International Journal of Material Forming最新文献

{"title":"Cladding performance of CMT + P wire arc additive manufacturing using nitrogen-containing filler wire for producing Z2CN19-10-like stainless steel","authors":"Ziqiao Zhong,&nbsp;Tiancheng An,&nbsp;Sergii Maksymov,&nbsp;Olena Berdnikova","doi":"10.1007/s12289-026-02014-w","DOIUrl":"10.1007/s12289-026-02014-w","url":null,"abstract":"<div><p>In this study, a 100-mm-thick deposit was fabricated by wire arc additive manufacturing on a forged Z2CN19-10 steel substrate using the cold metal transfer plus pulse process and an AM-304L filler wire with a nominal nitrogen content of 0.10 wt.%. This approach produced an additively manufactured material with an actual nitrogen content of 0.09 wt.%, comparable to that of Z2CN19-10 steel. A systematic comparison was conducted between the forged Z2CN19-10 steel and the additively manufactured specimens after solution treatment at 1050 ℃ for 2 h, focusing on differences in microstructure and phase constitution. In addition, mechanical properties in multiple orientations, including room-temperature and 350 ℃ tensile tests as well as room-temperature impact tests, were evaluated for the forged steel, the as-built additively manufactured samples, and the solution-treated additively manufactured samples. Comprehensive characterization was carried out using optical emission spectroscopy, optical metallography, scanning electron microscopy combined with electron backscatter diffraction for crystallographic orientation and grain boundary analysis, and transmission electron microscopy, together with thermodynamic calculations performed using the OpenCalphad software.The results indicate that the additively manufactured deposits exhibit pronounced microstructural anisotropy, with columnar grains dominating the vertical plane and a near-equiaxed morphology on the horizontal plane. In the as-built condition, repeated thermal cycling between 600 and 765 ℃ promotes localized precipitation of the metastable hard epsilon nitride phase, leading to chromium-depleted regions at grain boundaries and melt pool boundaries. These regions act as preferential sites for microcrack initiation, resulting in a significant reduction in toughness. Solution treatment at 1050 ℃ effectively dissolves the epsilon nitride phase and homogenizes the elemental distribution, thereby markedly improving both room-temperature and elevated-temperature ductility and impact toughness. The treatment also reduces the degree of three-dimensional mechanical anisotropy, enabling the additively manufactured material to meet the property benchmarks of forged Z2CN19-10 steel. These findings demonstrate the potential interchangeability between components produced by wire arc additive manufacturing and conventionally forged Z2CN19-10 products. Based on these results, processing and post-treatment guidelines for additively manufactured components produced with nitrogen-bearing filler wire are proposed to ensure service reliability and to mitigate the risks of epsilon nitride-induced embrittlement and degradation of corrosion resistance.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829181","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multi objective optimization of stamping process parameters based on improved ASAE-GP-BPNN hybrid model and NSGA-II algorithm","authors":"Junmeng Zhang,&nbsp;Guang Tong,&nbsp;Haijun Yang","doi":"10.1007/s12289-026-02016-8","DOIUrl":"10.1007/s12289-026-02016-8","url":null,"abstract":"<div><p>Stamping-forming parameter optimization is a core technical hurdle in enhancing product quality. To tackle the low accuracy of existing surrogate models and the uneven Pareto fronts produced by current multi-objective algorithms, this paper introduces a novel framework that couples an Adaptive Sparse Autoencoder–Gaussian Process–Back-Propagation Neural Network (ASAE-GP-BPNN) hybrid surrogate model with an improved Non-dominated Sorting Genetic Algorithm-II (INSGA-II). ASAE-GP-BPNN achieves accurate modeling of complex nonlinear relationships through competitive sparse mechanism for dynamic feature extraction, Gaussian process uncertainty quantification, and BPNN deep fusion, showing 15–40% improvement over single models on test functions. INSGA-II introduces K-Nearest Neighbor(KNN) local density evaluation and adaptive parameter strategy, increasing the hypervolume of Pareto front by about 15%. Using TRIP780 double C-shaped parts as a case study, the surrogate model was trained with 120 groups of Latin hypercube sampling data. After optimization, the optimal process parameter combination was obtained achieving maximum thinning rate of 11.3%, thickening area of 4.6%, springback amount of 0.952 mm, and 20% reduction in overall defects. The research shows that the proposed method has both prediction accuracy and engineering applicability in high-dimensional nonlinear stamping process multi-objective optimization.