Journal of Materials Processing Technology最新文献

{"title":"Achieving strength-ductility synergy in wire-arc additively remanufactured part by in-situ hot rolling and thermal history engineering: A case study on 42CrMo low-alloy steel motor shaft","authors":"Rui Wang ,&nbsp;Jie Ren ,&nbsp;Xu Chen ,&nbsp;Yipeng Wang ,&nbsp;Xin Ren ,&nbsp;Hongbin Zhu ,&nbsp;Hong Li","doi":"10.1016/j.jmatprotec.2025.118815","DOIUrl":"10.1016/j.jmatprotec.2025.118815","url":null,"abstract":"<div><div>Wire-arc additive manufacturing (WAAM) is extensively employed in remanufacturing owing to high efficiency and cost-effectiveness. However, it often results in coarse grain structures and considerable residual stress, ultimately deteriorating mechanical properties and fatigue life of remanufactured components. This study addresses this issue by utilizing a customized in-situ hot rolling-assisted WAAM (HR-WAAM) system, specially designed for rotational components, to remanufacture a motor shaft using a high-strength low-alloy steel wire. The rolling temperature was maintained within the ferrite phase region. Comparative analyses of single-layer, double-layer, and multi-layer samples were conducted to uncover the combined effects of in-situ hot rolling and thermal cycling on microstructure and mechanical properties. In-situ hot rolling introduces substantial low-angle grain boundaries and dislocations, serving as nucleation sites for recrystallization. Thermal cycling during subsequent deposition not only provides necessary activation energy to enhance grain boundary mobility and thus promotes recrystallization, but also induces various solid-state phase transformations to facilitate grain refinement and microstructural homogenization. An optimal processing window was identified with a rolling temperature of 600–700 °C and 23 % rolling strain. The yield strength of HR-WAAM low-alloy steel increased from 604 MPa to 786 MPa while maintaining an elongation of 20 %, comparable to that of WAAM samples. Moreover, the high-cycle fatigue strength substantially increases from 428 MPa to 501 MPa. These enhancements primarily result from grain refinement and the introduction of compressive residual stress. This work demonstrates that HR-WAAM can effectively tailor microstructures to achieve strength-ductility synergy and provides a technical reference for its application in shaft remanufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118815"},"PeriodicalIF":6.7,"publicationDate":"2025-03-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725320","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":"Graphene nanosheets networking: A novel material design strategy to enhance ultra-precision machining of titanium alloys and composites","authors":"Yunfa Guo ,&nbsp;Qi Yan ,&nbsp;Dingyifei Ma ,&nbsp;David Yan ,&nbsp;Hao Wang","doi":"10.1016/j.jmatprotec.2025.118816","DOIUrl":"10.1016/j.jmatprotec.2025.118816","url":null,"abstract":"<div><div>Positive efforts (e.g., cryogenic machining, vibration assistance, and laser assistance) have been proposed to address the challenges of low thermal conductivity and the heterogeneous structure in titanium alloys and titanium metal matrix composites (Ti-MMCs) during ultra-precision machining. However, these techniques often require complex auxiliary equipment with high costs and stringent precision control precision control, posing a major challenge to the sustainable production of titanium alloys and Ti-MMCs. Unlike other existing methods relying on external assistance, this study introduces a novel material design strategy to intrinsically improve the machinability of titanium alloys and Ti-MMCs by incorporating networked graphene nanosheets (GNSs) as internal reinforcement. To systematically evaluate this approach, three Ti-6Al-4V (Ti64) alloy-based materials: the matrix alloy, a composite reinforced with randomly dispersed GNSs (GNSs/Ti64 composite), and a composite reinforced with a networked GNSs structure (networked GNSs/Ti64 composite), were respectively designed and employed as workpiece in ultra-precision micro-cutting tests. The results reveal that the networked GNSs/Ti64 composite exhibits significantly reduced machining vibration induced by machining force, enhanced surface integrity, and more uniform chip formation compared to both the Ti64 alloy and GNSs/Ti64 composite. In-depth material characterization and mechanistic analysis attribute this improvement to the networked GNSs structure that optimizes the occurrence of shear fracture in the primary shear zone, leading to more uniform serrated chips for chip formation. This research effectively improves the ultra-precision machinability of titanium alloys and Ti-MMCs, which lays the foundation for the subsequent fabrication of advanced products from titanium alloys and composites.