International Journal of Material Forming最新文献

{"title":"Achieving strength-ductility synergy in As-cast 7075 aluminum alloy via additive friction stir deposition","authors":"Shuaipu Wang,&nbsp;Lei Zhao,&nbsp;Mingjian Wu,&nbsp;Hui Xu,&nbsp;Zihe Xu,&nbsp;Zhilin Wu","doi":"10.1007/s12289-026-02094-8","DOIUrl":"10.1007/s12289-026-02094-8","url":null,"abstract":"<div><p>As-cast 7075 aluminum alloy suffers from dendritic segregation, coarse second phases, and shrinkage porosity, which limit its direct structural use. In this work, as-cast 7075 feedstock was processed by additive friction stir deposition (AFSD), and the effects of rotation speed on microstructure and mechanical properties were investigated. AFSD markedly reduced casting defects in the as-cast feedstock, with the pore area fraction decreasing from 2.22% to 0.12–0.22% in the deposits. The coarse dendritic structure was transformed into a 3.24–5.16 μm fine-grained microstructure through dynamic-recrystallization-related grain refinement, while interdendritic segregation regions and coarse second phases were fragmented and redistributed as discrete particles. Increasing rotation speed raised the deposition temperature and promoted slight grain coarsening. The deposits showed simultaneous strength and ductility improvements over the as-cast feedstock. The 500 rpm deposit achieved the highest strength, with a yield strength of 320.6 MPa and an ultimate tensile strength of 434.4 MPa, while the highest elongation of 19.0% was obtained at 600 rpm. The improved strength–ductility balance was attributed to grain refinement, pore defect reduction, second-phase fragmentation and redistribution, and local residual deformation. This study demonstrates AFSD as a promising short-process solid-state strategy for as-cast high-strength aluminum alloy feedstocks.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149132379","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":"Joining by pin shear caulking: an alternative process route using metallic pins as shear cutting tool","authors":"L. Elbel,&nbsp;A. Harms,&nbsp;D. Römisch,&nbsp;M. Lechner,&nbsp;M. Merklein","doi":"10.1007/s12289-026-02090-y","DOIUrl":"10.1007/s12289-026-02090-y","url":null,"abstract":"<div><p>Pin joining represents a promising approach for the mechanical joining of multi-material structures, as it enables the formation of joints without auxiliary joining elements. To improve process efficiency, a modified pin joining process chain is proposed in which the pin itself acts as the cutting element, eliminating the need for pre-drilled joining partners. However, the interactions between the shear-cutting operation and the subsequent caulking process are not yet fully understood. This work experimentally investigates the influence of sheet thickness, relative pin height and cutting clearance on joint formation and mechanical performance in steel-aluminium joints produced by the pin shear-caulking process. A full-factorial design of experiments is employed. Joint performance is evaluated by tensile-shear and cross-tension testing, while metallographic analyses and microhardness measurements are conducted to characterise cut-edge morphology, undercut geometry and local strain hardening. The results demonstrate the feasibility of the proposed process chain and reveal pronounced interactions between the investigated process parameters. Tensile-shear strength is strongly influenced by the interaction between sheet thickness and cutting clearance. A previously reported non-linear effect of cutting clearance is confirmed for a wide range of process conditions and is linked to differences in burnish-zone formation. In contrast, cross-tension strength increases with increasing cutting clearance and is primarily determined by the geometry of the mechanical interlock formed during caulking. Furthermore, increasing sheet thickness and relative pin height generally enhance joint performance by promoting undercut formation and increasing the available load-transfer area. The findings provide a deeper understanding of the mechanisms governing the pin shear-caulking process and support the identification of suitable parameter combinations for future lightweight multi-material structures.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02090-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149133209","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":"Forming methodology for highly aligned discontinuous fiber composite blanks via epoxy matrix staging","authors":"Matthew Abraham,&nbsp;Thomas A. Cender,&nbsp;Pavel Simacek,&nbsp;Suresh G. Advani","doi":"10.1007/s12289-026-02088-6","DOIUrl":"10.1007/s12289-026-02088-6","url":null,"abstract":"<div><p>A methodology for rapid manufacturing of complex geometry stretch formed parts from highly aligned discontinuous fiber (ADF) epoxy matrix multiaxial composite blanks is demonstrated in this paper. During typical forming processes, forming and curing occur within the same tool, leading to bottlenecks in processing time. In this new methodology, the epoxy resin is partially cured to increase glass transition temperature above