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10 October 2026, Volume 18 Issue 10
    

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    Composites Forming
  • YUAN Zhenhao, ZHANG Mengfei, WEI Junxin, LI Sha, CAO Shouzhen, JIA Yi, HAN Jianchao
    Journal of Netshape Forming Engineering. 2026, 18(10): 1-11. https://doi.org/10.3969/j.issn.1674-6457.2026.10.001
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    The work aims to investigate the effect of annealing process on the microstructure and bending formability of rolled Mg/Al composite plates, and to reveal the intrinsic mechanism by which annealing improves the bending formability of Mg/Al composite plates. The evolution and morphological characteristics of the interfacial microstructure of Mg/Al composite plates were characterized by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and electron backscatter diffraction (EBSD); the bending formability of Mg/Al composite plates was tested through bending experiments. The experimental results showed that moderate annealing treatment could significantly enhance the bending formability of the composite plates, which was manifested in an 8.7%-15% reduction in the maximum bending stress, effectively decreasing the energy consumption of bending forming, and the maximum increase in bending angle could reach 41.4%, which remarkably elevated the forming limit. The improvement of the plasticity of Mg/Al composite plates by annealing was attributed to the activation of the softening mechanism inside the plates: the static recrystallization (SRX) of the magnesium layer and the recovery behavior of the aluminum layer acted synergistically to jointly regulate the release of internal stress inside the plates, thereby improving the plasticity of each layer of material. It was also found that excessive annealing at 300 ℃ for 120 min led to excessive thickening of the brittle intermetallic compound layer, which made it a sensitive zone for crack initiation and further induced premature cracking failure at the interface, resulting in a decrease in bending fracture displacement. Compared with the as-rolled Mg/Al composite plates, the bending formability of Mg/Al composite plates is improved after annealing with different process parameters, and the annealing process of 300 ℃ for 60 min enables the Mg/Al composite plates to obtain the optimal bending formability. However, excessive annealing treatment will induce interfacial brittleness of Mg/Al composite plates and reduce their bending formability.
  • ZHANG Jing, LU Chang, HE Jianxin, GUO Yingjian
    Journal of Netshape Forming Engineering. 2026, 18(10): 11-19. https://doi.org/10.3969/j.issn.1674-6457.2026.10.002
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    The work aims to propose a sol-gel wet spinning technique to fabricate boron nitride/aramid (BNNS/ANF) composite thermally conductive filaments with a structured three-dimensional (3D) heat-transfer network, so as to address the growing demand for fiber materials with high thermal conductivity, robust electrical insulation, and excellent mechanical properties in flexible electronics, wearable technology, and personal thermal management systems. Aramid nanofibers (ANF) were employed as the matrix, while boron nitride nanosheets (BNNS) were synthesized via hydrothermal intercalation and ball milling. The BNNSs were further grafted and modified with branched polyethyleneimine (BPEI) to enhance their dispersibility and interfacial compatibility. Graphene nanosheets (GN) were introduced as bridging fillers to enhance the interfacial interactions among thermally conductive components, thereby improving the mechanical and thermal properties of the fibers. A continuous three-dimensional thermal conduction network was constructed within the fibers via sol-gel wet spinning, Cu²+ ionic crosslinking, and subsequent wet drawing treatment. The experimental results demonstrated that the composite fibers, produced under optimized processing conditions, exhibited superior performance. At a BNNS loading of 30wt% and a GN content of 0.2wt%, the composite fibers achieved an axial tensile strength of 105.9 MPa, an axial thermal conductivity of 9.2 W/(m·K), and a volumetric resistivity of 1×1013 Ω·cm. Cooling performance tests using an LED chip as the heat source revealed that the composite fiber fabric effectively reduced the LED surface temperature from 47.0 ℃ (when using cotton fabric) to 44.8 ℃, highlighting its significant potential for thermal management. In conclusion, the sol-gel wet spinning strategy developed in this study provides a viable pathway for the fabrication of composite fibers that balance high thermal conductivity with excellent electrical insulation. These fibers hold broad application prospects in fields such as heat dissipation for flexible electronics, personal thermal management, and smart textiles, providing insights into the structural design and processing of high-performance functional fibers.
  • HU Shaohua, CAO Lu, LUO Shen, GAO Fei, TAN Jing, YANG Weimin
    Journal of Netshape Forming Engineering. 2026, 18(10): 20-30. https://doi.org/10.3969/j.issn.1674-6457.2026.10.003
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    Graphite-based radiative heaters feature high infrared emissivity and excellent high temperature stability, and have been widely used in thermal testing and high temperature heat treatment equipment. To achieve high-efficiency and uniform heating of graphite-based radiative heaters and the integrated fabrication of complex configurations, extensive research has been conducted worldwide on the high-performance forming, complex structure manufacturing, and precision machining of graphite composites. The work aims to review the recent progress in the forming and advanced manufacturing processing technologies of graphite composites, including the introduction of graphene and other reinforcements with interfacial regulation, in situ formation of vertically oriented graphene reinforced architectures, composite forming routes such as solution mixing and hot pressing sintering, and vapor deposition based forming control strategies toward structural and functional integration of heater components. In addition, recent developments in multi axis CNC precision machining, ultrashort pulse laser microstructuring, ultrasonic vibration assisted machining, and microforming are summarized with emphasis on improving surface integrity and dimensional consistency. The opportunities and limitations of additive manufacturing for one step fabrication of complex integrated structures are also discussed, particularly the challenges in achieving consistent densification, microstructural uniformity and forming consistency. Finally, combined with typical applications, the oxidation resistance life, performance evaluation methods and engineering application characteristics of graphite-based radiative heaters are summarized, and future development directions are proposed.