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118816"},"PeriodicalIF":6.7,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143716098","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":"Dynamic laser beam shaping by means of a deformable mirror to tailor microstructure in Directed Energy Deposition","authors":"Scholte J.L. Bremer ,&nbsp;Martin Luckabauer ,&nbsp;Ronald G.K.M. Aarts ,&nbsp;Gert-willem R.B.E. Römer","doi":"10.1016/j.jmatprotec.2025.118797","DOIUrl":"10.1016/j.jmatprotec.2025.118797","url":null,"abstract":"<div><div>In Laser-based Direct Energy Deposition (DED-L), the resultant mechanical properties depend on thermal cycles during deposition. Traditionally these cycles are usually optimized by tuning the laser power, traverse speed of the laser beam or material feed rate. By adapting, in real-time, the spatial power density distribution (intensity profile) in the focal spot of the laser beam, thermal cycles and thus the microstructure can be further tailored during processing. In this paper, a developed dynamic beam shaping setup, based on a deformable mirror, is used to deposit single tracks, where the high power laser intensity distribution is adapted during deposition. Melt pool monitoring showed that this setup allows to significantly change melt pool morphology during deposition. Next, microstructure analysis (EBSD) of the deposited track shows that various microstructures can be achieved, ranging from a track with larger equiaxed grains in the centre and columnar grains at the bottom and sides of the track to equiaxed grains with a strong crystallographic texture throughout the track. This proofs that the dynamic beam shaping setup is a powerful tool to steer the microstructure and therefore the functional properties of the material.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118797"},"PeriodicalIF":6.7,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143706270","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Rolling in-situ generation of metallurgical and mechanical bonding improves mechanical properties and synergistic deformation ability of semi-solid cast-rolled aluminum/steel composite plate","authors":"Jin Qiu ,&nbsp;Yuandong Li ,&nbsp;Wenjing Liu ,&nbsp;Hongwei Zhou ,&nbsp;Chi Cao ,&nbsp;Guangli Bi","doi":"10.1016/j.jmatprotec.2025.118821","DOIUrl":"10.1016/j.jmatprotec.2025.118821","url":null,"abstract":"<div><div>A nowel processing technology was developed to solve the problem of low bonding strength caused by intermetallic compounds (IMCs) of aluminum/steel composites. This approach utilizes semi-solid cast-rolling to fabricate composite plates with a thin metallurgical bonding layer, followed by in situ formation of metallurgical and mechanical bonding through rolling, thereby enhancing the mechanical properties of aluminum/steel composite plate. Results demonstrated that a primary metallurgical bonding layer of approximately 6 μm formed after semi-solid cast-rolling, with a shear strength of only 38.8 MPa, while a reduction rate of 20 % increased the mechanical bonding strength to 46.0 MPa. The optimal mean mechanical bonding strength of 59.5 MPa was achieved at a reduction rate of 30 % with five rolling passes, exceeding the lower limit of the critical reduction rate required for aluminum/steel composite plate preparation by traditional rolling. With an increasing reduction rate, steel deformation, crack gaps (equivalent deformation) in IMCs, and coordinated deformation in composite plates also increase, promoting the formation of secondary bonding with alternating soft and hard phases. At a 50 % reduction rate, the shear strength of the aluminum/steel composite plate reaches 119.0 MPa, representing a 206.7 % increase compared to semi-solid cast-rolling. The ultimate tensile strength (UTS) of the composite plates with a 50 % reduction rate exceeded that predicted by the rule of mixtures by 17.1 MPa, while uniform elongation (UE) and fracture elongation (FE) increased by 35.3 % and 120.0 %, respectively, compared to high-elongation steel. The current study presents a novel investigation into the influence of bonding modes on the shear strength of aluminum/steel composite plates, offering new perspectives for designing and manufacturing dissimilar alloy interfaces.