International Journal of Material Forming最新文献

{"title":"Zener pinning-induced suppression of dynamic recrystallization in CaO-added AM30 magnesium alloy under hot torsion","authors":"Chang-Hee Cho,&nbsp;Dong-Bum Byun,&nbsp;Taek-Kyun Jung,&nbsp;Jong-Su Kim,&nbsp;Yoon-Ok Park,&nbsp;Ji-Woon Lee,&nbsp;Soong-Keun Hyun","doi":"10.1007/s12289-026-02008-8","DOIUrl":"10.1007/s12289-026-02008-8","url":null,"abstract":"<div><p>This study examines the effect of CaO addition on the high-temperature torsional deformation behavior of the wrought AM30 magnesium alloy. CaO introduced during melting partially reduces in the Mg-rich melt, releasing Ca that preferentially reacts with Al to form the thermodynamically stable Laves phase Al₂Ca. Electron probe micro-analyzer (EPMA) mapping confirmed that Al₂Ca forms predominantly along grain boundaries, with an areal fraction of ~ 4–5% and a boundary coverage of ~ 20%, providing a quantitative basis for its role in deformation. Torsion tests conducted at 300–500 °C and strain rates of 0.01–1 s⁻¹ showed that AM30-0.5CaO exhibits consistently higher flow stresses and lower fracture strains compared with base AM30. Constitutive analysis revealed hyperbolic-sine behavior for both alloys, with the apparent activation energy increasing from ~ 181 kJ mol⁻¹ (AM30) to ~ 190 kJ mol⁻¹ (AM30-0.5CaO), indicating reduced grain-boundary mobility. The higher flow stresses in AM30-0.5CaO are attributed to Zener pinning by Al₂Ca and to the immobilization of grain boundaries, which decreases the effective area available for migration. These effects collectively suppress dynamic recrystallization (DRX), resulting in delayed flow softening and higher steady-state stresses. The experimental trends align with theoretical predictions derived from the measured Al₂Ca fraction and morphology. Overall, the results establish that CaO-induced Al₂Ca formation governs both strengthening and DRX kinetics in AM30, highlighting the trade-off between improved melt processability and reduced high-temperature ductility in CaO-modified Mg alloys.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938177","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 distribution and process optimization in deep drawing followed by redrawing of a 316 L bottom head for nuclear waste storage tanks","authors":"Junqi Liu,&nbsp;Bensheng Huang,&nbsp;Dongmei Liang,&nbsp;Jianneng Zheng,&nbsp;Yongyou Zhu,&nbsp;Hongyu He","doi":"10.1007/s12289-026-02025-7","DOIUrl":"10.1007/s12289-026-02025-7","url":null,"abstract":"<div><p>Local thickening, thinning, and thickness nonuniformity are critical quality issues in deep drawing followed by redrawing of a 316 L stainless steel bottom head for nuclear waste storage tanks. In this study, a constitutive model was established from uniaxial tensile tests, and a two-step finite element model was developed to investigate wall-thickness evolution during forming. The effects of punch speed, blank-holder force, and friction coefficient on thickness distribution were analyzed, and a three-factor, four-level orthogonal design was used to optimize the process parameters based on a thickness-distribution uniformity index. The results show that the spatial locations of the thickness extrema remain nearly unchanged under different process conditions. The minimum thickness is mainly located in the fillet transition zone after the first-step drawing and shifts to the top corner region after the second-step redrawing, whereas the maximum thickness remains near the lower edge of the sidewall. Among the three factors, the friction coefficient has the strongest effect on thickness-distribution uniformity, followed by punch speed and blank-holder force. Within the investigated parameter ranges, the preferred parameter combination for thickness control is a punch speed of 7000 mm/s, a blank-holder force of 870 kN, and a friction coefficient of 0.18. Forming experiments show good agreement with the numerical predictions, indicating that the proposed model can provide reasonable support for thickness prediction and process optimization.