  • TIAN Hao, SHI Xiaolong, DENG Qilin, WANG Xingdong, YI Zhihao, HU Hongjun, MA Xiang
    Journal of Netshape Forming Engineering. 2026, 18(10): 31-47. https://doi.org/10.3969/j.issn.1674-6457.2026.10.004
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    Tantalum and tantalum alloys have become core functional materials of space radiation-resistant layered composite structures due to their high atomic number, excellent radiation resistance and good mechanical stability. However, due to the problems of high density and high cost, it is difficult to meet the ultimate pursuit of radiation resistance and lightweight spacecraft. In view of the above problems, scholars at home and abroad have conducted a series of studies on the layered composite structure of tantalum alloys and achieved remarkable results. This paper reviews the current progress of space radiation-resistant tantalum alloy layered composites preparation and forming technology at home and abroad, including rolling composite technology, explosive composite technology, diffusion composite technology, hot isostatic pressing technology, additive manufacturing technology, surface coating and interface strengthening technology. Finally, the research progress of space radiation-resistant tantalum alloy layered composites preparation and forming technology is summarized and prospected, aiming to provide references for promoting the rapid development of space radiation-resistant tantalum alloy layered composites preparation and forming technology in China.
  • HOU Qingjiang, HUANG Zhigao, CHEN Zhikun, WU Junjun, ZHOU Huamin
    Journal of Netshape Forming Engineering. 2026, 18(10): 48-55. https://doi.org/10.3969/j.issn.1674-6457.2026.10.005
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    The work aims to investigate the effect of replacing polytetrafluoroethylene (PTFE) fibers with polyester (PET)/PTFE blended fibers of different orientations and carbon nanotube (CNTs) modification at various concentrations on the interlaminar properties of composite materials, thus exploring the underlying mechanisms. Through 180° peel tensile testing, shear beam experiments, and double cantilever beam tests, the 180° interlaminar peel strength, interlaminar shear strength, and Mode I interlaminar fracture toughness of PTFE fibers, PET/PTFE blended fibers with different orientations, and the blended fibers reinforced epoxy resin treated with different CNTs concentrations were compared. The effect patterns on interlaminar properties of double-layer composite bearing materials were systematically analyzed. Ultra-depth-of-field microscopy and scanning electron microscopy were employed to reveal the mechanisms by which CNTs affected the interlaminar properties. When PET/PTFE blended fibers with different orientations were used to replace PTFE fibers, the interlaminar properties of the composite materials were significantly improved. Particularly, when the polyester fiber orientation in the blended fibers was perpendicular to the shear direction, the 180° peel strength, interlaminar shear strength, and Mode I interlaminar fracture toughness of the composite material increased by 170%, 20.63%, and 104.15%, respectively. This substantial enhancement was primarily attributed to the superior bonding properties between polyester fibers and the resin compared to PTFE fibers. When blended fibers were treated with different concentrations of CNTs, as the CNTs concentration increased from 0 to 1%, the 180° peel strength, interlaminar shear strength, and Mode I interlaminar fracture toughness all exhibited a trend of initial increase followed by a decrease, reaching maximum values at a CNTs concentration of 0.5%. This was mainly due to the bridging effect of CNTs, which effectively enhanced the interlaminar properties. However, when the CNTs concentration was excessive, agglomeration occurred, leading to a weakening of this effect and a reduction in interlaminar property enhancement. The use of PET/PTFE blended fibers to replace PTFE fibers and the CNTs modification of fibers both effectively improve the interlaminar bonding properties of the material. The synergistic effect of both approaches can effectively enhance the interlaminar bonding properties, reduce the delamination risk of bearing materials under extreme conditions, and provide guidance for the design of epoxy resin-based composite bearing bushing materials.
  • HUANG Qiang, LIU Qingwei, ZHENG Xudong, LU Shuping, SU Lei, LIANG Biqiang, ZHOU Keqiu
    Journal of Netshape Forming Engineering. 2026, 18(10): 56-64. https://doi.org/10.3969/j.issn.1674-6457.2026.10.006
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    The work aims to fabricate SS304/Cu/Al layered composites through the WAAM process to investigate their microstructure and macroscopic mechanical properties, and provide a new approach for the preparation of aluminum-stainless steel materials. A Cu substrate was prepared as a transitional bonding layer. Combining the high heat input and flexible forming advantages of the WAAM process, interfacial products were effectively controlled while promoting good interfacial bonding. SEM, EDS, XRD, and tensile testing were used to analyze the macroscopic mechanical properties and microstructure of the layered composites. Interfacial microstructure and phase analysis showed that the Cu substrate, as a transitional layer, effectively suppressed the formation of brittle phases at the interface, resulting in a distinct wavy interfacial morphology. The elemental diffusion layer thicknesses at the SS304-Cu substrate interface and the Al-Cu substrate interface were 2 μm and 53 μm, respectively. Bending, tensile tests, and fracture morphology revealed a clear stepwise decrease in stress-strain curves. Optimized heat input parameters lead to favorable kinetic characteristics between the heterogeneous materials, promoting interfacial bonding. Multi-level failure modes and excellent crack propagation resistance enable the layered composites to exhibit superior structural safety and damage tolerance.
  • Light Alloy Forming
  • LEI Bingwang, YUN Xuefeng, WANG Yongqiang, ZHAI Pengyuan, QIN Ruiting
    Journal of Netshape Forming Engineering. 2026, 18(10): 65-81. https://doi.org/10.3969/j.issn.1674-6457.2026.10.007
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    Ti-6Al-4V (TC4) alloy has attracted extensive attention in aerospace, biomedical, and marine engineering fields due to its high specific strength, excellent biocompatibility, and outstanding corrosion resistance. Powder metallurgy technology provides an ideal pathway for achieving near-net shaping of complex-shaped Ti-6Al-4V components and improving material utilization. However, the interrelated and co-evolving issues of oxygen embrittlement, residual porosity, and microstructural coarsening in powder metallurgy Ti-6Al-4V alloys constitute key processing challenges that restrict the synergistic enhancement of strength and ductility. How to simultaneously regulate oxygen content and microstructure morphology while ensuring densification to achieve synergistic improvement of strength and ductility is a focal point of current research. Based on the raw material characteristics, pressing and sintering processes, and post-treatment methods of Ti-6Al-4V, the work aims to clarify oxygen control mechanisms, densification behaviors, and microstructure tailoring strategies, and summarize the research progress in synergistic strength-ductility modification of powder metallurgy Ti-6Al-4V alloys. Finally, future directions for powder metallurgy Ti-6Al-4V are prospected.
