Journal of Materials Processing Technology最新文献

{"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 ,&nbsp;Meng Wang ,&nbsp;Xueping Li ,&nbsp;Yufan Shen ,&nbsp;Shuai Guo ,&nbsp;Jiabao Guo ,&nbsp;Xin Lin ,&nbsp;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. Al₃Ti 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 Al₃Sc and Al₃Zr near the molten pool center is suppressed. The microstructure is controlled by the various sizes of Al₃Ti particles formed under different laser parameters. The size of Al₃Ti particles increased from 30 to 80 nm to about 200–300 nm with elevated laser energy density, which reduces the required activating undercooling for Al₃Ti 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}

{"title":"Influence of localized alloy composition tailoring by laser-induced element evaporation on the mechanical properties of aluminum alloy AA7075","authors":"Henrik Zieroth ,&nbsp;Marcel Stephan ,&nbsp;Eva Hufnagel ,&nbsp;Michael Schmidt ,&nbsp;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}

{"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 ,&nbsp;Yongqiang Yang ,&nbsp;Di Wang ,&nbsp;Wenjun Ge ,&nbsp;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}

{"title":"LIPSS in thin films as a large-scale mask for deep etching of sub-micron photonic structures","authors":"Mantas Mikalkevičius ,&nbsp;Mindaugas Juodėnas ,&nbsp;Andrius Vasiliauskas ,&nbsp;Sigitas Tamulevičius ,&nbsp;Tomas Tamulevičius ,&nbsp;Asta Tamulevičienė","doi":"10.1016/j.jmatprotec.2025.118994","DOIUrl":"10.1016/j.jmatprotec.2025.118994","url":null,"abstract":"<div><div>Reactive ion etching (RIE) processes are often involved in the fabrication of high aspect ratio structures. While a material with high etch selectivity to substrate is preferred, it can be compensated for by increasing the thickness of the mask. However, fabricating a mask that is both thick and maintains high lateral resolution is a difficult technological task. Laser-induced periodic surface structures (LIPSS) offer a promising route to surpass the diffraction limit in conventional photolithography. Here, we demonstrate the formation of sub-micron LIPSS using femtosecond laser processing as a rapid, wafer-scale alternative for fabricating hard masks suitable for RIE. We identify optimal conditions for LIPSS formation in chrome thin films by varying the spatial pulse overlap of a 1030 nm wavelength Yb:KGW laser and demonstrate how LIPSS formation regime transitions from short-range to long-range order in the fluence interval from 147 mJ/cm² to 245 mJ/cm². Under optimized conditions, we produce nearly ideal patterns that we subsequently employ as a mask for diffraction grating fabrication. We transfer these periodic structures into silicon using RIE, resulting in 880 nm period linear diffraction gratings. Measurements show that the structures formed using the highest laser fluence have &lt; 1 % reflectance in Vis-nIR. Whereas LIPSS made with 220 mJ/cm² fluence indicated 1.3 % relative diffraction efficiency in reflection at 635 nm wavelength. Scalability of high-quality diffraction grating origination technology under 245 mJ/cm² fluence was evidenced by wafer-scale patterning and feasibility for replication in PDMS, carrying 8.2 % diffraction efficiency in transmission at 405 nm wavelength.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118994"},"PeriodicalIF":6.7,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703449","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":"Magnetically controlled homogenised plasma-assisted mechanochemical lapping of calcium fluoride optical components","authors":"Xiaolong Hu ,&nbsp;Wei Li ,&nbsp;Minhao Qu ,&nbsp;Qiancheng Huang ,&nbsp;Maojun Li ,&nbsp;Wei Feng","doi":"10.1016/j.jmatprotec.2025.118993","DOIUrl":"10.1016/j.jmatprotec.2025.118993","url":null,"abstract":"<div><div>Calcium fluoride (CaF₂) optical components are ideal candidates for potential applications in Inertial Confinement Fusion megascience facilities. However, their high brittleness and chemical inertness pose significant challenges in achieving uniformity and near-damage-free processing for large-aperture optical elements. To address this, this study innovatively employs magnetron-controlled H₂O(g) plasma to homogeneously modify CaF₂ surfaces, effectively reducing material brittleness and expanding the ductile-domain machinable scale. A strategy integrating strongly oxidative mechanochemical lapping tools is proposed, enabling contact-based chemical modification followed by soft abrasive removal, thereby realizing high-precision flattening