Journal of Materials Processing Technology最新文献

{"title":"Influence of SiC interlayer on mechanical and electrical joint characteristics of Cu-Al-Cu sandwich spot welds obtained using a new friction processing technique","authors":"Debanjan Maity,&nbsp;Vikranth Racherla","doi":"10.1016/j.jmatprotec.2025.118737","DOIUrl":"10.1016/j.jmatprotec.2025.118737","url":null,"abstract":"<div><div>Al busbars with Cu welded to Al on top and bottom, at lug connections, offer huge potential in carrying large currents at lower weight, cost and connection temperatures. Smaller weld areas increase joint electrical contact resistance and thinning of Cu, Al sheets during welding can cause premature failure in spot welds particularly in multilayer configuration. This work aims to overcome these drawbacks by obtaining large joint area Cu-Al-Cu sandwich spot welds using a new friction processing technique with and without SiC interlayer at joint interfaces. The technique eliminates direct stirring and reduces thinning of metal sheets to be joined. Localized melting and interdiffusion at Al-Cu interfaces at near eutectic temperatures is used to obtain the welds simultaneously at top and bottom joint interfaces. Thrust load and joint temperatures are used to investigate changes in weld microstructure and joint mechanical, electrical properties from presence of SiC particles at joint interfaces. Introduction of SiC particles, resulted in homogenous welds at top as well as bottom interfaces with smaller pores and thicker melt layer from enhanced interdiffusion. Improved wetting of eutectic melt with SiC particles and Al, Cu sheets, increased effective joining area, reduced electrical contact resistance, and increased joint strength. During fracture, cracks originated in brittle Al₂Cu intermetallic phase next to Cu. However, the intermetallic phase appeared as scattered with interspersed Al in between. Consequently, cracks took a tortuous route around the SiC particles embedded in eutectic melt region increasing fracture toughness.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118737"},"PeriodicalIF":6.7,"publicationDate":"2025-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174104","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":"Pressure-dependent shape adaptive multi-jet polishing for edge effect restraint","authors":"Zili Zhang ,&nbsp;Chi Fai Cheung ,&nbsp;Jiang Guo ,&nbsp;Chunjin Wang","doi":"10.1016/j.jmatprotec.2025.118734","DOIUrl":"10.1016/j.jmatprotec.2025.118734","url":null,"abstract":"<div><div>Fluid jet polishing (FJP) can achieve high surface quality and form accuracy in finishing freeform surfaces. Due to its advantages, FJP has been widely used in the ultra-precision manufacturing process of high-end components. However, the edge effect in FJP poses a great challenge to the uniform material removal control at the edge, which has not been investigated in depth hitherto. The non-uniform material removal at the edge deteriorates the form accuracy and affects the functional performance of components, especially in the field requiring extremely high precision. The traditional strategy for restraining the edge effect through the movement system is limited by the extremely high acceleration speeds within a small distance. To address this problem, the cause of the edge effect in FJP is first revealed by computational fluid dynamics (CFD) simulation. Hence, this study presents a pressure-dependent shape-adaptive multi-jet polishing (PDSAMJP) system to restrain the edge effect. The material removal discrepancies were compensated for by adjusting the jet pressure, rather than modifying the feed rate of the machine tool. A surface generation model at the edge was established to optimize the jet pressure distribution. The effectiveness of the PDSAMJP system was validated by jet pressure response measurements and a series of polishing experiments. Compared to traditional jet polishing, the PDSAMJP method enhanced the radius of curvature of the edge surface from 15.2–41.4 μm to 73.2–143.9 μm by mitigating edge collapse. The success of this study provides an approach to restraining the edge effect of FJP, thereby enhancing the manufacturing accuracy of ultra-precision freeform surfaces. Furthermore, the principles established herein can be applied to other polishing processes, such as bonnet polishing, to achieve uniform material removal by adjusting a parameter with a fast response, without compromising the stability of the movement system.