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829619","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Simulation framework for material property-based pellet formation","authors":"Prutha Nagaraja,&nbsp;Shailendra Singh,&nbsp;Laurent Cavin,&nbsp;Thomas Georg Gfroerer,&nbsp;Rou Hua Chua","doi":"10.1007/s12289-026-02013-x","DOIUrl":"10.1007/s12289-026-02013-x","url":null,"abstract":"<div>\u0000 \u0000 <p>Plastic additives are used to strengthen the mechanical properties of polymers, improve processing efficiency, and enhance product durability, thereby enabling their use for diverse applications across many chemical industries. These additives are typically produced in powder form; however, the handling and storage of fine powders in industrial environments present significant challenges, making it necessary to convert them into pellets. The process of pellet formation involves compression of the powder under controlled pressure and temperature. Several models have been developed to explain pelletization in various fields, including biomass, metals, pharmaceuticals, and ceramic production. A common theme of these studies is the use of a continuum approximation for the powder using the Drucker-Prager Cap (DPC) model. These studies relied on an instrumented die to measure the material model parameters. Furthermore, the identification of DPC model cap surface and hardening parameters typically relied on preparing multiple pellets at different target densities, making the parameter calibration process time-consuming and experimentally intensive. In contrast, the present work extracts material parameters from load-displacement data, avoiding extensive pellet preparation without relying on a specialized instrumented die. Additionally, we have presented a modified approach to calculate cap hardening parameters based on global optimization of stress-strain values. Finally, the framework was applied to plastic additive powders and validated against experimental results. An additional sensitivity analysis of the model, based on a full factorial design of experiments (DoE), was performed to evaluate the influence of key parameters on the predicted compaction response. Overall, our findings may help reduce pre-production iterations and improve pellet quality, given the constraints at the factory.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02013-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147797137","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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":"Finite element simulation of the slurry printing process in material extrusion additive manufacturing","authors":"Xuanzheng Zhou,&nbsp;Yunchen Zhang,&nbsp;Yaping Sun,&nbsp;Wenjie Lv,&nbsp;Huiping Shao,&nbsp;Tao Lin","doi":"10.1007/s12289-026-02015-9","DOIUrl":"10.1007/s12289-026-02015-9","url":null,"abstract":"<div>\u0000 \u0000 <p>In this study, the material extrusion-based additive manufacturing process of TiC steel-bonded carbide slurries with solid contents ranging from 44 to 52 vol% was simulated using ANSYS Polyflow. The flow behavior, including shear stress and viscosity distribution within the barrel and nozzle, was analyzed to evaluate printability. The results show that printability initially improves with increasing solid content, peaking at 50 vol%, after which it declines. Simulation results were validated experimentally, showing good agreement. Optimal printing performance and product precision were achieved when the outlet viscosity ranged from 90 to 132 Pa·s at a printing speed of 10 mm/s. This study demonstrates that numerical simulation is an effective tool for optimizing printing parameters and improving print quality in material extrusion additive manufacturing.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147797134","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical investigation of Portevin-Le Chatelier effect in Ti-15Mo alloy considering machine stiffness effect","authors":"Shiyuan Luo,&nbsp;Shicong Hu,&nbsp;Liang Xiao,&nbsp;Yaru Liu,&nbsp;Gui Li","doi":"10.1007/s12289-026-02010-0","DOIUrl":"10.1007/s12289-026-02010-0","url":null,"abstract":"<div>\u0000 \u0000 <p>In this work, the spatiotemporal beha<i>v</i>iors and the effect of machine stiffness on the Portevin-Le Chatelier (PLC) effect in Ti-15Mo alloy are quantitatively investigated by numerical simulation supported by experimental validation. The McCormick (MC) constitutive model parameters are precisely identified, and a 3D finite element (FE) model integrated with the calibrated MC constitutive model is developed and rigorously validated by experiments. Numerical results reveal distinct strain staircases and a pronounced increase in the slope of strain-time curve, corresponding to the transition from elastic to plastic deformation. The average stress drop magnitude exhibits a bimodal distribution, peaking at 13.7 MPa, and generally decreases as increasing strain rate and machine stiffness. Moreover, the PLC band width demonstrates significant fluctuations in the early stage and then stabilizing at about 2 mm with increasing strain. Additionally, the PLC band propagation basically appears as continuous and hopping propagations, with continuity markedly enhanced by higher machine stiffness.