of large-aperture optical components. Through multiscale simulations and experimental validation, the mechanisms of magnetron plasma homogenization and mechanochemical lapping-induced surface generation are systematically elucidated. Results demonstrate that the magnetron plasma-modified layer exhibits excellent uniformity with a modification depth of approximately 50 nm. After oxidative composite abrasive mechanochemical lapping, the plasma-modified layer is preferentially removed at an enhanced efficiency of 172 nm/min without introducing secondary damage. The processed CaF₂ surface achieves a surface roughness of 1.1 nm. This research propels the application of magnetically controlled homogenized plasma modification technology in ultra-precision machining, establishing critical technical support for processing advanced optical components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118993"},"PeriodicalIF":6.7,"publicationDate":"2025-07-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144714093","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":"Investigating novel forging mechanisms for thin dissimilar copper-aluminum rod weldments via pressure-controlled Joule-heating and interfacial deformation","authors":"Rishabh Shotri ,&nbsp;Gakuto Masuno ,&nbsp;Masakazu Mori ,&nbsp;Yoshiaki Morisada ,&nbsp;Kohsaku Ushioda ,&nbsp;Hisashi Serizawa ,&nbsp;Hidetoshi Fujii","doi":"10.1016/j.jmatprotec.2025.118992","DOIUrl":"10.1016/j.jmatprotec.2025.118992","url":null,"abstract":"<div><div>The novel mechanism of pressure-controlled Joule heating and interfacial deformation offers a route to forging high-strength aluminum-copper weldments, crucial for electrical connections and discharge systems. However, despite their lightweight, rigidity, and high conductivity, differences in melting points, thermal expansion, and strength often hinder effective joining. This study investigates plastic yielding at a controlled temperature while maintaining pressure for high-strength bonding in 5 mm thin aluminum copper rods. A novel experimental setup is developed using an electro-servo press and pneumatically controlled retractable tapered hollow semi-circular copper electrodes for localized heating and mechanical displacement at set pressure for interfacial plastic flow. Finite element-based coupled electric-thermal and dynamic mechanical simulations evaluated the transient heat flux, thermal gradients, and plastic stress that drive the interfacial strain and deformation. Computed and measured results reveal high-strength welds (113–155 MPa) with 2–4.6 interfacial plastic strain, forming thin (0.114–0.176 μm) intermetallic layers under 25–40 MPa applied pressure. The external die enclosures enhance contact and strain concentration. Additionally, the joining behavior under the axial current discharge are investigated and compared. Both copper and aluminum weld interfaces undergo grain refinement via dynamic recrystallization under low-temperature plastic deformation, slightly increasing weld microhardness. Computed lower temperature increment during welding at higher pressure and smaller stroke implies homogeneous interfacial yielding for high-strength welds, enhancing the understanding of forging mechanisms for industrial applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118992"},"PeriodicalIF":6.7,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144686896","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":"Strategic design of oxidation-resistant nickel-based superalloys: Comparative study of enhancing mechanism of Y2O3 doping and Y alloying on the high-temperature oxidation","authors":"Xiaopeng Cheng ,&nbsp;Xin Chen ,&nbsp;Teng Ma ,&nbsp;Zhengjiang Gao ,&nbsp;Zhu Qian ,&nbsp;Xia Sun ,&nbsp;Zongqing Ma","doi":"10.1016/j.jmatprotec.2025.118991","DOIUrl":"10.1016/j.jmatprotec.2025.118991","url":null,"abstract":"<div><div>Nickel-based superalloys fabricated via laser powder bed fusion (LPBF) suffer from microsegregation and microdefects due to rapid solidification, which destabilize the oxidation protective layer and accelerate high-temperature oxidation, severely deteriorating their oxidation resistance during high-temperature service. In this work, two distinct powder processing strategies, Y₂O₃ nanoparticles doping and Y element alloying, were employed to enhance the high temperature oxidation resistance of LPBF Hastelloy X (HX) nickel-based alloy through targeted microstructural engineering. The results show that both Y₂O₃-doping (HX-Y₂O₃) and Y-alloying (HX-Y) can enhance the high-temperature oxidation