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118734"},"PeriodicalIF":6.7,"publicationDate":"2025-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174930","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":"Investigation on control of middle and high-spatial frequency errors of fused silica optics melt polished by CO2 lasers","authors":"Tianhao Zhang ,&nbsp;Zhaoyang Yin ,&nbsp;Linjie Zhao ,&nbsp;Jian Cheng ,&nbsp;Mingjun Chen ,&nbsp;Tianyuan Li ,&nbsp;Wei Liao ,&nbsp;Xiaodong Yuan ,&nbsp;Xiaolong Jiang","doi":"10.1016/j.jmatprotec.2025.118733","DOIUrl":"10.1016/j.jmatprotec.2025.118733","url":null,"abstract":"<div><div>Surface and subsurface defects introduced in traditional mechanical polishing seriously influence the laser damage threshold of fused silica. As a non-contact processing technology, CO₂ laser melt polishing could obtain smooth surface by healing surface defects and cracks. However, due to the non-uniformity of the thermal interaction, the mid- and high-spatial frequency errors of the polished optic are pretty high, which seriously reduces the surface quality and even causes light field modulation. In this work, the formation mechanism of the mid- and high-spatial frequency errors of fused silica polished by lasers was explored through temperature and fluid fields multi-physics coupling simulation. Then, the factors influencing the mid-and high-spatial frequency errors were explored. The results showed that the errors of the optic were greatly influenced by the laser scanning speed and track pitch. Then, an innovative polishing strategy was proposed by combining multi-layer high-speed polishing with single-layer low-speed polishing. The mid- and high-spatial frequency error was reduced from 47 nm to 17.7 nm and the high-spatial frequency error was reduced from 8.4 nm to 1.5 nm compared with the previous results. This work revealed the formation mechanism of the mid- and high-spatial frequency errors through multi-physics coupling simulation and effectively controlled the errors by using an innovative polishing strategy. It can offer both theoretical and experimental advice for the ultra-precision machining technique employed on fused silica.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118733"},"PeriodicalIF":6.7,"publicationDate":"2025-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174105","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":"A novel and efficient multi-jet plasma polishing process for optical fabrication","authors":"Zhe Fan ,&nbsp;Zhoulong Li ,&nbsp;Rui Wang ,&nbsp;Nan Yu ,&nbsp;Mingjun Ren ,&nbsp;Xinquan Zhang ,&nbsp;Limin Zhu","doi":"10.1016/j.jmatprotec.2025.118735","DOIUrl":"10.1016/j.jmatprotec.2025.118735","url":null,"abstract":"<div><div>There is an increasing demand for higher precision, larger sizes, and greater machining efficiency for freeform optical elements due to the rapid development of advanced optics. Plasma processing technology has gained significant attention due to its capability for damage-free and high-precision optical fabrication; however, achieving high processing efficiency for medium- to larger-aperture optical elements remains a challenge. This paper proposes a novel multi-jet polishing process based on the atmospheric pressure plasma jet (APPJ), capable of high-efficiency deterministic optical polishing. First, the uniformity of the proposed tool was verified through spatial electric field simulations, and the electrode size parameters were further optimized to ensure uniformity and stability. Subsequently, etching experiments were conducted to optimize the relevant process parameters, achieving stable and efficient material removal. The volumetric removal rate increased to 9.4 times that of the conventional small-size single APPJ process, which was greater than the increase in the number of processing units. Then the surface generation mechanism was analyzed, verifying that the proposed process can effectively mitigate mid-spatial frequency errors induced by periodic tool path. Finally, a fused silica window with a form error of PV 111.6 nm and RMS 16.63 nm was achieved through the deterministic polishing experiment and the processing efficiency is nearly 9 times higher than that of a single APPJ, which shows that the proposed multi-jet plasma polishing process is an efficient, high-precision and stable optical fabrication process. The number of processing units could be increased from a few to dozens by extending the periodic array of single-unit APPJs, thus demonstrating significant potential for the optical fabrication of medium- to large-aperture elements.