its effects on interfacial microstructure and tensile properties of thick 2219 aluminum alloy in friction plug welding 2219厚铝合金摩擦塞焊成形行为及其对界面组织和拉伸性能的影响

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-30 DOI: 10.1016/j.jmatprotec.2025.118999

Zhen Shao , Hang Liang , Yiming Huang , Suhong Zhang , Lina Zhang , Feifan Wang , Yanhua Zhao , Lei Cui , Guoqing Wang

{"title":"Forming behavior and its effects on interfacial microstructure and tensile properties of thick 2219 aluminum alloy in friction plug welding","authors":"Zhen Shao , Hang Liang , Yiming Huang , Suhong Zhang , Lina Zhang , Feifan Wang , Yanhua Zhao , Lei Cui , Guoqing Wang","doi":"10.1016/j.jmatprotec.2025.118999","DOIUrl":"10.1016/j.jmatprotec.2025.118999","url":null,"abstract":"<div><div>Friction plug welding (FPW) is a promising solid-state repair method for large aluminum alloy structures in aerospace applications, improving structural reusability and cost-efficiency. However, the unclear forming behavior and interfacial bonding mechanism hindered the improvement of joint quality, leading to suboptimal mechanical performance and restricting broader application. In this study, forming behavior of 20 mm thick 2219 aluminum alloy FPW joint was systematically investigated via integrated experiments and numerical simulations. During the welding, the workpiece material exhibited bidirectional material flow, while the maximum interface temperature during welding reached 548 °C. Meanwhile, the stress evolved from a localized concentration to a near-linear distribution along the thickness, and plastic deformation was more pronounced in the lower region of the joint. These spatiotemporally non-uniform thermo-mechanical fields influenced the spatial distribution and progression of dynamic recrystallization (DRX) across the bonding interface. DRX initiated at the lower region of the joint and gradually extended upward as strain and temperature evolved, accompanied by the progressive formation of medium angle grain boundaries. Notably, sustained high temperature and intense deformation in the middle and lower region led to Cu enrichment at interface and triggered the formation of Al–Al<sub>2</sub>Cu eutectic structure, thereby deteriorating local tensile properties. In contrast, the upper region exhibited refined equiaxed grains and superior strength and ductility. These findings elucidate the forming behavior and microstructural evolution in thick-plate FPW, and provide a scientific basis for welding process optimization and the rational design of joint geometry to achieve improved performance.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"344 ","pages":"Article 118999"},"PeriodicalIF":7.5,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144780527","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

Engineering heterostructures via layer-wise in-situ alloying in additive manufacturing: Compositional and architectural design in heterogeneous 316 L stainless steel for strength-ductility synergy 增材制造中通过分层原位合金化的工程异质结构：异质316 L不锈钢强度-延性协同的成分和建筑设计

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-28 DOI: 10.1016/j.jmatprotec.2025.118998

Yicheng Wang , Qihang Hu , Zhihong Yao , Bo Mao , Gangxian Zhu , Jiaqiang Li , Xing Zhang

{"title":"Engineering heterostructures via layer-wise in-situ alloying in additive manufacturing: Compositional and architectural design in heterogeneous 316 L stainless steel for strength-ductility synergy","authors":"Yicheng Wang , Qihang Hu , Zhihong Yao , Bo Mao , Gangxian Zhu , Jiaqiang Li , Xing Zhang","doi":"10.1016/j.jmatprotec.2025.118998","DOIUrl":"10.1016/j.jmatprotec.2025.118998","url":null,"abstract":"<div><div>Achieving a favorable balance between strength and ductility remains a critical challenge in additive manufacturing (AM) of structural metals. This study proposes a universally applicable design strategy based on layer-wise in-situ alloying, which enables flexible and coordinated control over composition and architecture within a single-alloy system. Using 316 L stainless steel as a model material, titanium (Ti) was selectively introduced into alternating layers during laser-directed energy deposition (L-DED) to construct laminated structures comprising Ti-alloyed (hard) and pure (soft) domains. The resulting heterostructures exhibit superior combinations of strength and ductility as compared to the homogenous samples. The high strength arises from the rule of mixture and hetero-deformation-induced (HDI) strengthening, while HDI strain hardening and twinning-induced plasticity (TWIP) delay necking and contribute to sustained ductility. Systematic investigations revealed that Ti content and laminate spacing critically influence microstructural heterogeneity and mechanical incompatibility due to the dilution phenomenon. Optimal mechanical performance was achieved with 1.5 wt.% Ti and a bilayer alloying pattern, yield a tensile strength of 726.1 MPa and uniform elongation of 41 %. These findings establish layer-wise in-situ alloying as a general design route for tailoring mesoscale heterogeneity and unlocking new performance regimes in AM-fabricated structural components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118998"},"PeriodicalIF":7.5,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144766492","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

