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Microstructure and mechanical properties of ZK61 magnesium alloy thin-walled cylindrical component processed by two-step forging

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Journal of Magnesium and Alloys 2025年

作者： Chai, Fang Feng, Jianqiang Han, Xinghui Zhuang, Wuhao Chen, Yizhe Hu, Zhili Hu, Xuan Zheng, Fangyan Hua, Lin Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Longzhong Laboratory Xiangyang441000 China

Magnesium alloy thin-walled cylindrical components with the advantages of high specific stiffness and strength present broad prospect for the lightweight of aerospace components. However, poor formability resulting from the hexagonal close-packed crystal structure in magnesium alloy puts forwards a great challenge for thin-walled cylindrical components fabrication, especially for extreme structure with the thickness-changing web and the high thin-wall. In this research, an ZK61 magnesium alloy thin-walled cylindrical component was successfully fabricated by two-step forging, i.e., the pre-forging and final-forging is mainly used for wed and thin-wall formation, respectively. Microstructure and mechanical properties at the core, middle and margin of the web and the thin-wall of the pre-forged and final-forged components are studied in detail. Due to the large strain-effectiveness and metal flow along the radial direction (RD), the grains of the web are all elongated along RD for the pre-forged component, where an increasingly elongated trend is found from the core to the margin of the wed. A relatively low recrystallized degree occurs during pre-forging, and the web at different positions are all with prismatic and pyramid textures. During final-forging, the microstructures of the web and the thin-wall are almost equiaxed due to the remarkable occurrence of dynamic recrystallization. Similarity, except for few basal texture of the thin-wall, only prismatic and pyramid textures are found for the final-forged component. Compared with the initial billet, an obviously improved mechanical isotropy is achieved during pre-forging, which is well-maintained during final-forging. © 2025

关键词： Magnesium alloys

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Blast resistance of sandwich panels with 3D sinusoidally curved negative Poisson's ratio honeycombs

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Structures 2025年 76卷

作者： Zou, Zhen Xu, Fengxiang Jiang, Zhoushun Fang, Tengyuan Zhu, Yifan Hubei Key Laboratory of Advanced Technology of Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of Technology Wuhan430070 China

Auxetic honeycomb cored sandwich panels are attractive solutions for anti-blast application attributed to their excellent designability and tailorable mechanical properties. However, the well-known negative Poisson's ratio (NPR) effect of conventional auxetic honeycombs is only produced in one dimension, leading to their potential for resisting blast not being inspired fully. Herein, the 2D and 3D re-entrant honeycombs (RH) with straight and sinusoidal sides are proposed, respectively. Furthermore, their metallic specimens are fabricated with step-by-step methods to conduct compression experiments. The results show the 3D RH can produce plastic hinges and NPR effect in two dimensions (xoy and yoz planes), and achieve almost two-time enhancements in plateau stress. Subsequently, the sandwich panels corresponding to these RHs are constructed to explore their blast resistance. When pursuing smaller deflection of back facesheets, increasing the thickness of front facesheets can achieve better results than enhancing the thickness of back facesheets. Additionally, compared to other typical sandwich panels, the 3D sinusoidal RH cored sandwich panel exhibits higher energy absorption and smaller deflection of back facesheets, achieving a better "conquering the unyielding with the yielding" effect. © 2025 Institution of Structural Engineers

关键词： Sandwich structures

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Innovative warm rolling plus electromagnetic shock treatment for high-quality M50 bearing ring manufacturing

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Journal of Materials Science 2025年第18期60卷 7710-7731页

作者： Zhai, Jiajun Yin, Fei Yi, Yuxuan Song, Chao Hubei Longzhong Laboratory Xiangyang441000 China Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China School of Automotive Engineering Wuhan University of Technology Wuhan430070 China