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938178","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":"Research on the plastic deformation law and fatigue performance during hole expansion","authors":"Fei Liu,&nbsp;Biao Xiao,&nbsp;Bangfu Wu,&nbsp;Xiaofeng Jia,&nbsp;Yang Cao","doi":"10.1007/s12289-026-02028-4","DOIUrl":"10.1007/s12289-026-02028-4","url":null,"abstract":"<div><p>The hole expansion strengthening is a pivotal technology for enhancing the performance of hole structures. The structural design of the mandrel plays a crucial role in determining the effectiveness of expansion strengthening and the subsequent fatigue performance of the hole structure. To explore the impact of the mandrel structure on hole expansion strengthening, a 3D finite element simulation model was established to analyze the hole expansion processes for both solid mandrel and split mandrel. Additionally, a series of hole expansion strengthening experiments were carried out, along with fatigue performance tests on specimens with holes, to investigate the influence of plastic deformation on the fatigue performance. The research results show that the maximum relative error range between the simulated residual stress values on the hole wall and the experimental data ranges from 5.3% to 9.7%. During the expansion process of the split mandrel, the deformation displacement of the hole wall in the Y-axis direction is 1.72 times that of the solid mandrel, while the deformation displacement in the Z-axis direction is smaller than that of the solid mandrel. Furthermore, when using the split mandrel hole expansion strengthening method with a relative expansion amount of 3%, the average fatigue life of the specimen can be enhanced to 1.52 times that of the specimen unexpanded. The hole expansion strengthening using a split mandrel can increase the degree of plastic deformation in the radial direction of the hole wall material, thereby improving the fatigue performance of the specimen with hole.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938176","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":"Mechanisms of porosity and hot cracking in laser–TIG hybrid welding of 4J36 invar steel under varying process parameters","authors":"Fei Zhao,&nbsp;Pengfei Wang,&nbsp;Shuili Gong,&nbsp;Haiyan Zhao,&nbsp;Lifeng Ma","doi":"10.1007/s12289-026-02019-5","DOIUrl":"10.1007/s12289-026-02019-5","url":null,"abstract":"<div><p>This study employs laser-TIG hybrid welding technology on 4J36 Invar steel to investigate the mechanisms and influence of welding process parameters on the formation of porosity and hot cracking defects in the weld. The results indicate that porosity defects in the weld can be primarily classified into two categories: process-induced and metallurgical; the former are primarily caused by keyhole collapse and insufficient liquid metal refilling, while the latter are closely related to oxidation reactions and gas entrapment within the molten pool. The study found that porosity may act stress concentration sites and influence the initiation and propagation of hot cracks. The segregation of elements such as O, C, P, and S at grain boundaries may reduce grain boundary strength and increase defect susceptibility. Further analysis shows that the effects of process parameters on porosity and cracking exhibit a non-monotonic trend. Within the parameter range of this study, for 12 mm thick 4J36 Invar steel, a laser power of 5 kW, an arc current of 150 A, and a welding speed of 0.68 m/min provide a relatively balanced performance in controlling both porosity and cracking. This parameter combination helps improve weld quality to a certain extent. The results provide a reference for understanding defect formation mechanisms and for optimizing process parameters in laser–TIG hybrid welding of Invar steel.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938224","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":"Real-Time optimization of sheet molding compound production using complementary reduced-order and data-driven modeling","authors":"Mikhael Tannous,&nbsp;Konstantinos Tzimanis,&nbsp;Iason Tzanetatos,&nbsp;Jon Larreina,&nbsp;Chady Ghnatios,&nbsp;Salvatore Sottile,&nbsp;Francisco Chinesta","doi":"10.1007/s12289-026-02020-y","DOIUrl":"10.1007/s12289-026-02020-y","url":null,"abstract":"<div><p>Sheet Molding Compound (SMC) compression molding enables the cost-efficient manufacturing of lightweight structural components for automotive applications. However, the final part quality is highly sensitive to complex interactions between various manufacturing parameter that are difficult to optimize through trial-and-error. Physics-based Finite Element simulations support process understanding and parameter optimization, but their computational cost and modeling assumptions limit their applicability during production. This work introduces a co-deployed decision-support