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118735"},"PeriodicalIF":6.7,"publicationDate":"2025-01-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174938","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":"A symmetric and asymmetric yield function based on normalized stress invariant suitable for sheet and bulk metals under various stress states","authors":"Jia Wang ,&nbsp;Aiguo Pi ,&nbsp;Zhao Zhang ,&nbsp;Mingze Wu ,&nbsp;Fenglei Huang ,&nbsp;Zijun Wang ,&nbsp;Fei Hao","doi":"10.1016/j.jmatprotec.2025.118728","DOIUrl":"10.1016/j.jmatprotec.2025.118728","url":null,"abstract":"<div><div>Sheet and bulk metals experience stress states in a wide stress state range under most of the static and dynamic service environments, but the existing yield functions cannot reasonably and accurately describe the strength or different hardening behaviors under those stress state ranges. In this paper, to accurately characterize the strength in a wide stress state range, a yield function is proposed that considers the effects of hydrostatic pressure and the third invariant and symmetric and asymmetric behavior. Experiments are carried out to characterize the plastic behavior of Al 6061 and high-strength 30CrMnSiNi2MoVE steel (30VE) between plane strain compression and plane strain tensile, and the strain hardening law is obtained by the inverse engineering approach. The strength of FCC metal Al 6061 and Al 7075-T6, BCC metal 30 V and QP1180, and HCP metal AZ31 is characterized by the proposed isotropic yield function to validate its effectiveness and flexibility and compared with the Yoon (2014), Lou (2020), and Lou (2022), Tresca, and Mises yield functions. Flowering, the proposed function is extended to model the different hardening behaviors and applied to model the evolution of yield surfaces of Al6061 and QP1180 at different strain levels. Finally, the proposed yield function is extended into anisotropic form by three different fourth-order linear transformation tensors to the second and third invariants, respectively. And applied to characterize the anisotropic behavior of different types of metals. The effectiveness of the proposed yield function’s anisotropic form is validated by the FCC metals Al 2090-T3 and Al 5754-O, BCC metal DP980, and HCP metal AZ31B, pure textured magnesium, and Mg-0.5 % Th alloy; and compared with Yld2000–2d, Lou (2013), and Yoon (2014) yield functions. The result shows that the proposed yield function in the isotropic form provides higher flexibility and universality to model the strength and the different hardening behaviors of BCC, FCC, and HCP metals. The flexibility of the proposed yield function’s anisotropic form can accurately characterize the anisotropic behavior of BCC, FCC, and HCP metals. Accordingly, the proposed yield function is not only recommended to model the strength and the different hardening behavior of isotropic sheet and bulk metal but also anisotropic. Since the yield function is the key to accurately predicting the plastic deformation and fracture behavior of engineering structures, it is suggested to use the proposed yield function to simulate the plastic and fracture behavior of sheet and bulk metal structures in both static and dynamic analysis.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118728"},"PeriodicalIF":6.7,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174101","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":"A generic framework for tailoring microstructures and mechanical properties in extruded magnesium alloys via rotational strain porthole die extrusion: A case study on Mg-RE hollow profiles","authors":"Kui Wang ,&nbsp;Xinwei Wang ,&nbsp;Chenyang Luo ,&nbsp;Shijie Liu ,&nbsp;Peng Huan ,&nbsp;Jiacheng Li ,&nbsp;Chengchao Du ,&nbsp;Shaozhu Wang ,&nbsp;Cunlong Wang ,&nbsp;Jingfeng Wang","doi":"10.1016/j.jmatprotec.2025.118732","DOIUrl":"10.1016/j.jmatprotec.2025.118732","url":null,"abstract":"<div><div>Controlling microstructural evolution and texture to improve mechanical properties and weld seam integrity in Mg-RE hollow profiles is a generic challenge in materials processing. To address this, a novel Rotational Strain Porthole Die Extrusion (RSPDE) technique was developed, introducing circumferential shear strain during extrusion to refine texture and enhance dynamic recrystallization. Using Mg-8.8Gd-3.8Y-1.0Zn-0.7Mn hollow profiles as a case study, the RSPDE process achieved finer grains in the matrix zone, narrowed the precipitation-free zone in the welding seam, and reduced basal texture intensity compared to conventional porthole die extrusion (CPDE). Although the weld seam remained somewhat weaker due to larger grain sizes and absence of β' and γ' precipitates, subsequent aging treatments improved tensile strength. These improvements, however, came with reduced ductility due to precipitate-dislocation interactions. Despite this trade-off, RSPDE produced more homogeneous microstructures, weaker basal textures, and superior weld seam quality than CPDE. Fundamentally, this work establishes a transferable framework that links controlled shear deformation to predictable microstructural refinement and texture control, enabling more informed process optimization and alloy design strategies. This generic approach thus offers predictive guidelines for structural design and optimization across a broad range of high-strength magnesium alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118732"},"PeriodicalIF":6.7,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174103","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":"Effects of arc waveforms on morphology, microstructure, and properties of unsupported bars in wire and arc additive manufacturing","authors":"Hao Mao ,&nbsp;Changmeng Liu ,&nbsp;Xue Ling ,&nbsp;Hanwen Xu ,&nbsp;Jiawei Xie ,&nbsp;Rui Fu ,&nbsp;Chenchen Jing ,&nbsp;Donghai Wang ,&nbsp;Chan Wang ,&nbsp;Jianguo Lv","doi":"10.1016/j.jmatprotec.2025.118722","DOIUrl":"10.1016/j.jmatprotec.2025.118722","url":null,"abstract":"<div><div>Large-scale engineering structures are placing greater emphasis on lightweight, high-performance, and multifunctional capabilities. Spatial structures based on bar elements, such as lattice, reinforced concrete, and steel-concrete-steel structures, demonstrate significant application potential. Wire and arc additive manufacturing (WAAM) is suitable for the low-cost and high-efficiency fabrication of such large-scale spatial structures. However, insufficient manufacturing precision and mechanical properties of unsupported bars in WAAM are the primary challenges limiting the application and promotion of this technology. In this study, unsupported bars at 90°, 45°, and 0° were manufactured using various arc waveforms. The effects of arc waveforms on the morphology, microstructure, and mechanical properties of the unsupported bars were systematically analyzed. Additionally, an in-depth investigation into the impact mechanism of arc waveform was conducted through the combination of simulation and theoretical analysis. The results show that the arc waveform regulates the evolution of the molten pool's temperature field, thereby influencing the dynamic flow characteristics of the molten pool and the grain growth behavior. As the fabrication angle decreases, increasing the arc pulse frequency to enhance the molten pool's fluidity becomes crucial for improving the forming quality of unsupported bars. For the 0° unsupported bars, the cross-sectional area fluctuation range and center displacement decreased by 51.0 % and 36.4 %, respectively. In contrast, the constant current arc waveform exhibits insufficient molten pool fluidity, resulting in inadequate manufacturing precision at all angles. Furthermore, as the pulse frequency decreases, the solidification rate and temperature gradient of the molten pool increase significantly, leading to finer grain sizes and enhanced mechanical properties of unsupported bars. Unsupported bars manufactured using the constant current arc waveform exhibit intermediate grain sizes and mechanical properties. These findings establish a systematic framework linking arc waveforms to the evolution of the molten pool's temperature field. Optimizing the arc waveform significantly enhances the manufacturing quality and mechanical properties of unsupported bars at various angle. This provides a theoretical foundation and technical support for the promotion and application of WAAM in the fabrication of large-scale spatial bar structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118722"},"PeriodicalIF":6.7,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174100","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":"Laser efficient truing and rotary precision dressing of concave-surface coarse-grained diamond grinding tools","authors":"Wei Zhou ,&nbsp;Genyu Chen ,&nbsp;Song Duan ,&nbsp;Feng Mei ,&nbsp;Nengru Tao ,&nbsp;Yi Wei","doi":"10.1016/j.jmatprotec.2025.118726","DOIUrl":"10.1016/j.jmatprotec.2025.118726","url":null,"abstract":"<div><div>This study addresses the challenges associated with internal dimension and profile accuracy in the profiling of concave-surface coarse-grained diamond grinding tools, with a particular focus on solving the problems of thermal damage during laser truing and the significant wear and inefficiency associated with rotary dressing. A novel combination method of non-deflection laser rough truing, deflection laser semi-precision truing and rotary precision dressing was proposed. A mathematical model for deflection laser truing has been established for the first time, which is crucial for understanding and optimizing the truing process. Utilizing a grinding wheel intended for oil pipeline cutting tools as a test case, a combination experiment of laser truing and rotary dressing was conducted. The material removal and wear mechanisms were thoroughly investigated. The findings indicate that the thickness of the diamond’s graphite layer and the thermal damage layer of the bronze bond is less than 5 µm under the specified laser truing parameters, according to the analysis of the surface and subsurface materials. And rotary dressing effectively removes the thermal damage layer and the graphite layer when adjusted to varying dressing depths. The mathematical model confirms that the deflection laser is effective