resistance of HX alloy. Compared to the HX sample, the parabolic oxidation rate constant of the HX-Y₂O₃ and HX-Y samples decrease from 12.46 × 10⁻³ mg² cm⁻⁴ h⁻¹ to 1.45 × 10⁻³ mg² cm⁻⁴ h⁻¹ and 0.2312 × 10⁻³ mg² cm⁻⁴ h⁻¹, respectively. Y₂O₃ nanoparticles provide extra nucleation sites for oxidation products, contributing to the rapid formation of dense oxide layers. As for the HX-Y alloy, the Y element can effectively occupy the grain boundary (GB) vacancies and reduce the diffusion rate of the oxide-forming elements, thus significantly reducing the oxidation rate and improving the adherence and the resistance to spallation of the oxide layer. This study establishes a fundamental framework correlating powder processing strategies with oxidation protection mechanisms. The findings provide generalized guidelines for designing oxidation-resistant additive manufacturing (AM) alloys through targeted microstructural engineering during powder processing. Furthermore, the developed principles demonstrate substantial potential for extension to other oxidation-susceptible alloy systems.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118991"},"PeriodicalIF":6.7,"publicationDate":"2025-07-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144679412","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":"Mechanistic investigation of thickness-controlled microstructure and magnetic performance in Sb-microalloyed ultra-thin Fe-6.5 %Si ribbons fabricated by planar flow casting","authors":"Feilong Sun,&nbsp;Xinyuan Zhang,&nbsp;Pei Li,&nbsp;Guoyang Li,&nbsp;Guilin Wu,&nbsp;Honghui Wu,&nbsp;Junheng Gao,&nbsp;Haitao Zhao,&nbsp;Chaolei Zhang,&nbsp;Jun Lu,&nbsp;Yuhe Huang,&nbsp;Shuize Wang,&nbsp;Xinping Mao","doi":"10.1016/j.jmatprotec.2025.118990","DOIUrl":"10.1016/j.jmatprotec.2025.118990","url":null,"abstract":"<div><div>Planar flow casting (PFC) is recognized as a promising near-net-shape technology for fabricating Fe-6.5 %Si alloy ribbons. However, its application is constrained by poor melt wettability, insufficient cooling efficiency, and unstable thickness control. To address these challenges, this study introduces a synergistic strategy combining Sb-induced surface energy reduction with enhanced system cooling capacity, enabling the stable fabrication of ultra-thin Fe-6.5 %Si-0.1 %Sb ribbons with controlled thicknesses. Subsequent low-strain rolling and annealing were further employed to optimize magnetic performance. A systematic investigation was conducted to clarify the mechanisms linking processing conditions, microstructural evolution, and magnetic performance. Results reveal that ribbon thickness regulates the cooling rate, thereby governing grain growth, texture formation and B2/D0₃ ordered phases precipitation. Thicker ribbon exhibits a more favorable texture, resulting in higher magnetic induction. Based on loss separation theory and microstructural analysis, total iron loss in annealed ribbons is determined by the frequency-dependent interplay between hysteresis and eddy current losses, which are primarily governed by grain size and ribbon thickness, respectively. At medium frequencies where hysteresis loss dominates, total loss decreases monotonically with grain size. At high frequencies, thicker ribbons exhibit increased eddy current loss but reduced hysteresis loss due to larger grain size. Such a competitive mechanism leads to a non-monotonic variation in total iron loss. This work presents a research paradigm for planer flow casting of ultra-thin Fe-6.5 %Si ribbons and provides theoretical insights and useful references for the manufacture of other high-performance metallic foils.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118990"},"PeriodicalIF":6.7,"publicationDate":"2025-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144679413","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":"Enhancing formability via reciprocating counter-roller spinning: Dynamic coordination of complex flexible return path","authors":"Ning Yang ,&nbsp;Lijun Zhang ,&nbsp;Liuyang Jiao ,&nbsp;Hong Chi ,&nbsp;Yucai Li ,&nbsp;Kaiguang Luo ,&nbsp;Shen Fan ,&nbsp;Jian Zhong ,&nbsp;Hao Zhang","doi":"10.1016/j.jmatprotec.2025.118988","DOIUrl":"10.1016/j.jmatprotec.2025.118988","url":null,"abstract":"<div><div>To address the inherent trade-off between high performance and insufficient precision in the conventional counter-roller spinning (CRS) process, a novel reciprocating counter-roller spinning (RCRS) methodology is proposed, featuring coordinated control between the working path and a complex flexible return path. Crucially, the