  • LYU Meiyuan, SUN Weihao, YIN Quanfeng, XU Changcheng, LENG Xinlin, TANG Mingyao, TIAN Siyu, MA Mingqing, REN Yuping, CAI Minghui, JIANG Min, QIN Gaowu
    Journal of Netshape Forming Engineering. 2026, 18(10): 82-91. https://doi.org/10.3969/j.issn.1674-6457.2026.10.008
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    The work aims to systematically compare the microstructural evolution and changes in mechanical properties of medical TC4ELI alloy bars at different stages of continuous hot working and reveal the corresponding relationship among microstructural reconstruction, texture evolution, and mechanical properties under multi-stage hot working conditions, so as to provide a reference for hot working process optimization and microstructure-property regulation of medical TC4ELI alloy bars. Optical microscopy (OM), electron backscatter diffraction (EBSD), and room-temperature tensile testing were employed to investigate the microstructure and mechanical properties of TC4ELI alloy in the as-cast, forged, rolled, and drawn states. The Widmanstätten microstructure formed in the as-cast alloy was transformed into a fine lamellar basketweave microstructure after forging in the high-temperature β phase region, and the α lamellar spacing was refined to 0.96 μm. After subsequent hot rolling in the α+β two-phase region, the microstructure was further refined, and the average α grain size was reduced to 0.9 μm. The grains were slightly elongated along the rolling direction, with the preferred orientation concentrated near <10-10>. During further hot drawing in the α+β two-phase region, although the average α grain size was about 0.7 μm, the microstructure exhibited obvious fibrous characteristics along the drawing direction, and the preferred orientation remained <10-10> parallel to the drawing direction. Finally, the rolled TC4ELI alloy exhibited the best overall mechanical properties, with a yield strength, ultimate tensile strength, and elongation of 937 MPa, 1 022 MPa, and 16.9%, respectively. In contrast, the drawn alloy showed higher yield strength and ultimate tensile strength, reaching 1 022 MPa and 1 208 MPa, respectively, but the elongation decreased significantly to 8.2%. Continuous hot working can promote the refinement and reconstruction of the microstructure of as-cast TC4ELI alloy and lead to obvious changes in texture and mechanical properties. Among the different states, the rolled alloy shows the best strength-ductility balance, whereas the drawn alloy achieves the highest strength.
  • LI Guoxing, GAO Peihu, CHEN Baiyang, ZHAO Daming
    Journal of Netshape Forming Engineering. 2026, 18(10): 92-102. https://doi.org/10.3969/j.issn.1674-6457.2026.10.009
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    Against the background of automotive lightweighting, A356 aluminum alloy cylinder heads face thermal failure risks during service. The work aims to reveal the thermal stability of microstructures and the degradation mechanism of mechanical properties of T6-treated alloy within the temperature range of 250-385 ℃, providing quantitative theoretical support for the thermal aging resistance design of cylinder heads. Thermal exposure tests were conducted at 250 ℃, 325 ℃ and 385 ℃ for 45 hours to simulate actual engine service conditions. Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) were adopted to characterize phase microstructure evolution. Combined with Transmission Electron Microscopy (TEM) and Geometric Phase Analysis (GPA), the phase transformation sequence, loss of coherency and evolution law of strain field were clarified at the atomic scale. Room-temperature tensile tests and hardness measurements were performed to verify the variations in mechanical properties. The macroscopic mechanical properties of A356 aluminum alloy were significantly temperature-dependent and exhibited distinct nonlinear characteristics with prolonged thermal exposure time. At 250 ℃, the microstructure remained relatively stable with only slight overaging, resulting in a marginal reduction of 6.7% in yield strength and a moderate increase in elongation. 325 ℃ served as the critical transition temperature for mechanical properties. The coarsening rate constant K rose sharply to 13.455 03, the coherent relationship between precipitates and the matrix was destroyed, and the dislocation pinning capacity decreased by 40%, leading to a sharp drop of 27% in yield strength. Under the extreme condition of 385 ℃, the magnesium content in the matrix was depleted to 0.52%. Metastable strengthening phases completely transformed into coarse equilibrium phases, and the contribution rate of dislocation reinforcement dropped below 10%. Consequently, the yield strength plummeted by 45% to 130.35 MPa, with a 41% reduction in hardness. Meanwhile, the full spheroidization of eutectic silicon fundamentally changed the fracture mode from quasi-cleavage fracture to micropore-aggregated ductile fracture, and the elongation surged to 17.16%. The thermal failure of A356 aluminum alloy is predominantly dominated by the coarsening, destabilization and coherency loss of Mg2Si strengthening phases. The alloy maintains stable mechanical properties at 250 ℃ and below, while irreversible strength degradation occurs at 325 ℃ and above. This work defines 250 ℃ as the critical temperature threshold for safe service, which can directly support the life prediction and reliability evaluation of complex high-strength aluminum alloy components.