room temperature. Advanced matrix staging allows a blank to be easily removed from a room temperature tool after forming. In a production environment, blanks would be (<i>i</i>) staged in an oven vacuum bag process, (<i>ii</i>) preheated in an IR oven, (<i>iii</i>) rapidly stamp formed into a room temperature tool, (<i>iv</i>) ejected as a near net shape part, and then (<i>v</i>) fully cured/formed in a parallel batch process. To implement this methodology, accurate relationships between viscosity, cure, and glass transition temperature are established and used to manufacture partially cured material for mechanical testing and extensibility characterization. Several key benefits are realized by using partially cured material; namely, the ability to rapidly form and eject a preformed part from tooling and reduced resin bleed during cure and consolidation. The staging process is also shown to retain similar formability and mechanical properties relative to the uncured material form.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149133206","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":"Roll pass design for an 18 mm wire rod section using a mill-derived spread-ratio criterion","authors":"Chinta Siva Santosh Dharma Kowshik,&nbsp;Ramesh S,&nbsp;Deepak Kumar,&nbsp;Rajkumar Ohdar","doi":"10.1007/s12289-026-02089-5","DOIUrl":"10.1007/s12289-026-02089-5","url":null,"abstract":"<div><p>Wire rod is a coiled, round-section steel product hot-rolled from a reheated billet, used as feedstock for wire drawing. Introducing a section beyond an installed mill’s range is constrained by its fixed stand configuration and gear ratios, so that a schedule obtained by simple extension can leave a groove under-filled, a problem addressed sparsely in the literature. This study develops and validates, through a plant trial, a roll pass sequence for 18 mm wire rod meeting dimensional and out-of-roundness requirements without altering the mill’s configuration. The finishing geometry, speed and loads were established analytically for an 18.23 mm hot section. An initial sequence modifying only the last two passes of the block under-filled the round; a lead-bar trial traced the deficit to the pre-finishing oval. A spread ratio, the ratio of imposed reduction to resulting lateral spread per groove, was derived from adjacent validated schedules and adopted as the four-pass design target; the initial two-pass attempt left the side dimension deficient by up to 2.7 mm. The developed four-pass schedule, with reductions of 15.6%, 19.6%, 14.3% and 12.1%, raised the spread ratios to 1.41–3.12, and produced rod measuring 17.95 mm <span>(times )</span> 17.88 mm at mid-coil, within the ±0.5 mm tolerance, at an ovality of 0.07 mm against a 0.75 mm limit, with loads within the installed drive capacity. The section is now rolled commercially. Expressed as a ratio rather than an absolute spread, it supplies a design target for an unscheduled size; validation here is dimensional.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149133208","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":"Thickness-compensation-driven preform design for hot-press forming of composite hemispherical shells using variable-spacing and variable-angle tow placement","authors":"Jiazhong Xu,&nbsp;Shanyu Cao,&nbsp;Meijun Liu,&nbsp;Ze Jin,&nbsp;Yinghao Liu","doi":"10.1007/s12289-026-02085-9","DOIUrl":"10.1007/s12289-026-02085-9","url":null,"abstract":"<div><p>Non-uniform area deformation during hot-press forming can result in local material accumulation and thickness variation in composite hemispherical shells manufactured from planar tow-placed preforms. This study proposes a thickness-compensation-driven preform design method using variable-spacing and variable-angle tow placement. A geometric inverse mapping relationship is first established between the target hemispherical shell and the planar blank. Based on the local area variation ratio and approximate volume conservation assumption, the formed-thickness requirement is projected back to the planar preform as a spatial material-compensation demand. This compensation demand is subsequently converted into constrained path-spacing, path-density, and local tow-angle distributions. Furthermore, coverage-count statistics are employed to transform discrete tow centerlines into an equivalent initial thickness field for finite element forming analysis.The proposed preform design method is evaluated using an Abaqus/Explicit hot-press forming model and compared with a conventional fixed-angle equal-spacing preform under identical tooling, contact, loading, and mesh conditions. The proposed design reduces the thickness-matching error from 0.024 to 0.019 while satisfying the prescribed minimum curvature-radius constraint of 50 mm. After forming, the thickness standard deviation decreases from 0.231 to 0.171 mm, the coefficient of variation decreases from 14.50% to 10.44%, and the root-mean-square thickness deviation decreases from 0.470 to 0.402 mm. The mean and 95th-percentile von Mises equivalent stresses decrease by 10.7% and 21.1%, respectively, while the mean contact pressure remains at a comparable level. The proposed method establishes a quantitative relationship between planar preform material distribution and formed-thickness control. This framework provides a forward design tool for general double-curvature composite components by linking preform architecture with post-forming thickness uniformity.