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118821"},"PeriodicalIF":6.7,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682241","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 duplex surface modification method for increasing bending fatigue life of aviation carburized gear steel considering its mechanical properties and microstructure gradients","authors":"Fei Yang ,&nbsp;Peng He ,&nbsp;Wenhe Wang ,&nbsp;Yanqing Yu ,&nbsp;Xinlei Pan ,&nbsp;Hongwei Yang ,&nbsp;Xiaoqing Liang ,&nbsp;Cenchao Xie ,&nbsp;Liucheng Zhou","doi":"10.1016/j.jmatprotec.2025.118812","DOIUrl":"10.1016/j.jmatprotec.2025.118812","url":null,"abstract":"<div><div>As an effective surface modification technology, laser shock peening can improve the fatigue performance of aerospace components. However, for gear components with complex configurations, this technology exhibits significant technical limitations such as difficulties in adhering absorbed layers and distortion of the laser spot due to the curvature at tooth roots. This paper innovatively introduces a method combining laser shock peening without coatings and vibratory polishing, aiming to enhance the bending fatigue performance of gear steel. Underlying mechanisms of bending fatigue resistance have been elucidated through the examination of mechanical properties, surface integrity, and microstructural evolution during modification. After LSP without coatings combined with vibratory polishing, a gradient structure of nanocrystals-fine grains was formed along the depth direction, with significant increases in dislocation density and types of dislocations. The mechanical properties of samples were improved by introducing a work hardening layer with thickness of 570 μm and a residual compressive stress layer with thickness of 510 μm. Adverse surface factors such as ablation and remelting morphologies were mitigated. Compared to as-received samples, bending fatigue limit was significantly increased by approximately 86.1 %. Fatigue resistance mechanisms can be attributed to combined effects of the second-phase strengthening mechanism caused by amorphous dispersed carbides, residual compressive stress, high-density dislocations, and interlocking structure coupled with nanotwins and intergranular dislocations. The duplex surface modification process integrates the advantages of the shockwave force effect induced by laser with the exceptional surface integrity achieved through vibration polishing, which renders impetus for the researchers striving for aerospace gear performance improvement.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118812"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682240","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":"Liquid bridged deposition for 3D shaping","authors":"Jiahao Zhao ,&nbsp;Xiaolong Yang ,&nbsp;Di Zhu","doi":"10.1016/j.jmatprotec.2025.118820","DOIUrl":"10.1016/j.jmatprotec.2025.118820","url":null,"abstract":"<div><div>Additive manufacturing has emerged as a vital technology for fabricating three-dimensional (3D) structures. However, in many cutting-edge applications, creating sophisticated 3D metallic structures with high surface quality and precision is required, which remains a significant challenge. Here we developed the liquid bridge-constrained electrodeposition for 3D shaping. Leveraging the discontinuous dewetting of wettability contrast pattern, the catenoid-like liquid bridge was spontaneously formed between the electrolyte pool and the surface plate. The liquid bridge serves a tunnel, to effectively confine the deposition and enable precision growth of 3D curved structures. The generated umbrella-shaped structure exhibits a base diameter of 0.4 mm, a maximum width of 1.0 mm, and achieves an aspect ratio of 0.6, with its sidewall profile perfectly conforming to the catenary equation. Furthermore, these structures have fine surface quality while exhibiting hardness comparable to those of pure copper. Notably, leveraging engineered wettability patterns enables scalable fabrication of 3 × 3 arrayed 3D structures, demonstrating that utilizing liquid bridge electrodeposition to achieve bulk fabrication is readily feasible. This method simultaneously considers the manufacturing requirements of 3D complexity, accuracy, scalability and discontinuous dewetting, which holds promise for applications ranging from heat transfer, microfluidic and electronic devices where 3D shaping of exquisite structures matters.