  • WANG Feilong, ZHANG Guozheng, GUO Kai, LIANG Shunxing, MA Mingzhen
    Journal of Netshape Forming Engineering. 2026, 18(10): 103-111. https://doi.org/10.3969/j.issn.1674-6457.2026.10.010
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    The work aims to study the thermal plastic deformation behavior and the microstructure evolution mechanism during the deformation process of the new titanium alloy, and to provide a theoretical basis for the optimization of titanium alloy thermal processing. The thermal deformation behavior and the microstructure evolution behavior of the Ti-6Al-3Nb-2Zr-1Mo alloy were studied through thermal compression experiments, thermal processing maps under different strain conditions were drawn, the power dissipation characteristics and the distribution of the instability zone of the alloy were analyzed, and its optimal thermal processing window was determined. The microstructure evolution laws of the Ti-6Al-3Nb-2Zr-1Mo titanium alloy during the single-phase and two-phase thermal deformation processes were studied. The isothermal thermal compression experiments were carried out on a thermal simulation testing machine, with the experimental temperature range of 750-1 100 ℃, a strain rate of 0.001-10 s‒1, and a deformation amount of 60%. Through linear regression, the constitutive equation of the Ti-6Al-3Nb-2Zr-1Mo alloy was constructed. The results showed that the activation energy of the Ti-6Al-3Nb-2Zr-1Mo alloy was 620.93 kJ/mol at 750-950 ℃, and 198.76 kJ/mol at 1 000-1 100 ℃. The thermal processing map of the Ti-6Al-3Nb-2Zr- 1Mo alloy was drawn based on the dynamic material model and Murty criterion. In conclusion, as the deformation temperature increases, the volume fraction of the equiaxed α phase decreases, and the microstructure gradually coarsens. The optimal hot working window for the Ti-6Al-3Nb-2Zr-1Mo alloy is defined within the temperature range of 930-1 080 ℃ and strain rates below 0.1 s‒1. Under these processing conditions, a mixed microstructure comprising equiaxed α grains and lamellar (α+β) colonies is obtained, effectively suppressing the formation of defects such as adiabatic shear bands and cracks.
  • SHI Zhonglou, YANG Xiangjie, QU Binwen, YANG Xiaoyuan, LI Jiehua
    Journal of Netshape Forming Engineering. 2026, 18(10): 112-122. https://doi.org/10.3969/j.issn.1674-6457.2026.10.011
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    The work aims to explore the evolution law of surface temperature and residual stress during milling and optimize the milling process parameters to solve the problem of surface quality degradation caused by thermal-mechanical coupling effect in TA11 titanium alloy milling, such as low dimensional accuracy and poor roughness. The dry milling test of bulk titanium alloy (88 mm×30 mm×4 mm) was carried out by orthogonal experimental design, combined with infrared thermal imager and X-ray diffraction (XRD) instrument. The effects of different milling speed (vc=4 700, 5 300, 5 900, 6 500 r/min), feed per tooth (fz=0.01, 0.02, 0.03, 0.04 mm/z), milling depth (ap=0.5, 1.0, 1.5, 2.0 mm) and milling width (ae=0.2, 0.3, 0.4, 0.5 mm) on the surface temperature and residual internal stress of the sample were studied. Results showed that the milling depth had the most significant effect on the surface temperature, with a contribution rate of 61%, and the feed per tooth had the least effect on it. The milling width had the most significant effect on the residual stress, with a contribution of 43.53%, and the milling depth had the least effect on it. The surface temperature and residual internal stress prediction models based on multiple linear regression were constructed, and the average prediction errors were 2.67% and 5.19%, respectively. After solving by the dung beetle optimization algorithm, the optimal process parameters could reduce the milling temperature by 37.64% and the residual stress by 21.14%. In conclusion, the prediction simulation has high goodness of fit. When the milling speed vc is 7 085.32 r/min, the feed per tooth fz is 0.02 mm/z, the milling depth ap is 0.32 mm, and the milling width ae is 0.1 mm, the milling temperature is 29.3 ℃, and the surface residual stress is 48 MPa. This parameter combination can effectively suppress surface degradation and significantly improve the milling quality of TA11 titanium alloy.
  • Iron and Steel Forming
  • WANG Jinlei, GUO Yanbing, ZHANG Wang, TANG Xin
    Journal of Netshape Forming Engineering. 2026, 18(10): 123-131. https://doi.org/10.3969/j.issn.1674-6457.2026.10.012
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    The work aims to employ the high-throughput laser cladding technology to fabricate compositional samples with a continuously gradient-changing manganese nitride (MnN) content on a single sample through interleaved cladding, to solve the problem that during the preparation of 2205 duplex stainless steel (DSS) by laser cladding, rapid non-equilibrium solidification easily inhibits the δ→γ phase transformation, leading to an excessively high proportion of ferrite in the cladded microstructure and disrupting its phase balance and properties. By means of optical microscopy (OM), scanning electron microscopy (SEM), X-ray diffraction (XRD), etc., the evolution laws of microstructure, hardness and corrosion resistance in the direction of the compositional gradient were systematically characterized. With the gradient increase of MnN content, the proportion of austenite (γ) phase increased from 11.2% to 41.8%, achieving the regulation of the two-phase proportion. When the two-phase proportion approached 1∶1 (corresponding to sample 6), the material obtained the optimal comprehensive properties. The micro-hardness reached 280 HV, and the corrosion resistance was the best, with the lowest self-corrosion current density of 1.9×10-7 A/cm². This study indicates that using MnN as a composite additive can effectively compensate for the lack of austenite caused by rapid solidification during laser cladding and regulate the phase balance. More importantly, the high-throughput compositional gradient strategy adopted has successfully achieved a rapid and continuous mapping of the “composition, microstructure and property” relationship. This method improves the efficiency of alloy development and provides an efficient solution for targeted alloy design based on in-situ powder mixing.
  • CHEN Xueyan, YANG Liu, ZHAO Fuqiang, LIU Hao
    Journal of Netshape Forming Engineering. 2026, 18(10): 132-139. https://doi.org/10.3969/j.issn.1674-6457.2026.10.013
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    The work aims to propose a hybrid forming process that combines roll forming for pre-forming with stamping for precision shaping, to improve the forming accuracy and quality of 316L stainless steel bipolar plate flow channels in proton exchange membrane fuel cells, addressing key issues such as low geometric precision, uneven thickness distribution, and concentrated residual stress inherent in traditional single-step forming processes. Using 0.1 mm thick 316L stainless steel sheets as materials, the preliminary channel profile was first formed via roll forming, followed by precise geometric definition through stamping. The influence of die friction coefficient on the forming quality of high-aspect-ratio flow channels was systematically investigated using a combined approach of finite element simulation and physical experiments. The results indicated that at a friction coefficient of 0.1, the maximum thinning rate during the pre-forming stage was 4.7%, and the final thinning rate after finishing was controlled within 11.3%. The sidewall shape more closely approximated the designed 90° target, with the left and right sidewall angles increasing by 2.1% and 2.7%, respectively. The formed channel depth was further increased by 1.2%. The roll-stamping hybrid process effectively redistributed and optimized the internal residual stress field, resulting in an overall stress reduction of 12%-15%. In conclusion, the friction coefficient influences the interfacial shear stress, which in turn changes the material flow behavior and mold filling effect, ultimately affecting the stress-strain state, thickness distribution, and geometric accuracy of the flow channels. This provides a feasible process route and theoretical support for the high-quality and high-consistency precision forming of metallic bipolar plates for proton exchange membrane fuel cells.