framework combining a Reduced Order Model (ROM) derived from physics-based simulations with complementary Data-Driven Models (DDMs) trained on real manufacturing measurements. The ROM provides instantaneous predictions of internal process fields, while the DDMs infer quality indicators not reliably obtainable from simulation alone. Both models are integrated into the manufacturing machine’s Process Control Manager and connected to the press via OPC-UA, enabling real-time insight for operators. The methodology is demonstrated on the industrial production of an automotive upper suspension control arm manufactured by MARELLI, yielding reduced design time, lower scrap rates, enhanced quality, and actionable feedback. These results highlight the potential of complementary digital-twin approaches for optimizing composite manufacturing processes.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02020-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147937808","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":"Characterisation and modelling of the damage and delamination behaviour of oxide scale layers in hot bulk forming","authors":"Simon Peddinghaus,&nbsp;Norman Mohnfeld,&nbsp;Hendrik Wester,&nbsp;Tim Bergelt,&nbsp;Marcel Graf,&nbsp;Johanna Uhe,&nbsp;Thomas Lampke,&nbsp;Bernd-Arno Behrens","doi":"10.1007/s12289-026-02017-7","DOIUrl":"10.1007/s12289-026-02017-7","url":null,"abstract":"<div><p>In hot forming processes of steel, oxide scale layers are formed in dependence of the occurring process conditions. As remaining oxide scale can weaken the formed workpiece, it has to be removed at the end of the process. Through this, the oxide scale formation can lead to a mass loss of up to 3% in addition to influencing the forming process for example by affecting the friction conditions or increasing the die wear. However, oxide scale layers can protect against further oxidation and limit the mass loss as long as they are not damaged or separated from the workpiece, for example through cracks or delamination. In order to evaluate the resulting forming process in dependence of the oxide scale layer, numerical simulations can be applied. For a precise numerical description of a forming process using a finite element simulation, it is necessary to model the delamination and damage behaviour of the oxide layer. This paper presents a characterisation and modelling approach to describe the delamination and damage behaviour based on the occurring stresses in dependence of the temperature. The results of the experimental study indicate that the investigated oxide scale layers were more sensitive towards delamination than crack initiation. The derived models allowed to numerically recreate the experimental tests.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02017-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147937807","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":"Controlling the pressure distribution in thermoplastic molding of metallic glass through in-situ merging kinetics","authors":"Naheen Ibn Akbar,&nbsp;Kalyan Nandigama,&nbsp;Golden Kumar","doi":"10.1007/s12289-026-02023-9","DOIUrl":"10.1007/s12289-026-02023-9","url":null,"abstract":"<div><p>Metallic glasses can be patterned on a nanometer scale by thermoplastic molding to generate durable replicas of master templates. However, the pattern area and uniformity are inherently limited by the alloy-dependent sample size and the nonuniform pressure distribution in molding. Here, we demonstrate a novel technique to overcome both limitations simultaneously by manipulating the supercooled liquid merging kinetics. The results from Pt-based metallic glass reveal that molding small samples with controlled arrangement and spacing can generate patterns over large areas with improved uniformity. The spatial distribution of pressure is modified by controlling the merging kinetics of individual samples. Distributed pressure fields enable uniform template filling over large area in multi-sample molding compared to conventional single-sample approach. The experimental results for single- and multi-sample molding are compared with analytical predictions based on the lubrication theory. The findings suggest that the use of multiple small samples is a better approach for thermoplastic molding and drawing of metallic glasses.