M50 bearing steel is a high-carbon alloy extensively utilized in the aerospace industry due to its exceptional mechanical properties at elevated temperatures. Its production typically involves cold ring rolling (CRR) at room temperature and hot ring rolling (HRR) at high temperatures. The CRR process offers high precision but is susceptible to microcrack formation, while HRR can effectively eliminate defects but may induce coarse grain structures, reducing material performance. To address these issues, this study proposes a novel warm ring rolling (WRR) process, which integrates the benefits of both CRR and HRR. The aim is to optimize the forming rate while improving the plasticity limit and microstructural integrity of the material. Additionally, the study investigates the hot deformation behavior of M50 bearing steel under various deformation conditions and derives strain-compensated constitutive equations to predict its deformation, failure, and fatigue characteristics during the warm forming process. Temperature-dependent compression tests, along with electromagnetic shock treatment (EST) experiments, were also conducted. Results indicate that increasing the compression temperature reduces void formation, while EST significantly mitigates voids and promotes the dissolution and fragmentation of carbides. Furthermore, under the influence of EST, the average grain size of the WRR specimen notably decreases. The study concludes that the optimal processing temperature for EST–WRR technology is 400 ℃, with a current density of 140 A/mm2. This research provides a theoretical foundation for the future processing and performance optimization of M50 bearing steel and validates the efficacy of EST in the WRR process. © The Author(s), under exclusive licence to Springer Science+Business Media, LLC, part of Springer Nature 2025.

关键词： Compression testing

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Enhancing fracture toughness of Al/CFRP joints bonded with CNT-modified epoxy adhesive using ultrasonic adhesive-impact bonding process

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Journal of Materials Research and technology 2025年 36卷 5559-5573页

作者： Yaoyao Wang Hui Wang Yizhe Chen Wei Zhou Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan 430070 China School of Vehicle and Traffic Engineering Henan Institute of Technology Xinxiang 453000 China Hubei Longzhong Laboratory Xiangyang 441000 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan 430070 China

Incorporating carbon nanotubes (CNTs) into epoxy adhesives can enhance the fracture toughness of adhesively bonded joints, but the effectiveness is limited by the challenge of embedding CNTs into the micropores on adherend surface that prevents the formation of adequate interfacial fiber bridging, as well as the insufficient interfacial adhesion between the CNTs and adhesive. This study introduced a novel ultrasonic adhesive-impact bonding process in which ultrasonic vibrations are applied to a CNT-modified epoxy adhesive on the adherend surfaces before joint fabrication to enhance the mode-I fracture toughness of Al/CFRP joints. The results showed that this process increased the mode-I energy release rate ( G Ic ) reached 2.91 N/mm, representing an increase of 36.62 % compared to the joints bonded using conventional bonding process. The toughening mechanisms were analyzed from both physical and chemical perspectives using SEM, XPS, and FTIR techniques. On one hand, the ultrasonic adhesive-impact bonding process enhanced the infiltration of CNT-modified epoxy adhesive into the micropores on the Al surface through the synergistic effects of reduced adhesive viscosity and micro-liquid jet impacts, thereby improving mechanical interlocking and strengthening the fiber bridging of the CNTs at the interface. On the other hand, the ultrasonic adhesive-impact bonding process accelerated the chemical reactions of the adhesive with the aminated CNTs and the chemical groups of Al surface, which enhanced the interfacial adhesion between the CNTs and adhesive, and increased the number of C–O–Al bonds at the interface, forming an efficient stress transfer.

关键词： Ultrasonic adhesive-impact bonding process Mode-I fracture toughness CNT-modified epoxy adhesive Toughening mechanisms

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Two-Stage Hand-Eye Calibration based on Variance Minimization Principle

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IEEE Transactions on Instrumentation and Measurement 2025年

作者： Ding, Tao Tian, Dazhuang Wu, Hao Zhu, Dahu Li, Wenlog Wuhan University of Technology Hubei Key Laboratory of Advanced Technology for Automotive Components School of Automotive Engineering Wuhan430070 China Wuhan University of Technology Hubei Digital Manufacturing Key Laboratory School of Mechanical and Electronic Engineering Wuhan430070 China Wuhan University of Technology Hubei Key Laboratory of Advanced Technology for Automotive Components Hubei Provincial Engineering Research Center of Robot and Intelligent Manufacturing Wuhan430070 China Huazhong University of Science and Technology State Key Laboratory of Intelligent Manufacturing Equipment and Technology Wuhan430074 China

Hand-eye calibration in industrial scenarios greatly determines the efficiency and effectiveness of 3D vision-guided robotic tasks. Most of the existing hand-eye calibration methods, however, rely on collecting large-scale point cloud samples to guarantee high measurement accuracy, which is time-consuming and particularly influenced by measurement defects such as local missing, noise, and uneven density. To overcome this challenging problem, we present a novel two-stage hand-eye calibration method based on the variance minimization principle. In the first stage, a robust function weighted variance minimization (RFWVM) registration algorithm is proposed for fine registration of defective point clouds, aiming at solving the coarse hand-eye calibration matrix with few-shot point clouds. In the second stage, an objective function of the calibration error correction algorithm is established via the point-to-plane distance variance minimization, which is intended to suppress the influence of measurement defects. Through these two stages, the globally optimal hand-eye matrix is solved by iteratively correcting the coarse hand-eye calibration matrix. A series of experiments validate the universality, accuracy, and robustness of the proposed method. © 1963-2012 IEEE.