  • DENG Yulian, ZHOU Xiaoguang, CHANG Binghui, WANG Huajun, PAN Pingfeng, FANG Haojie, YAO Zhenhua
    Journal of Netshape Forming Engineering. 2026, 18(10): 140-146. https://doi.org/10.3969/j.issn.1674-6457.2026.10.014
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    The work aims to clarify the strengthening and anti-wear mechanisms of the Fe65 coating on hot-stamping dies and to improve the high-temperature tribological performance and service life of the dies. The Fe65 coating was fabricated on H13 steel substrate via plasma powder surfacing. The microstructure and hardness of the coating were characterized, and high-temperature friction-wear tests were conducted to compare the tribological behaviors and wear mechanisms of the H13 substrate, the Fe65 coating and the high-strength steel. The as-prepared Fe65 coating formed a sound metallurgical bond with the H13 substrate, with uniform and dense microstructure. Carbon-boron hard phases in the coating exerted a remarkable strengthening effect, and the coating hardness was 2.6 times that of the substrate. The friction coefficient of the H13 substrate fluctuated drastically, with an average value above 0.4 at various temperatures, while the Fe65 coating presented a stable friction coefficient of merely 0.389 at 500 ℃. Under identical test conditions, the wear loss of the H13 substrate was far higher than that of the Fe65 coating. The worn surface of the H13 substrate against high-strength steel was dominated by oxidative, adhesive, abrasive and fatigue wear. In contrast, the worn surface of the Fe65 coating against high-strength steel was characterized by oxidative wear and slight abrasive wear only, as the coating effectively suppressed micro-cutting and oxide agglomeration. In conclusion, surfacing the Fe65 coating on H13 hot-stamping dies can significantly improve surface hardness and stabilize friction coefficient and reduce wear loss, which is an effective surface modification method to enhance the die performance and service life.
  • YU Zhengyang, SHU Zhankai, WANG Yongfeng, WANG Huan, ZHANG Kaiming, ZHONG Bin, LIU Wenzhuo
    Journal of Netshape Forming Engineering. 2026, 18(10): 147-153. https://doi.org/10.3969/j.issn.1674-6457.2026.10.015
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    The work aims to solve the problem of unclear cracking behavior of metal bars during low stress separation. Based on Hall-Petch plasticity theory and shear modified Gurson-Tvergaard-Needleman (GTN) model proposed by Zhou, an extended GTN model considering grain size effect was constructed, and the elastic-plastic parameters and model parameters of 304 stainless steel were identified by uniaxial tensile test, reverse solution method and microscopic observation method. On this basis, the numerical simulation method of low stress bending fatigue separation with coupled damage was used to study the mechanism of cracking behavior induced by material damage evolution under low stress bending fatigue separation process. The reliability of extended GTN model theory and finite element numerical simulation considering grain size effect was verified by conducting a precision separation test and relying on cross-section evaluation index and separation time. The cracking behavior of 304 stainless steel bar in the process of low stress bending fatigue separation began with the root of artificially prefabricated annular notch. With the increase of the downward displacement of the hammer head, the hole volume fraction and Mises stress at the root of the annular notch increased. Based on the evaluation index of cross-section, when the pressing displacement of the hammer head was 1.5 mm, the high-efficiency near-net cross-section was obtained. The extended GTN model considering grain size effect can be applied to predict the cracking behavior under low stress precision separation process, which provides theoretical support for the reasonable selection of subsequent separation process parameters.
  • Advanced Joining Technology
  • MIAO Guanghong, NI Yadong, WEI Zhengmei, WU Weida, TIAN Guangkuo
    Journal of Netshape Forming Engineering. 2026, 18(10): 154-165. https://doi.org/10.3969/j.issn.1674-6457.2026.10.016
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    The work aims to investigate the effect of stand-off distance on explosive welding of TA2 and Q235B. Based on the ANSYS/LS-DYNA finite element software, the explosive welding process under two stand-off distances (8 mm and 10.5 mm) was simulated three-dimensionally with the ALE and SPH-FEM algorithms. The vertical displacement of the flyer plate, collision velocity, collision pressure, interface plastic deformation, and the variation of waveforms were systematically analyzed. On the basis of the experiment with an explosive thickness of 28 mm and a stand-off distance of 8 mm, two control groups with an explosive thickness of 25 mm and a stand-off distance of 14 mm, and an explosive thickness of 22 mm and a stand-off distance of 28 mm were added to explore the welding effect of reducing the explosive thickness and increasing the stand-off distance. The simulation showed that the vertical displacement of the flyer plate was greater than the corresponding stand-off distance between the base plate and the flyer plate in both cases, and successful welding was achieved. The peak collision velocity of the flyer plate fell within the explosive welding window of 313.05 m/s<Vp<1 161.07 m/s. As the stand-off distance increased from 8 mm to 10.5 mm, the collision velocity, kinetic energy loss, and interface plastic deformation of the flyer plate increased accordingly. The collision pressure of the flyer plate increased with the increase of the distance from the initiation point to the base plate-flyer plate stand-off distance. The amplitude and wavelength of the interface wave increased from 73.55 μm and 415.30 μm to 165.48 μm and 579.78 μm, with increases of 124.99% and 39.61%, respectively. The simulated wavelengths and amplitudes of the two control groups were 68.95 μm and 409.10 μm, and 73.55 μm and 413.70 μm, respectively. The comparison indicated that the simulation results of the control groups were in good agreement with those of the original experimental group. Both ALE and SPH-FEM algorithms can effectively simulate the explosive welding process. When the flyer plate is in the acceleration stage, the same welding effect as that in the experiment can be achieved by reducing the explosive thickness and increasing the stand-off distance between the base plate and the flyer plate. This not only ensures the quality of the welding but also reduces the amount of explosive used and lowers the cost of explosive welding experiments. The combined application of the two algorithms provides reliable theoretical guidance for explosive welding production practice.