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118820"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682254","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":"Mechanisms for manufacturing NiAl thin-walled spherical shell by combining superplastic forming of Ni/Ni2Al3 heterogeneous bimodal-grained composite sheet with subsequent in-situ reaction","authors":"Peng Lin ,&nbsp;Pengle Kong ,&nbsp;Bingyao Yan ,&nbsp;Yupeng Lu ,&nbsp;Dong Sun ,&nbsp;Hao Feng ,&nbsp;Lin Yang ,&nbsp;Shuyong Jiang","doi":"10.1016/j.jmatprotec.2025.118813","DOIUrl":"10.1016/j.jmatprotec.2025.118813","url":null,"abstract":"<div><div>As a novel lightweight and heat-resisting alloy, NiAl intermetallic compound has become the best candidate for replacing Ni-based high-temperature alloy to manufacture thin-walled component. However, NiAl intermetallic compound is characterized by intrinsic brittleness, so it fails to be made into sheet to be directly used for forming complex thin-walled component. A novel approach of “fabrication-forming-reaction” is proposed to NiAl thin-walled spherical shell in the present work. Firstly, Ni/Ni₂Al₃ composite sheet with heterogeneous bimodal grains containing coarse-grained Ni layer and fine-grained Ni₂Al₃ layer is fabricated by first-order reaction between Ni foil and Al foil and it exhibits a certain superplasticity at the temperatures of 700–850 ℃ in the case of 1 × 10⁻³ s⁻¹, where the maximum elongation to fracture achieves to 348 %. Then, Ni/Ni₂Al₃ composite sheet is made into thin-walled spherical shell by superplastic forming at 750 ℃. Finally, NiAl thin-walled spherical shell is manufactured by subsequent in-situ reaction of Ni/Ni₂Al₃ thin-walled spherical shell and it is completely composed of homogeneous bimodal grains. The current work contributes to the fundamental advancement in superplastic deformation mechanism of Ni/Ni₂Al₃ composite sheet with heterogeneous bimodal grains as well as manufacturing NiAl thin-walled components with complex shape.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118813"},"PeriodicalIF":6.7,"publicationDate":"2025-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682255","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":"Fabrication of different shapes of tool electrodes using a variable-parameter bipolar-pulsed liquid membrane electrochemical etching method","authors":"Xiujuan Wu ,&nbsp;Li Wang ,&nbsp;Tao Yang ,&nbsp;Weijing Kong ,&nbsp;Yusen Hang ,&nbsp;Yongbin Zeng","doi":"10.1016/j.jmatprotec.2025.118798","DOIUrl":"10.1016/j.jmatprotec.2025.118798","url":null,"abstract":"<div><div>With traditional liquid membrane electrochemical etching methods, it is difficult to effectively control the electrolytic products. In this paper, a variable-parameter bipolar-pulsed liquid membrane electrochemical etching technique is proposed for the preparation of microelectrodes. The introduction of negative voltage will generate insoluble electrolytic products on the electrode surface. By adjusting the processing parameters, these electrolytic products can be precisely controlled, thereby shaping the morphology of the electrodes. In step one, the positive voltage is larger and the electrode surface is coated with a layer of insoluble electrolytic products. In step two, the positive voltage is smaller and hydrogen is generated on the electrode surface, dispersing the electrolytic products. The effects of positive voltage, negative voltage and processing time on the distribution of electrolytic products and electrode morphology were investigated in different steps. It was found that the upper and lower electrodes changed significantly with the change of processing time. Based on the experimental results, the droplet-shaped upper electrode and conical-shaped lower electrode with tiny size and controllable shape were prepared. In addition, a repeated-variable-parameter method was used to mitigate the problem of inconsistent etching speed that was caused by the electrolytic product coating, and enabled the preparation of cylindrical electrodes that are uniform in size. While keeping the processing mode unchanged, different shaped electrodes can be manufactured by simply adjusting the parameters to control the distribution of electrolytic products, demonstrating good processing flexibility.