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149035431","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 amplitude on microstructure and properties of hot oscillating pressure sintering AlCoCrNiFe high-entropy alloys","authors":"Ka Gao,&nbsp;Yuan Rao,&nbsp;Teng Fang,&nbsp;Yuhang Han,&nbsp;Yufan Tang,&nbsp;Wei Chen,&nbsp;Ziheng Gao,&nbsp;Furong Xie,&nbsp;Bin Chen,&nbsp;Chuan Li","doi":"10.1007/s12289-026-01986-z","DOIUrl":"10.1007/s12289-026-01986-z","url":null,"abstract":"<div><p>This work employs the hot oscillatory pressure (HOP) sintering technique for the first time to prepare AlCoCrNiFe high-entropy alloy at varying amplitudes, systematically investigating the influence of amplitude on their microstructure and properties. As the amplitude increased, the grain boundaries of HOP sintered alloy were disappeared, and significant improvements in density and microstructural uniformity were observed. Specifically, when the amplitude increased from ± 1 to ± 10 MPa, the density of the HOP sintered alloy was rose from 93.65% to 99.11%, achieving near-complete densification. The increased amplitude also effectively enhanced their hardness and corrosion resistance. At an amplitude of ± 10 MPa, the Vickers hardness of the HOP sintered AlCoCrNiFe high-entropy alloy was reached a maximum of 481.52 HV₁, which was significantly higher than that of the hot-press sintered samples. Moreover, its corrosion current density was minimized at 9.1 µA/cm², indicating the strongest corrosion resistance. The research results demonstrate that the increasing the HOP amplitude can produce high-entropy alloys with high density, well hardness, and excellent corrosion resistance in lower temperature.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149034756","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":"Effects of the chip size on flow resistance, structural development and mechanical properties in the direct extrusion of twill woven carbon-fibre reinforced thermoplastic composite chips","authors":"Izuru Ohtake,&nbsp;Michihiko Hoshino,&nbsp;Haruki Kobayashi,&nbsp;Teppei Kaji,&nbsp;Kaito Kajiwara","doi":"10.1007/s12289-026-02077-9","DOIUrl":"10.1007/s12289-026-02077-9","url":null,"abstract":"<div><p>Direct extrusion is a potential route for re-forming chipped carbon-fibre-reinforced thermoplastic composites (CFRTPs), but the influence of feedstock size on processing and final properties remains unclear. Unused commercial 2/2 twill-woven CFRTP sheets were cut into 4-, 8- and 12-mm square chips and used as a controlled model feedstock rather than as manufacturing scrap or end-of-life material. The chips were compression-moulded into 30-mm-diameter, 30-mm-long billets, reheated and directly extruded into 10-mm-diameter rods. As chip size increased from 4 to 12 mm, ram speed increased from 2.238 ± 0.091 to 2.713 ± 0.063 mm/s, whereas the pressure–ram-stroke slope decreased from 21.32 ± 1.40 to 16.43 ± 0.63 MPa/mm. Apparent flexural strength increased from 52.9 ± 10.9 to 108.4 ± 6.8 MPa and apparent flexural modulus from 2.02 ± 0.27 to 3.65 ± 0.35 GPa. Apparent shear strength varied only from 20.7 to 21.6 MPa. Structure tensor analysis of one longitudinal section per condition yielded global <i>a</i>₁₁ values of 0.976, 0.951 and 0.963 for the 4-, 8- and 12-mm conditions, respectively. The analysed 8-mm section showed the largest standard deviation of local <i>a</i>₁₁ and the largest misalignment. Under the present material, geometry and thermal conditions, chip size was associated with extrusion resistance, cross-sectional morphology, local orientation heterogeneity and apparent flexural performance. These results are condition-specific and require validation using practical recycled feedstock and independently sampled cross-sections.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 4","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02077-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148974849","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":"Straightening methods for flexible T-profile rolling","authors":"Franziska Sophie Peukert,&nbsp;Keanu Engel,&nbsp;Peter Groche","doi":"10.1007/s12289-026-02083-x","DOIUrl":"10.1007/s12289-026-02083-x","url":null,"abstract":"<div><p>Varying material thicknesses along the longitudinal axis of stringer profiles in aircraft structures serve to reduce weight, a goal that is currently achieved through chemical milling. To introduce this thickness variation in a more environmentally friendly manner, a new flexible rolling process for T-profiles has been developed. The flexible T-profile rolling is based on a novel roll gap geometry that enables the simultaneous rolling of the web and flange of the T-profile. The rolls have varying radii, which leads to different longitudinal strains across the