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s12289-026-02023-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938146","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":"Deformation behavior of ultra-thin-walled microchannel structures in soft mold roll forming","authors":"Zhuangzhuang Wang,&nbsp;Jialin Zhu,&nbsp;Chunju Wang,&nbsp;Zhenwu Ma","doi":"10.1007/s12289-026-02027-5","DOIUrl":"10.1007/s12289-026-02027-5","url":null,"abstract":"<div><p>Metal bipolar plates are critical components in high-performance fuel cells. However, when fabricating ultra-thin-wall microchannel structures using the roll forming process, issues such as cracking and distortion frequently occur, which limit the enhancement of the reaction performance and service life of metal bipolar plates. This study proposes a novel soft mold roll forming process for ultra-thin-wall microchannel structures. A dedicated soft mold roll forming apparatus was developed, comprising roller modules, pressure modules, and intelligent control modules. Based on this, the effects of roller structural features and soft mold properties on the deformation behavior of microchannel structures were investigated. The results indicate that the soft mold roll forming process enables tensile deformation along the entire profile of the microchannel structures, thereby reducing the risk of cracking and weakening the size effect. The greater the roller pressure, the thinner the soft mold thickness, and the larger the groove depth and fillet radius, the stronger the bulging capability of the soft mold, resulting in a higher depth-to-width ratio of the formed microchannel structure. When the groove spacing-to-width ratio is less than 0.5, the foil within the groove interval enters a material-starved state, and excessively small groove spacing results in severe thinning of the microchannel structures. A critical soft mold hardness value, Shore A50, was identified, at which the depth-to-width ratio of the formed microchannel structures reaches its maximum. Finally, optimized process parameters were selected to fabricate microchannel structures with uniform geometry, high distribution density, large depth-to-width ratio, and uniform thickness distribution. These findings provide methodological guidance for eliminating forming defects in microchannel structures and improving the forming quality of bipolar plates.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938222","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":"Heated double-sided incremental forming of AZ31B magnesium alloy based on pass parameter gradient design: wall thickness distribution and accuracy control","authors":"Chunjian Su,&nbsp;Yun Mi,&nbsp;Lingao Zhang,&nbsp;Qinglin Li,&nbsp;Yansheng Zang,&nbsp;Xiang Meng,&nbsp;Congjie Wei,&nbsp;Changting Xu,&nbsp;Yuepeng Ma,&nbsp;Kai Zhang","doi":"10.1007/s12289-026-02018-6","DOIUrl":"10.1007/s12289-026-02018-6","url":null,"abstract":"<div><p>To address the poor room-temperature plasticity and difficulty in forming complex components of AZ31B magnesium alloy, this study investigates its multi-pass double-sided incremental forming process under heated conditions, focusing on the influence of gradient strategies for key inter-pass parameters on forming quality. By establishing an ABAQUS finite element model combined with experimental validation, the effects of heating temperature (150–250 °C) and forming modes were systematically analyzed, and gradient designs of three parameters—forming angle, axial spacing, and tool radius—were compared. The results show that support forming at 250 °C is the optimal baseline process. The gradient of the pass forming angle has the most significant impact: an increasing angle sequence (45°–55°–70°) helps improve wall thickness uniformity, while a decreasing angle sequence (45°–60°–70°) is more conducive to dimensional accuracy. Increasing axial spacing (0.5–1.0–1.5 mm) enhances overall wall thickness, and increasing tool radius (3–4–5 mm) improves forming accuracy. Orthogonal experiments indicate the optimal combinations for maximizing minimum wall thickness (M1V3N1) and dimensional accuracy (M3N2V2). This research provides theoretical and practical guidance for parameter gradient optimization in heated multi-pass double-sided incremental forming of AZ31B magnesium alloy.</p></div>","PeriodicalId":591,"journal":{"name":"International Journal of Material Forming","volume":"19 2","pages":""},"PeriodicalIF":2.6,"publicationDate":"2026-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147938217","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":"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}