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147797135","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 indenter geometry and machine-learning-based prediction on the quasi-static indentation response of stitched carbon-glass quadraxial laminates","authors":"Avinash Thirunavukkarasu,&nbsp;Chandrasekar Muthukumar,&nbsp;Sanjay Dakshinamoorthy","doi":"10.1007/s12289-026-02012-y","DOIUrl":"10.1007/s12289-026-02012-y","url":null,"abstract":"<div>\u0000 \u0000 <p>This study investigates the indentation behavior of stitched hybrid carbon-glass quadraxial laminates with varying thickness under hemispherical, conical and flat indenters. The experimental results show peak load and energy absorption increased with laminate thickness, where thicker laminates exhibited an increase of 30–40%. A transition in damage behavior was observed for CGT-3 laminate where failure modes transitioned from matrix cracking and fiber fracture in thin laminates to delamination and shear plugging in thicker laminates. Flat indenters produced a larger damage area due to through thickness shear, whereas hemispherical and conical indenters resulted in more distributed damage zones. A machine -learning based model was developed to predict indentation response. Multilayer perceptron model (MLP) accurately predicted displacement with R² ~ 0.90, while Extra Trees Regressor model showed superior performance for force and displacement prediction where R² ~ 0.97–0.98. The results demonstrate that machine learning can be effectively used to predict indentation response and damage behavior of stitched composite laminates with good accuracy.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147738728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 of springback behavior in creep age forming of AA2024 sheets used in the aerospace industry","authors":"Başaran Bekir Başpınar,&nbsp;Mehmet Fatih Aycan,&nbsp;İbrahim Uslan","doi":"10.1007/s12289-026-02011-z","DOIUrl":"10.1007/s12289-026-02011-z","url":null,"abstract":"<div>\u0000 \u0000 <p>Although inverse relationships among sheet thickness, forming pressure, and springback are widely reported in the creep-age forming (CAF) literature, limited statistically validated experimental data exist for AA2024 undergoing a T3-T81 transformation under industrial autoclave conditions. This study experimentally investigates and parametrically assesses the springback behavior of AA2024-T3 sheets, focusing on the comparative sensitivity of thickness (0.81–1.6 mm) and pressure (6–9 bar). Two-factor ANOVA confirmed statistically significant main effects for both parameters (<i>p</i> &lt; 0.001), while a multiple linear regression model (R² = 98.27%) was developed to quantify their influence. The independence of these predictors was verified using the Variance Inflation Factor (VIF) analysis (VIF = 1.00). The results show that springback decreases from 68.4% to 53.0% over the investigated window, a trend fundamentally driven by stress-relaxation kinetics and the precipitation of fine S′ phases that stabilize the microstructure. Furthermore, thickness thinning remained negligible (&lt; 1%), and the achievement of the T81 state was confirmed by hardness and electrical conductivity measurements. While the model provides a robust tool for preliminary mold compensation, its applicability is limited to the evaluated industrial parameter space and cylindrical geometry. These findings provide statistically supported guidance for optimizing CAF processes in aerospace structural applications.