Ti modification mechanisms and effects of processing parameters on defect control and equiaxed grain formation in laser powder bed fused Al-Li-Cu alloy 激光粉末床熔铝锂铜合金Ti改性机理及工艺参数对缺陷控制和等轴晶粒形成的影响

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-26 DOI: 10.1016/j.jmatprotec.2025.118997

Qian Wang , Meng Wang , Xueping Li , Yufan Shen , Shuai Guo , Jiabao Guo , Xin Lin , Weidong Huang

{"title":"Ti modification mechanisms and effects of processing parameters on defect control and equiaxed grain formation in laser powder bed fused Al-Li-Cu alloy","authors":"Qian Wang , Meng Wang , Xueping Li , Yufan Shen , Shuai Guo , Jiabao Guo , Xin Lin , Weidong Huang","doi":"10.1016/j.jmatprotec.2025.118997","DOIUrl":"10.1016/j.jmatprotec.2025.118997","url":null,"abstract":"<div><div>Elements such as Sc, Zr and Ti have been employed for the modification of aluminum alloys to enhance their laser powder bed fusion (L-PBF) formability. However, critical knowledge gaps persist in elucidating the fundamental mechanisms and differential modification behaviors among these elements, while the parametric effects of laser processing on modification efficacy remain insufficiently characterized, necessitating comprehensive mechanistic investigations. In this study, Ti, with a lower density and cost, was incorporated into the Al-Li-Cu alloy to improve the formability. The results indicated that Ti incorporation notably refined the grain structure, eliminated the defects, and granted the alloy excellent mechanical properties with a tensile strength of 516.5 ± 2.7 MPa and an elongation of 6.78 ± 0.80 % obtained after heat treatment. Results indicated that the modification capability of Ti is predominantly constrained by forced undercooling in the melt pool. Al<sub>3</sub>Ti particles are activated near the center of the molten pool with the development of undercooling during solidification, contributing to a microstructure with columnar grains at the boundary and equiaxed grains near the center of the molten pool. While the modification capabilities are restricted by the cooling rate for Sc and Zr, as the formation of Al<sub>3</sub>Sc and Al<sub>3</sub>Zr near the molten pool center is suppressed. The microstructure is controlled by the various sizes of Al<sub>3</sub>Ti particles formed under different laser parameters. The size of Al<sub>3</sub>Ti particles increased from 30 to 80 nm to about 200–300 nm with elevated laser energy density, which reduces the required activating undercooling for Al<sub>3</sub>Ti particles, results in samples with complete fine equiaxed grains.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118997"},"PeriodicalIF":7.5,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750294","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

Influence of localized alloy composition tailoring by laser-induced element evaporation on the mechanical properties of aluminum alloy AA7075 激光诱导元素蒸发局部化合金成分裁剪对AA7075铝合金力学性能的影响

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-25 DOI: 10.1016/j.jmatprotec.2025.118996

Henrik Zieroth , Marcel Stephan , Eva Hufnagel , Michael Schmidt , Marion Merklein