  • DENG Boran, ZHAO Tengxiang, CHENG Lingchao, QIU Ping, XIAO Hong
    Journal of Netshape Forming Engineering. 2026, 18(10): 166-176. https://doi.org/10.3969/j.issn.1674-6457.2026.10.017
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    The work aims to employ the finite element simulation and response surface methodology to investigate the forming mechanism, tool improvement, and process optimization of heat-assisted clinching for AZ31B/Q345 sheets, and conduct experiments to evaluate the feasibility of clinching AZ31B magnesium alloy with carbon steel sheets of different strength levels. Taking AZ31B/Q345 sheets as the research objects, a two-dimensional axisymmetric finite element model was established to compare and analyze the evolution of joint morphology during the clinching process before and after tool improvement. Neck thickness and interlock value were selected as evaluation indexes, and the punch radius, die depth, and die radius were taken as variables to optimize the improved tool by response surface methodology. In addition, heat-assisted clinching experiments were carried out on AZ31B/Q235, AZ31B/Q345, and AZ31B/Q460 sheets to analyze the influence of different steel sheets on joint quality. Under the conventional tool condition, the upper AZ31B sheet was prone to reverse flow and warping, making it difficult to form an effective interlock, whereas under the improved tool condition, an effective interlock could be achieved. The die radius was more sensitive to neck thickness, while the die depth was more sensitive to interlock value. After optimization, a punch radius of 2.8 mm, a die depth of 1.5 mm, and a die radius of 3.9 mm were found to be reasonable. The improved tool can achieve effective clinching of AZ31B/Q235 and AZ31B/Q345 sheets. Since the strength of the Q460 sheet is excessively high, a preforming clinching process is adopted in this study to obtain effective joints.
  • WAN Yi, ZHANG Man, YANG Yuke, ZHOU Liurui, ZHU Shuai
    Journal of Netshape Forming Engineering. 2026, 18(10): 177-187. https://doi.org/10.3969/j.issn.1674-6457.2026.10.018
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    The work aims to study the effect of Al element content on the property of 2A12 Al-alloy/12Cr13 stainless steel joint brazed by the Zn-Al welding wire, and realize the reliable connection of 2A12 Al-alloy and 12Cr13 stainless steel. Spread test was carried out by a box-type resistance furnace. 2A12 Al-alloy/12Cr13 stainless steel lap joints were brazed by furnace brazing. The joint strength and microhardness were analyzed by a tensile testing machine and a microhardness vickers hardness tester. The joint microstructure and fracture analysis were carried out by the metallographic microscope and scanning electron microscope. The spreading area of Zn-Al welding wire on both 2A12 Al-alloy and 12Cr13 stainless steel substrates increased with the increase of Al element content in the welding wire when Al element content was in the range of 5% to 20% (mass fraction), and the maximum value occurred when the Al element content was 20% (mass fraction). When the content of Al element continued to increase, the spreading area decreased on both 2A12 Al-alloy and 12Cr13 stainless steel substrates. The brazed joint strength increased first and then decreased with the increase of Al element content in the welding wire. The joint brazed by 78Zn-22Al welding wire had the highest strength, which was 117.43 MPa. Meanwhile, the Fe-Al intermetallic compound layer was the thinner at the 12Cr13 side interface. It was less prone to cause stress concentration. Tearing morphology was observed in fractography. Therefore, the property of 2A12 Al-alloy and 12Cr13 stainless steel joint can be significantly enhanced by adjusting Al element content in the Zn-Al welding wire. The joint brazed by 78Zn-22Al welding wire has the highest strength and its spreadability is excellent. However, since its melting point is close to that of 2A12 Al-alloy base metal, the heating temperature and heating time during the brazing process must be strictly controlled. Under the condition that the welding wire melts while the base metal remains unmelted, the78Zn-22Al welding wire can achieve optimal brazing results.
  • Superalloy Forming
  • ZHOU Shengzhi, TU Xianmeng, JI Xiaoyuan, ZHANG Zejun, CHEN Wei, WANG Hao, SHI Hao, WANG Zeming, XIE Yujiang, ZHOU Jianxin
    Journal of Netshape Forming Engineering. 2026, 18(10): 187-198. https://doi.org/10.3969/j.issn.1674-6457.2026.10.019
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    The work aims to establish a layer-wise porosity prediction model which can provide decision support for defect pre-judgment before SLM forming and process parameter optimization by predicting the porosity of single layers. Firstly, GH4169 superalloy was used as the material to design orthogonal experiments and fabricate SLM specimens. Partial specimens were scanned by CT to obtain internal layer-wise images, and a BlackHat-Otsu algorithm targeting measured relative density was proposed to accurately extract the porosity features of each layer from the CT images. Secondly, based on process parameters, a one-dimensional feature vector reflecting the state of a single layer and a two-dimensional feature matrix integrating the process information of the current layer, upper and lower layers were constructed. Finally, a Support Vector Regression (SVR) model and a Backpropagation (BP) Neural Network model were established for the one-dimensional and two-dimensional features respectively, and a Convolutional Neural Network (CNN) model fusing the two types of features was designed. The error between the layer-wise porosity extracted by the proposed BlackHat-Otsu algorithm and the overall measured value was less than 0.5%. Among the three prediction models, the SVR model achieved an optimal R2 of 0.840 5 on the test set. After hyperparameter optimization, the R2 of the BP Neural Network model increased to 0.883 1 and the dual-channel CNN model reached a test set R2 of 0.904 5. The results indicated that the two-dimensional features constructed by introducing inter-layer process parameter interaction information could effectively improve the model's prediction capability. By fusing process parameter data and CT image data, and utilizing deep learning models capable of capturing inter-layer spatiotemporal correlations, higher-precision prediction of layer-wise porosity in SLM parts can be achieved. This method refines porosity prediction from the overall component to the single-layer scale, providing an effective technical approach for realizing refined and proactive control of SLM forming quality.