关键词： Error correction

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Numerical simulation of a multi-tube automotive thermoelectric generator for heat transfer and power generation performance

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Case Studies in Thermal Engineering 2025年 70卷

作者： Wang, Xiao-Bi Zeng, Jin-Liang Liu, Xun Su, Chu-Qi Xiong, Xin Wang, Yi-Ping Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan China Hubei Collaborative Innovation Centre for Automotive Components Technology Wuhan University of Technology Wuhan China Dongfeng Motor Corporation Research and Development Institute Hubei Wuhan China

To improve the performance of automotive exhaust thermoelectric generators, a numerical evaluation of automotive exhaust gas thermoelectric generators with multi-tube heat exchangers is carried out in this paper. The influence of complex flow states in corrugated tubes with different geometric structures on the device's heat transfer and power generation is analyzed. The calculation considers different mass flow rates of exhaust gas, heat transfer efficiency and entropy change based on power generation output and power generation efficiency. The results show that the increase of the height-diameter ratio of the corrugated tube is beneficial to the strength of the fluid such as the secondary flow. The rise in distance of the corrugated ring is encouraged to increase the influence range of the fluid such as the secondary flow. When the exhaust gas flow rate is 10-30 g/s, these changes can enhance the heat transfer and heat transfer efficiency compared with the smooth tube, but at the same time, the frictional resistance inside the tube will also increase. The power generation efficiency is increased to 1.2-2 times, and the maximum output power is 120W, which provides data support for optimising thermoelectric generators. © 2025 The Authors.

关键词： Thermoelectric equipment

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Achieving enhanced thermoelectric and mechanical performance in p-type bismuth telluride through constrained hot deformation

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Ceramics International 2025年

作者： Chen, Quansheng Ji, Chen Yu, Jian Hua, Lin Zhao, Wenyu State Key Laboratory of Advanced Technology for Materials Synthesis and Processing Wuhan University of Technology Wuhan430070 China School of Automotive Engineering Wuhan University of Technology Wuhan430070 China School of Materials Science and Engineering Jiujiang University Jiujiang332005 China Hubei Key Laboratory of Advanced Technology for Automobile Components Wuhan University of Technology Wuhan430070 China

Bi2Te3-based alloys remain the only commercially available thermoelectric (TE) materials. However, their practical applications are severely constrained by the inferior mechanical performance of the zone melting (ZM) ingot. Herein, a simple constrained hot deformation (CHD) technology was developed to prepare the p-type Bi0.5Sb1.5Te3 polycrystalline materials derived from ZM ingots. It was discovered that the deformation process has negligible impact on the phase composition, but can efficiently refine the grains to approximately 5 μm through the dynamic recrystallization and simultaneously introduce high-density dislocations. Although the donor-like effect induced by deformation would obviously deteriorate the electrical conductivity, the recovery effect triggered by high deformation temperature can effectively optimize the carrier concentration and thus alleviate the degradation of power factor. The material deformed at 773 K maintains a relatively high power factor ∼3.33 mW K−2 m−1 at 300 K, together with a significantly decreased lattice thermal conductivity ∼0.59 W m−1 K−1, and an improved zT ∼1.1 was obtained ultimately. More importantly, the deformed materials show a significant improvement in mechanical performance due to the grain refinement. A maximum average Vickers hardness of 0.67 GPa was achieved for the material deformed at 723 K, which is ∼40 % higher than that of the ZM ingot. Our work indicates the simple CHD is an efficient technology to synergistically enhance both TE and mechanical properties of Bi2Te3-based ZM ingot. © 2025 Elsevier Ltd and Techna Group S.r.l.