{"title":"Influence of localized alloy composition tailoring by laser-induced element evaporation on the mechanical properties of aluminum alloy AA7075","authors":"Henrik Zieroth , Marcel Stephan , Eva Hufnagel , Michael Schmidt , Marion Merklein","doi":"10.1016/j.jmatprotec.2025.118996","DOIUrl":"10.1016/j.jmatprotec.2025.118996","url":null,"abstract":"<div><div>As the demand for lightweight materials in industries such as automotive and aerospace grows, high-strength aluminum alloys are essential to meet stringent performance requirements. While these alloys offer an excellent strength-to-weight ratio, they often face challenges in terms of formability, limiting their broader applicability. This investigation advances beyond conventional Tailor Heat Treated Blanks (THTB) by adjusting the chemical composition in forming-critical areas, such as transitions, radii, and flange zones. Tailor Alloyed Blanks (TAB) provide an approach for adapting both microstructure and elemental distribution, surpassing the capabilities of traditional thermal treatments. This study explores the application of Tailor Alloyed Blank to AA7075, with limited formability, demonstrating its local modification toward the properties of a more ductile 6xxx series alloy. By optimizing laser parameters, selective evaporation of zinc (Zn) and magnesium (Mg) was achieved, leading to enhanced ductility without compromising the base material’s strength. This approach enables the creation of regions with tailored strength and ductility profiles, allowing local adjustments in critical areas. The findings indicate that local modifications of the alloy composition improve formability, as evidenced by reduced forming forces and lower springback behavior observed in the forming trial. This principle can be extended to other precipitation-hardening alloys, provided that their mechanical behavior is governed by alloying elements whose addition or removal is physically feasible via thermal evaporation, based on their boiling points. These results establish a framework for achieving targeted mechanical properties, positioning it as a novel method for tailoring aluminum alloys requiring customized material properties.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118996"},"PeriodicalIF":7.5,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144738781","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

Spattering trajectory, residing pattern and trap ratio under various gas flow conditions in large-scale laser powder bed fusion: Experiment and simulation 大型激光粉末床熔合中不同气流条件下的溅射轨迹、滞留模式和俘获比：实验与模拟

IF 7.5 2区材料科学

Journal of Materials Processing Technology Pub Date : 2025-07-25 DOI: 10.1016/j.jmatprotec.2025.118995

Zixin Liu , Yongqiang Yang , Di Wang , Wenjun Ge , Wentao Yan

{"title":"Spattering trajectory, residing pattern and trap ratio under various gas flow conditions in large-scale laser powder bed fusion: Experiment and simulation","authors":"Zixin Liu , Yongqiang Yang , Di Wang , Wenjun Ge , Wentao Yan","doi":"10.1016/j.jmatprotec.2025.118995","DOIUrl":"10.1016/j.jmatprotec.2025.118995","url":null,"abstract":"<div><div>The larger build platform in large-scale laser powder bed fusion (LPBF) equipment results in a higher incidence of residual spatters, which can adversely affect the consistency of part quality. Inert gas flow is an efficient way to transport spatters to outlet, but a comprehensive understanding of spatter trajectory and residing pattern under gas flow effect remains unclear. In this study, Computational Fluid Dynamics (CFD) coupled with a Discrete Phase Model (DPM) is employed to simulate spatter trajectories, and the distribution of residual spatters are validated against experimental data obtained by processing images captured by camera. A significant quantity of sizable spatters land in close proximity to the melt region. According to our statistics, 96.5 % of droplet spatter are trapped on the powder bed when the gas flow velocity is 0.5 m/s, with the trap ratio diminishing as gas flow becomes stronger. Excessively high gas flow velocities result in droplet spatter engaging in secondary circulation by gas flow vortex within the building chamber, finally leading to a decline in the melted surface quality. The simulation approach can offer practical guidance in optimizing the design of the building chamber and inlet/outlet in large-scale LPBF equipment to minimize the impact of spattering on built quality.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118995"},"PeriodicalIF":7.5,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750372","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