  • TAN Longxian, YANG Jianbing, JI Xuanming, TAN Yuanbiao, XIANG Song
    Journal of Netshape Forming Engineering. 2026, 18(10): 199-208. https://doi.org/10.3969/j.issn.1674-6457.2026.10.020
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    The work aims to clarify the microstructural evolution of the GH4698 nickel-based wrought superalloy during cold processing and its influence on mechanical properties, as well as to elucidate the intrinsic mechanisms underlying the changes in strength and ductility under different cold-rolling strains. The microstructural features and mechanical properties of the alloy were systematically investigated under cold-rolling strains of 30%, 50%, and 70%. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM) were employed to characterize grain morphology, crystallographic orientation, and dislocation structures, while X-ray diffraction (XRD) was used to analyze the phase composition. Mechanical performance was evaluated by microhardness testing and room-temperature tensile experiments. With increasing cold-rolling strain, grains were elongated markedly along the rolling direction, the texture strength increased, and the fraction of low-angle grain boundaries and dislocation density rose significantly. The alloy maintained a stable FCC single-phase structure throughout the cold-rolling process. High-strain samples exhibited numerous dislocation cells, dislocation tangles, and stacking fault structures, along with grain refinement. Mechanical tests indicated that when the strain increased from 0% to 70%, the hardness increased from 395.8HV (solution-treated state) to 569.1HV, and the tensile strength increased from 872 MPa to 1 767 MPa, whereas elongation decreased significantly. In conclusion, the strength enhancement of the alloy during cold rolling is primarily attributed to significant work hardening induced by the high density of dislocations and defect structures generated during deformation. At the same time, these high-density defects impede dislocation motion, reducing the plastic deformation capacity of the alloy and leading to decreased elongation.
  • Additive Manufacturing
  • WANG Daming, CHE Long, GU Xingyu, YU Li, YONG Qingsong, YOU Yu, MENG Licheng
    Journal of Netshape Forming Engineering. 2026, 18(10): 209-219. https://doi.org/10.3969/j.issn.1674-6457.2026.10.021
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    The work aims to combine distortion compensation simulation and experimental verification to optimize the forming accuracy, so as to solve the problem that the thin-walled nozzle is prone to distortion and poor forming accuracy due to thermal stresses in the process of selective laser melting. First, the default cantilever specimens and a thin-walled nozzle were printed simultaneously, of which the former were used to derive the inherent strain values. Based on the derived inherent strain values, the simulation and distortion analysis of the thin-walled nozzle were then carried out. And the simulated results were compared with the actual model distortion contour of the printed nozzle, which was obtained by a three-dimensional laser scanner. Based on this actual contour, the inherent strain values were then modified accordingly, to make the re-simulated results come closer to the actual result. Finally, based on the above modified inherent strain values, distortion compensation was then conducted to optimize the forming accuracy, and its accuracy was verified by experiment. Comparing the simulated and measured results of the compensated thin-walled nozzle, it was found that the two matched well. The experimental result after distortion compensation showed that the distortion of the thin-walled nozzle was less than 0.5 mm, and most areas of the thin-walled nozzle was less than 0.2 mm, satisfying the usage requirement. The forming simulation of the thin-walled nozzle is carried out using the inherent strain values calibrated by cantilever specimens. The deformation of the nozzles differs significantly from the actual printing distortion results. A better forming accuracy would be reached by introducing the modified inherent strain values and the distortion compensation method based on the printing results of parts.
  • Copper Alloy Forming
  • HU Yong, JIANG Shangyuan, WANG Shaohua, GAO Zhiwei, ZHAO Geng, LI Jiehua, YAN Zhijie
    Journal of Netshape Forming Engineering. 2026, 18(10): 220-229. https://doi.org/10.3969/j.issn.1674-6457.2026.10.022
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    The work aims to investigate the effect of different initial microstructures on the comprehensive properties of the Cu-Fe-Zn-P alloy, and to reveal the mechanism by which rapid solidification optimizes the overall performance, thereby providing a reference for the process development of high-performance copper alloys. With the Cu-Fe-Zn-P alloy as the research object, the as-cast alloys in two initial states were prepared by vacuum suction casting (VSC) and solution treatment (ST). Both alloys with different initial microstructures were subject to identical two-pass cold deformation (70% reduction in the first pass and 40% in the second pass) and subsequent heat treatment. Microstructural evolution was characterized by optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Mechanical properties at room temperature were evaluated with a universal testing machine and a micro Vickers hardness tester. Electrical conductivity was measured with a digital micro-ohmmeter. By comparing the microstructural evolution and property variations between the two processing routes, the effect mechanisms of initial microstructure, as well as deformation and heat treatment processes, on the final properties were elucidated. After deformation and heat treatment, the alloy with an initial VSC state exhibited a tensile strength of 681.2 MPa, a microhardness of 165.8HV, and an electrical conductivity of 54.4%IACS. In comparison, the alloy initially processed by HR+ST showed corresponding values of 665.9 MPa, 156.2HV, and 56.2%IACS after identical subsequent treatments. Microstructural analysis revealed that the VSC-processed sample developed a higher density of finer and more uniformly dispersed precipitates within the matrix after subsequent treatments, leading to a more pronounced precipitation strengthening effect. Conversely, the precipitates in the HR+ST processed sample after subsequent treatments were relatively coarser and less uniformly distributed. Although both processing routes yielded similar electrical conductivity, the alloy prepared by suction casting demonstrated superior strength and hardness. Compared with the hot rolling and solution treatment route, the vacuum suction casting process effectively enhances the comprehensive properties of the Cu-Fe-Zn-P alloy. The rapid solidification inherent in suction casting substantially improves the solid solubility of alloying elements in the copper matrix, which creates favorable conditions for the precipitation of a high density of fine and dispersed strengthening phases during subsequent deformation and aging. This enables the alloy to achieve superior strength and hardness while maintaining relatively high electrical conductivity. This processing route offers a valuable reference for the preparation of high-performance copper alloys.