关键词： Polycrystalline materials

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Deformation behavior and its mechanism of Al–Zn–Mg–Cu alloys in different heat treatment states under electrically-assisted uniaxial tension

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Journal of Materials Research and technology 2025年 36卷 4162-4185页

作者： Yanli Song Long Chen Chuanchuan Hao Hainan Xu Lin Hua Jue Lu Lechun Xie Qian Sun Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan 430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan University of Technology Wuhan 430070 China Hubei Research Center for New Energy & Intelligent Connected Vehicle Wuhan University of Technology Wuhan 430070 China

Electrically-assisted manufacturing has proven to be an efficient process in improving formability for metal alloys. However, there are relatively few studies on the mechanism of the deformation behavior of Al–Zn–Mg–Cu alloys in different heat-treated states under electrically-assisted quasi-static uniaxial tension (EAT). This study presents the effects of EAT on the mechanical properties and microstructure of materials. The results showed that under suitable EAT parameters, the true strain of AA 7075-T6 is reduced by about 12.04 %, while the true strain of AA 7075-O is significantly increased by about 78.79 %. The electrical current reduces dislocation density, refines the recrystallized grains and increases the Cube texture content in AA 7075-O. From thermodynamic and kinetic perspectives, the athermal effects induced by electrical current are beneficial in promoting the dynamic dissolution of the metastable phase in AA 7075-T6 and the local dynamic precipitation of the GPII region in AA 7075-O, respectively. The stress drops and strain hardening behaviors were analyzed using the Orowan and the dislocation density strengthening equation. And, a mechanism for the improved plasticity of EAT in AA7075-O was revealed.

关键词： Aluminum alloy Electroshock treatment Dislocation Electroplasticity Mechanical property

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A simplified electrochemical lithium-ion batteries model based on physics-informed LSTM_Res network

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International Journal of Heat and Mass Transfer 2025年 246卷

作者： Kong, Chun Zhu, Guorong Wang, Jing V. Kang, Jianqiang Wang, Qian State Key Laboratory of Maritime Technology and Safety Wuhan University of Technology Wuhan430070 China School of Automation Wuhan University of Technology Wuhan430070 China Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China Hubei Collaborative Innovation Center for Automotive Components Technology Wuhan430070 China

Due to the high computational complexity of traditional electrochemical models, applying them to real-time battery management systems (BMS) is challenging. Most simplified electrochemical models lack sufficient accuracy due to assumptions and errors in the simplified solutions of partial differential equations. To strike a balance between complexity and accuracy, a Long Short-Term Memory Network with Residual Electrochemical Model (LrEM) for lithium-ion batteries is proposed. In this model, solid-phase lithium-ion transfer is approximated using a Long Short-Term Memory Network with Residuals (LSTM_Res), while lithium-ion transfer in the electrolyte is modeled using a standard Long Short-Term Memory (LSTM) network. The networks within the LrEM are trained by the underlying physical mechanisms in lithium-ion batteries. The results demonstrate that the LrEM can precisely predict the concentration of lithium ions in both solid and electrolyte phases, as well as accurately forecast the voltage under various current rates. Notably, the LrEM can complete 8000 s of charge and discharge dynamics in just 1.499 s, making it feasible for implementation in future real-time BMS. This advancement significantly enhances the mass transfer understanding and prediction in lithium-ion batteries, paving the way for more efficient and accurate battery management. © 2025 Elsevier Ltd

关键词： Lithium-ion batteries

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Performance evaluation of a novel off-grid CCHP system based on a semi-closed-loop PEMEC-PEMFC

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Energy 2025年 321卷

作者： Lu, Xinyu Chang, Huawei Tu, Zhengkai Xie, Changjun School of Energy and Power Engineering Huazhong University of Science and Technology Wuhan430074 China Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of Technology Wuhan430070 China

To improve the performance of a combined cooling, heating, and power (CCHP) system based on hydrogen energy storage, this study proposed a novel off-grid CCHP system based on a semi-closed-loop proton exchange membrane electrolysis cell (PEMEC)- proton exchange membrane fuel cell (PEMFC). Wind power and solar energy were used as electrical and thermal inputs to the system, respectively, and a semi-closed-loop PEMEC-PEMFC system with closed-loop gas circuits and open-loop water circuits was developed. Secondary heating of the PEMEC and PEMFC stack cooling water using solar thermal collectors improved the heating/cooling flexibility of the system. While meeting the residential load, the system still exhibited a surplus of hydrogen, oxygen, and heat storage, and could supply heated seawater to a desalination plant. Comparative exergy and economic evaluations showed that the proposed system performed better in summer. The average exergy efficiency of the system was 50.9 %, which was 2.4 % higher than that of a conventional system. It also increased by 1.8 % when only the residential load was considered. Moreover, the investment cost, annual benefit, and payback period of the system were $ 369,506, $ 141,958, and 2.8 years, respectively, 8.36 % lower, 12.6 % higher, and 19.5 % lower than those of the conventional system, respectively. © 2025 Elsevier Ltd

关键词： Solar energy

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