profile’s cross-section, causing vertical bow in the profiles. The objective of this study is to straighten the bow by three different methods: varying the thickness ratio between web and flange, varying the ratio between angular speeds of the rolls and using a straightening roll. The feasibility of these straightening methods is first tested experimentally. The straightening roll has proven to be the most robust and easiest to implement, though slightly less effective than ideally tuned methods. However, a residual bow remains in the profile due to the difference in longitudinal strain, which is why a combination of the various straightening methods is being investigated. To this end, experiments and numerical simulations are being conducted using extruded T-profiles made of Al7075 O.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02083-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148986482","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":"Data-driven optimization of moisture content in thermoset transfer moulding: an industrial case study on process stability and scrap reduction","authors":"Adrian Hermes,&nbsp;Neža Flisek","doi":"10.1007/s12289-026-02087-7","DOIUrl":"10.1007/s12289-026-02087-7","url":null,"abstract":"<div><p>This study investigates the influence of moisture content in an epoxy-based thermoset moulding compound on process stability and scrap rate during injection moulding, motivated by seasonal performance variations observed in an industrial setting. A controlled trial production series was conducted using six discrete moisture levels (1.38% to 2.76%), prepared from a single material batch. Data from 1 524 parts produced across 254 cycles were collected, including machine parameters and 100% automated camera inspection of eight surface defect types. Statistical analyses comprised Kruskal–Wallis testing, linear and quadratic logistic regression, and correlation modelling. A pronounced non-linear, quadratic relationship between moisture content and scrap rate was identified. At low moisture levels (&lt; 2.0%), scrap rates surged to 22–26%, driven by excessive slip surface, protrusion, and void defects, while peak injection pressures exceeded 2 100 bar. In contrast, an optimal moisture window of 2.0%–2.6% yielded scrap rates as low as 3%, accompanied by a stable switchover volume of 6.0 cm³ with zero variance and substantially reduced baric resistance. Quadratic logistic regression provided a significantly better fit than a linear model (ΔAIC &gt; 10, where AIC is the Akaike Information Criterion) and confirmed the optimal operating range. Switchover volume was shown to be a more sensitive leading indicator of visual defects than pressure, and moisture levels above ≈2.7% introduced melt cushion instability without further quality gains. These findings challenge the common assumption that drier material always improves quality, instead demonstrating an optimal moisture window that maximizes yield. Practical recommendations include standardizing incoming material to 2.1% ± 0.2% moisture and using real-time switchover volume monitoring for predictive quality control. This work provides a data-driven framework for reducing scrap, lowering energy consumption, and extending tool life in thermoset injection moulding.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02087-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148927334","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":"Springback prediction considering anisotropy and nonlinear strain paths in roll forming process","authors":"Hyunsung Choi,&nbsp;Jongsup Lee,&nbsp;Geunho Kim,&nbsp;Jeong Whan Yoon","doi":"10.1007/s12289-026-02076-w","DOIUrl":"10.1007/s12289-026-02076-w","url":null,"abstract":"<div><p>This study investigates the springback behavior in a roll forming process, with a particular focus on the sill-side inner component made of 1.5 GPa-grade steel. Springback was predicted using an anisotropic constitutive model that incorporates an advanced yield function along with nonlinear kinematic and distortional hardening models. The degradation of Young’s modulus, which is known to significantly influence springback in sheet metal forming, was also considered. The roll forming process, consisting of eighteen sequential roll stages, was simulated using the commercial software LS-DYNA3D, with both the Yoshida–Uemori and HAH constitutive models implemented using User MATerial (UMAT) subroutines. To replicate actual manufacturing conditions, a trimming simulation was performed following the roll forming process, considering that the formed part is typically cut to a length of approximately 300 mm. Springback analysis was then conducted by applying appropriate boundary conditions to suppress rigid body motion. The results were analyzed with respect to material anisotropy, hardening behavior, and the effects of nonlinear strain path associated with the overbending sequence in the roll forming process.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 3","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148927335","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}