  • Advanced Manufacturing Technology and Equipment
  • GE Xiaoyu, PEI Mengmeng, LI Boqiong, QI Huiping
    Journal of Netshape Forming Engineering. 2026, 18(10): 230-238. https://doi.org/10.3969/j.issn.1674-6457.2026.10.023
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    The work aims to elucidate the effect of feed rate and rolling ratio on the uniformity of temperature and equivalent plastic strain distribution during the rolling and expanding of L-shaped rings with conical rollers, thereby providing a theoretical basis for the development of this process. With the ABAQUS finite element analysis platform and the dynamic explicit integration algorithm, a three-dimensional thermal-force coupling numerical simulation model was developed for the radial and axial compound rolling process of ring parts with irregular cross-sections. A systematic study was conducted to analyze the spatial distribution characteristics of temperature and equivalent plastic strain during the hot rolling and expanding process of special-shaped ring parts, with particular emphasis on the conical roller's feed rate and the ring's rolling ratio as key affecting parameters. Raising the feed rate resulted in an increase in the ring's average temperature, whereas the equivalent plastic strain tended to decrease. Additionally, both the temperature field and equivalent plastic strain distribution became more uniform. At a conical roller feed rate of 2 mm/s, the uniformity of the overall temperature and equivalent plastic strain distribution in the ring was favorable. As the rolling ratio of the ring increased, the overall temperature showed a decreasing trend, while the equivalent strain gradually increased. Furthermore, the uniformity of the overall thermal distribution within the ring became more uniform, yet the uniformity of the equivalent strain showed a gradual deterioration. At a rolling ratio of 1.6, the distribution of equivalent plastic strain in the formed part exhibited acceptable uniformity. During the rolling forming process of special-shaped ring parts, a higher feed rate enhances the fluidity of the metal and improves the uniformity of temperature and equivalent strain distribution throughout the entire ring. Conversely, a reduced rolling ratio enhances the uniformity of the overall equivalent strain distribution but marginally reduces thermal uniformity.
  • WANG Meng, CHENG Zhan, ZHANG Lei, SUN Huawei, JIU Yongtao, LUO Yuxin
    Journal of Netshape Forming Engineering. 2026, 18(10): 239-254. https://doi.org/10.3969/j.issn.1674-6457.2026.10.024
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    As modern industrial service environments continue to evolve toward extreme conditions such as high speed and heavy load, sliding bearings, as critical load-bearing components in power systems, possess coating quality and service performance that directly determine the operational reliability and service life of equipment. To meet service requirements under extreme working conditions, achieving multi-dimensional synergistic regulation of coating materials, forming processes, and performance characteristics has become a research focus in the field of high-end sliding bearings. Brazing coating technology, with its remarkable potential for fabricating high-performance coatings, has emerged as a key direction for technological development. In this paper, the research progress of four commonly used coating material systems for sliding bearings, namly Babbitt alloys, copper-based alloys, aluminum-based alloys, and polymers, are reviewed. The technical characteristics and research status of four typical brazing coating forming processes, namely flame brazing, induction brazing, arc brazing, and laser brazing, are summarized. The advantages and disadvantages of various brazing coating processes are thoroughly discussed in terms of interfacial bonding, microstructural densification, and heat input methods, and the process characteristics and application prospects of different brazing techniques are compared. Common issues encountered during the forming of sliding bearing coatings are summarized, including insufficient interfacial bonding strength, high porosity and inadequate densification of coatings, incompatibility between coatings and lubrication systems, and the lack of reliable inspection and evaluation systems for coating quality. Finally, future development trends in the precision forming of sliding bearing coatings are prospected, aiming to provide references for the selection of coating materials, the optimization of brazing coating processes, and the engineering application of brazing coating technologies.
  • ZHANG Zijian, GUO Yibo, LIU Qingtao, XUE Zenghui, WANG Qing, YIN Enhuai
    Journal of Netshape Forming Engineering. 2026, 18(10): 255-265. https://doi.org/10.3969/j.issn.1674-6457.2026.10.025
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    To address the problems of increased surface roughness and non-uniform thickness distribution of dielectric layers during non-normal printing of piezoelectric valve based jetting on inclined substrates, the work aims to propose a synergistic process parameter optimization method for dielectric layer forming quality to improve surface quality and thickness uniformity. Substrate inclination angle, delay time, number of printed layers, line spacing, and printing speed were selected as the investigated factors, while surface roughness and thickness uniformity were taken as the evaluation indices. Significant affecting factors were first identified through an orthogonal experimental design. On this basis, dual-response regression models were established through the Box-Behnken design within Response Surface Methodology (RSM). The Pareto-optimal solution set was then obtained with the Multi-Objective Evolutionary Algorithm based on Decomposition (MOEA/D), and the non-dominated solutions were further ranked by the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) to determine the optimal process parameter combination for the best overall performance. Delay time, substrate inclination angle, and number of printed layers were identified as the significant factors affecting the surface roughness and thickness uniformity of dielectric layers fabricated by non-normal printing. The developed models showed high fitting accuracy, with coefficients of determination (R²) of 0.991 5 and 0.998 8 for the surface roughness model and thickness uniformity model, respectively. The optimized parameter combination was determined to be a substrate inclination angle of 16.69°, a delay time of 11.32 ms, and one printed layer, under which the surface roughness and thickness uniformity were 1.110 7 μm and 1.641 9%, respectively. Experimental validation yielded average values of 1.182 6 μm and 1.763 0%, with relative errors of 6.47% and 7.38%, respectively, both below 10%. In addition, process window analysis was conducted to identify the feasible parameter region satisfying the dual-response requirements. The multi-objective optimization method based on RSM-MOEA/D-TOPSIS can effectively achieve synergistic optimization of the forming quality of dielectric layers in piezoelectric valve based non-normal printing, providing a theoretical basis and process reference for the high-quality fabrication of dielectric layers in complex curved electronic devices.