in compensating the power density loss caused by the contour changes of the grinding wheel. The combination experiment demonstrates that the laser can achieve a controlled material allowance of approximately 10 µm. The thermal damage on the wheel can be eliminated by a rotary dressing allowance of 10 µm. The combination method of laser truing and rotary dressing significantly minimizes tool wear and offers substantial advantages in terms of truing efficiency and dressing accuracy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118726"},"PeriodicalIF":6.7,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174931","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 weld size on energy input and interfacial strength during dissimilar ultrasonic welding of stainless steel to titanium","authors":"Jhe-Chen Liao ,&nbsp;Yun-Ta Chung ,&nbsp;Jhong-Ren Huang ,&nbsp;Pei-Chun Wong ,&nbsp;Jhe-Yu Lin","doi":"10.1016/j.jmatprotec.2025.118727","DOIUrl":"10.1016/j.jmatprotec.2025.118727","url":null,"abstract":"<div><div>This study explored the impact of weld area size on heat input and its subsequent effects on the microstructure, temperature, and strength at the stainless-steel–Ti interface during ultrasonic spot welding (USW) of dissimilar hard metals with a constant clamping force. It was found that a larger weld area positively affected the strength evolution in the early stages of USW by inducing local plastic flow and bond formation. However, a larger weld area led to dispersion of clamping force, leading to insufficient temperature to trigger Fe-Ti eutectoid reaction, resulting in internal fractures of α-Ti at prolonged welding. In contrast, a smaller weld area (7 ×7) concentrated energy input and accelerated temperature rise to exceed β-transus point, inducing α-to-β phase transformation through the diffusion of β-stabilizer elements from stainless steel to Ti. This phase-transformation behavior reduced the number of interfacial defects and increased the interfacial strength by 37 % (1817 N–2485 N). The findings in this work suggested the importance of elevating temperatures above the β-transus point to improve joint integrity throughout phase transformation to obtain a robust bond.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118727"},"PeriodicalIF":6.7,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174102","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":"Effect of topological characteristics on manufacturability and mechanical performance of multiscale graded structures fabricated by laser powder bed fusion","authors":"Ruiqi Wang,&nbsp;Dongdong Gu,&nbsp;Lixia Xi,&nbsp;Han Zhang,&nbsp;Jianfeng Sun,&nbsp;He Liu,&nbsp;Linxuan Li,&nbsp;Jinming Xing","doi":"10.1016/j.jmatprotec.2025.118721","DOIUrl":"10.1016/j.jmatprotec.2025.118721","url":null,"abstract":"<div><div>Complex multiscale structures emerge as a current focal point due to the controllability of physical, mechanical and geometrical properties spatially. However, the multiscale structures often modify the topological characteristics of structures, primarily including scale and geometry variation, thereby adding complexity of the laser powder bed fusion process. To investigate the effects of topological characteristics on manufacturability and mechanical properties, we fabricated uniform Gyroid structures with different unit cell size to evaluate scale variation and unit cell size graded Gyroid structure with different graded magnitude to evaluate structural geometry variation. As the unit cell size of uniform structures decreased, the structural thickness increased and dross defects diminished, while the relative density deviation was insensitive to unit cell size. The correspondence between relative density and mechanical properties of uniform Gyroid structures was established based on Gibson-Ashby equation. Unit cell size grading led to structural distortion. As the graded magnitude increased, the mean structure thickness and relative density of graded structures increased, and the mechanical properties decreased. The mechanism by how unit cell distortion affects manufacturability and mechanical performances was revealed. Furthermore, we present a performance-driven strategy for designing multiscale Gyroid structures, in which the topologically optimized density distribution is mapped onto the unit cell sizes. A three-point bending beam was constructed by the multiscale optimization method, which showing a ∼9.6 % increase in bending strength and a ∼46.8 % improvement in bending displacement compared to uniform beam. This study could offer guidance for the design and manufacturing of multiscale structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"337 ","pages":"Article 118721"},"PeriodicalIF":6.7,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143174106","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}