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02011-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147738445","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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":"Hybrid tools for tube bending processes using additive manufacturing and digital twin","authors":"Muhammad Ali Kaleem,&nbsp;Peter Frohn-Sörensen,&nbsp;Rainer Steinheimer,&nbsp;Bernd Engel","doi":"10.1007/s12289-026-02009-7","DOIUrl":"10.1007/s12289-026-02009-7","url":null,"abstract":"<div>\u0000 \u0000 <p>Forming tools (dies, clamps etc.) are conventionally made from alloy steels (X153CrMoV12, EN-1.2379 or AISI-D2) and have a high material stiffness (Elastic Modulus). In comparison with alloy steels, polymeric materials such as polylactic acid (PLA) are light weight and inexpensive. The polymer-based tools are therefore more cost-effective and lightweight and hence suitable for manufacturing setups oriented towards customized production. However, relatively low material stiffness of polymers limits their use as forming tools. This paper presents a novel concept of developing hybrid tools consisting of highly stiff metallic surfaces and 3D printed polymeric base. In this case stainless steel (1.4301) slabs are produced using laser cutting and polylactic acid (PLA) polymeric bases 3D printed using the Additive Manufacturing technique of Fused Filament Fabrication (FFF). The hybrid tools are designed according to process parameters, tool material properties and the contact pressure pattern at the tool’s mating surfaces. The contact surfaces of the hybrid tool behave like actuators which respond according to pre-computed applied loads. This study follows a combined numerical-experimental approach. As a test case, a hybrid forming tool (hybrid pressure die) is designed, developed and tested in a cold form tube bending process. The digital twin of the tube bending process is developed and tool performance is investigated through FE-simulations and it’s accuracy is validated by conducting practical experiments. The focus lies on comparison between the hybrid pressure die and a conventionally used (steel) pressure die. The performance comparison is made based on the von Mises stress, major strain, contact forces, failure risk, elastic deformation and surface displacement at tool surfaces. The cost comparison is made based on the Ashby cost performance index. This study pioneers a concept of in-process adjustment of tool surfaces, in response to continuously increasing tube diameter. The proposed hybrid tools present more cost-effective and lightweight alternatives to conventional metallic tools used in production processes, while also allowing for in-process adaptation.</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02009-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147738138","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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":"Development and experimental validation of a path-dependent spin forming finite element model","authors":"Elizabeth Urig,&nbsp;Leonid V. Zhigilei","doi":"10.1007/s12289-026-01999-8","DOIUrl":"10.1007/s12289-026-01999-8","url":null,"abstract":"<div>\u0000 \u0000 <p>Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.</p>\u0000 <span>AbstractSection</span>\u0000 Graphical Abstract\u0000 <div><figure><div><div><picture><source><img></source></picture><span>The alternative text for this image may have been generated using AI.</span></div></div></figure></div>\u0000 \u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-01999-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147737804","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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":"Comparative study on the effect of kaolin clay calcination temperature on the fabrication and properties of ceramic membranes","authors":"Ferhat Bouzerara","doi":"10.1007/s12289-025-01964-x","DOIUrl":"10.1007/s12289-025-01964-x","url":null,"abstract":"<div>\u0000 \u0000 <p>This study presents the development and optimization of multilayer porous ceramic membranes for microfiltration, using kaolin as both the functional microfiltration (MF) layer and the macroporous support. A common challenge with tubular supports made from extruded raw kaolin is deformation during drying. To overcome this, kaolin calcination was investigated as a processing strategy. Pre-calcination prior to shaping significantly reduced shrinkage and deformation, thereby improving the structural integrity of the supports. The calcination temperature was found to be a key parameter, influencing support quality and pore characteristics. For instance, calcined kaolin supports (S4) exhibited a porosity of about 52% and an average pore size of around 4.1 μm, compared with 46% and 1.4 μm for uncalcined ones (S3), under identical sintering conditions. Furthermore, the effect of sintering temperature on porosity, pore size distribution, and mechanical strength was systematically examined. The fabricated MF membranes exhibited an average pore size of ~ 0.5 μm. Filtration tests with distilled water demonstrated their suitability for tangential microfiltration applications, with permeability values reaching approximately 680 Lh^− 1m⁻²bar ^− 1 for membranes based on calcined supports (M2), compared to about 140 Lh^− 1m⁻²bar ^− 1 for those based on uncalcined ones (M1).</p>\u0000 </div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147737316","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}