return stroke is transformed from an idle movement into a \"dynamic compensation path\" with active error-correction capability, fully leveraging the trajectory flexibility inherent in CRS to achieve path-level dynamic correction of forming errors. To realize this, a flexible return path optimization model based on ideal shape discrepancy compensation is established. A multi-objective optimization framework correlating the compensation coefficient <em>k</em> with geometric accuracy is developed. The optimal path design is achieved using the non-dominated sorting genetic algorithm (NSGA-II) on a Kriging surrogate model. Furthermore, an adaptive return path interpolation program is developed by integrating MATLAB and Mastercam, ultimately enabling the high-quality integrated forming of geometric precision and mechanical properties in cylindrical workpieces. Simulation and experimental results demonstrate significant improvements: The average straightness <em>L</em> and maximum outer generatrix contour deviation Δ<em>D</em>_R of formed parts are remarkably enhanced from the 10⁻¹ to the 10⁻² level, representing improvement rates of 71.38 % and 77.37 %, respectively. This effectively resolves the \"precision bottleneck\" of CRS. Although localized stress state changes occurred in the \"inner concave\" correction zone due to intensified material flow, the overall forming performance showed a clear enhancement over the original blank. Microstructural analysis further revealed a uniform {001}&lt; 100 &gt; texture and <em>η</em>-fiber structure. The primary strengthening mechanism is identified as dislocation multiplication and entanglement induced by geometrically necessary dislocation density <em>ρ</em>_GND. These results provide verifiable theoretical mechanisms and a key technical pathway for promoting the application of highly flexible CRS in high-precision manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118988"},"PeriodicalIF":6.7,"publicationDate":"2025-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144657031","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":"Solid-state additive manufacturing of dissimilar 7075–2024 aluminum alloys by additive friction stir deposition: Interfacial bonding and process optimization","authors":"Minglei Dong,&nbsp;Yuyu Li,&nbsp;Tingzhuo Chen,&nbsp;Chengchao Du,&nbsp;Xudong Ren","doi":"10.1016/j.jmatprotec.2025.118989","DOIUrl":"10.1016/j.jmatprotec.2025.118989","url":null,"abstract":"<div><div>Additive Friction Stir Deposition (AFSD), an emerging solid-state additive manufacturing technique, has shown great promise in processing single aluminum alloys. However, its applicability to dissimilar aluminum alloys remains unclear. In this study, the feasibility of additive friction stir deposition for fabricating dissimilar 7075–2024 aluminum alloy structures was investigated for the first time. The effects of tool rotational speed (800–1400 rpm) on interfacial bonding, microstructural evolution, and mechanical properties were systematically studied. All deposited samples exhibited defect-free macrostructures within the studied range. Increasing the rotational speed resulted in grain refinement in the mid-layer regions of both 7075 and 2024, reaching minimum average grain sizes of 1.14 µm and 1.40 µm, respectively. The fraction of high-angle grain boundaries (HAGBs) increased significantly, reaching 86.1 % and 67.0 %, along with recrystallization fractions of 91.04 % and 84.39 % in 7075 and 2024 layers, respectively. At 1100 rpm, a uniform distribution of strengthening precipitates was observed, with the hardness reaching 75 % of the base materials and the highest tensile strength (181.9 MPa) and elongation (6.3 %) obtained. Further increases in rotational speed led to partial dissolution of precipitates due to excessive heat input, reducing hardness. While additive friction stir deposition was proven effective for fabricating dissimilar aluminum alloys, the tensile properties in the build direction (BD) were noticeably inferior to those in the longitudinal direction (LD). This study demonstrates that large-area joining of dissimilar aluminum alloys can be achieved via the AFSD process, providing a novel approach for the bonding of dissimilar alloys and laying a theoretical foundation for the AFSD fabrication of such materials.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"343 ","pages":"Article 118989"},"PeriodicalIF":6.7,"publicationDate":"2025-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144657032","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}