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118798"},"PeriodicalIF":6.7,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682301","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":"Unveiling the mechanisms behind the inconsistent impact of casting pressure on macro and microsegregation","authors":"Hong-Chun Zhu ,&nbsp;Zhuo-Wen Ni ,&nbsp;Hua-Bing Li ,&nbsp;Zhi-Yu He ,&nbsp;Zheng-Rong Ai ,&nbsp;Zhou-Hua Jiang ,&nbsp;Hao Feng ,&nbsp;Shu-Cai Zhang","doi":"10.1016/j.jmatprotec.2025.118804","DOIUrl":"10.1016/j.jmatprotec.2025.118804","url":null,"abstract":"<div><div>Segregation is a common defect in the casting process of metallic materials. This phenomenon leads to uneven variations in the mechanical properties, corrosion resistance, and machinability of the material, ultimately increasing processing difficulty and affecting the quality and performance of the product. In this study, the impact of casting pressure on the segregation of M42 high-speed steel (HSS) during die casting was systematically investigated. The results indicated that there is inconsistency in the impact of casting pressure on macrosegregation and microsegregation, that is, as the casting pressure increases, the degree of macrosegregation mitigates, while the degree of microsegregation enhances. For macrosegregation, increasing the casting pressure reduces the width of the mushy zone and expands the range of the slurry zone, which promotes feeding flow and inhibits the transport of carbon solutes by the flowing molten steel to the center, thereby mitigating macrosegregation in the ingot center. For microsegregation, as the casting pressure increases, the grain size significantly decreases and the cooling rate increases. This leads to a shortened solidification time and a weakening of the back-diffusion effect in the solid phase. Therefore, as the casting pressure increases, the degree of microsegregation is enhanced. This study unveils the mechanisms behind the inconsistent impact of casting pressure on macrosegregation and microsegregation during die casting, providing theoretical guidance for alleviating segregation and reducing processing difficulty by controlling casting pressure.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118804"},"PeriodicalIF":6.7,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143642380","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":"Study on the crack healing behavior of aluminum alloy under the action of pulse electric current","authors":"Li Yu ,&nbsp;Zheng Qiu-yang ,&nbsp;Jiang Zhi-guo ,&nbsp;Yuan Zhi-peng ,&nbsp;Shi Hao-han ,&nbsp;Zhou Zhen-yu ,&nbsp;Piao Zhong-yu","doi":"10.1016/j.jmatprotec.2025.118803","DOIUrl":"10.1016/j.jmatprotec.2025.118803","url":null,"abstract":"<div><div>Aerospace structural parts fabricated from aluminum alloy are susceptible to crack damage during service, which diminishes the safety and life of the equipment. Compared with conventional repair methods, pulse electric current treatment can precisely locate cracks distributed throughout the material and enable efficient in-situ repair. Therefore, this study employs the pulse electric current treatment method to repair cracks and investigates the crack healing behavior using a combination of experiments and simulations. The effect of pulse electric current treatment on the crack-containing sample is revealed through a finite element method simulation. The electric current density, temperature, stresses, and displacements are all concentrated in the crack area and influence each other step by step, thereby gradually driving crack healing. The experimental results indicate that after pulse electric current treatment, the mechanical properties of the crack-containing sample are significantly recovered, with the tensile strength and elongation increasing by 23.2 % and ∼ 2 times, respectively. Metallurgical bonding and densification are achieved between the crack surfaces, and the healed interface possesses higher bonding strength. Combined with molecular dynamics simulations, the crack healing process under the action of pulse electric current is elucidated. While recrystallization occurs in the crack area, a large number of dislocations are continuously emitted and move from the crack tip, and the grain boundaries continuously progressively migrate toward the crack. The plastic deformation behavior at high temperature prompts the diffusion and migration between the atoms on both sides of the crack and the formation of fibrous bridging structures. This work provides new insights into the crack healing mechanism under the action of pulse electric current and contributes to the optimization of crack repair technology to enhance the reusability of aerospace equipment.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118803"},"PeriodicalIF":6.7,"publicationDate":"2025-03-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143682239","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}