A new technology named extreme high-speed laser melting deposition is presented in this paper. The deposition speed of this technology is as high as 30 m/min, which can promote the deposition efficiency from 0.09 to 0.54 m²/h. In addition, surface of EHLMD layer is smoother which can save part of the machining process after deposition and promotes the production efficiency by 6 times. AISI 431 martensitic stainless steel layers were fabricated on 27SiMn substrate by conventional laser melting deposition and extreme high speed laser melting deposition. The macroscopic morphology, microstructure, microhardness, and electrochemical corrosion resistance of the two kinds of layers were characterized. The results show that the microstructures of two kinds of layers comprise of martensite dendrite, retained austenite, and continuous inter-dendritic eutectic phases. Although results of the XRD test indicate that there are more retained austenite in the EHLMD layer, the microhardnesses of the two kinds of layers are basically the same, in the range of 600 to 720 HV. Corrosion resistance of the EHLMD layer is better than that of the LMD layer because of the higher Cr content and more uniform alloying elements distribution. Therefore, EHLMD can be considered as an effective alternative to electroplating and applied for production and repair of shaft parts in the manufacturing field.

High-performance complex gear cutters and high-temperature bearings are just some of the applications where high-speed steels (HSSs) shine as a preferred material choice owing to their high hardness and outstanding wear resistance. In this work, the effects of sintering temperature on the microstructure and mechanical properties of S390 HSS prepared via spark plasma sintering (SPS) were investigated with a range of sintering temperatures from 930°C to 1,090°C, a uniaxial pressure of 50 MPa, and a holding time of 5 min. The results demonstrated that the improvements in density, hardness, red hardness, and three-point bending strength were confirmed as the sintering temperature increased from 930°C to 1,090°C. Temperature-induced microstructure evolutions were assessed for their contribution to property enhancement, such as powders with varying dimensions and carbides with diverse morphology and diameter. The specimen with the best comprehensive mechanical properties (67.1 HRC and 1,196.67 MPa) was prepared at 1,050°C via SPS. The wear coefficients decreased as the sintering temperature increased, and the observation results of worn surfaces of test pins confirmed that abrasive wear and oxidation wear dominated the wear experiments. Furthermore, the wear mechanism of dense and porous SPS HSS was illustrated and analyzed in terms of the debris and trapped carbides.

The current design of negative Poisson’s ratio lattice structures is mainly forward-looking and predominantly dependent on several known deformation patterns. To automate the generation of structures with programmable Poisson’s ratio, the study utilized the energy homogenization method and the Solid Isotropic Material with Penalization (SIMP) method to establish an optimization model for negative Poisson’s ratio. By proposing a relaxed objective function and eliminating damping in the Optimality Criteria (OC) method, the study achieves the automatic evolution of negative Poisson’s ratio programmable lattice unit cells, with the lowest Poisson’s ratio achieving −0.5367, and an equivalent elastic matrix is derived. The iterative process’s efficiency is comparable to that of commercial software, with a maximum iteration time of 300 s, enabling the prompt identification of fundamental configurations. To validate the method’s effectiveness, finite element analysis was performed on four tubular structures, revealing evident tension–compression deformation patterns. Moreover, the microscale selective laser melting was used to successfully prepare multiple sets of tubular samples made from 316L stainless steel, each with a height of 5 mm. Quasi-static compression experiments showed negative Poisson’s ratio effects and buckling forms that align with finite element analysis results, providing valuable insights for industry applications.

The microstructure and wear behavior of S390 high-speed steel (HSS) reinforced with different volume fractions of MC-type carbides produced via spark plasma sintering were investigated using scanning electron microscopy (SEM) and transmission electron microscopy (TEM) in this study. SEM and TEM results show that V-W-rich carbides are formed around the added MC-type carbides, and these carbides have a similar composition to the M(C, N) carbides precipitated at high temperatures according to thermodynamic calculations. Both macrohardness and three-point bending results show that the carbide type is the dominant factor increasing the hardness, and the volume fraction of the carbide is the dominant factor leading to a decrease in the three-point bending strength. The wear mechanism of HSS metal matrix composites (MMCs) is confirmed as abrasive wear and oxidative wear via wear tracks and oxidation films. Compared with the sample without reinforcement (85 HRA, wear coefficient of 1.50 × 10⁻¹⁵ m²/N), the best MT-3 sample exhibits a hardness increase of 1.8 HRA and a three-fold increase in wear resistance.

With the aim to improve cladding coating quality and prevent cracking, this paper established an extreme high-speed laser cladding thermo-mechanical coupling simulation model to study the evolution of the temperature field and the residual stress distribution. Process parameters that impacted the macroscopic morphology of single-pass coatings were investigated. Numerical calculations and temperature field simulations were performed based on the process parameter data to validate the effects of the temperature gradient and cooling rate on the coating structure and the residual stress distribution. The results showed that a good coating quality could be achieved using a laser power of 2400 W, a cladding speed of 20 m/min, and a powder feeding rate of 20.32 g/min. The coatings’ cross-sectional morphology corresponded well with the temperature distribution predicted by the numerical modeling of the melt pool. The microstructure of the molten coatings was affected by the temperature gradient and the cooling rate, which varied greatly from the bottom to the middle to the top. Maximum residual stress appeared between the bonding region of the coatings and the substrate, and the coatings themselves had significant residual stress in the form of tensile strains, that were mostly distributed in the direction of the laser cladding.

With the aim to improve cladding coating quality and prevent cracking, this paper established an extreme high-speed laser cladding thermo-mechanical coupling simulation model to study the evolution of the temperature field and residual stress distribution. Process parameters that impacted the macroscopic morphology of single-pass coatings were investigated. Numerical calculations and temperature field simulations were performed based on the process parameter data to validate the effect of the temperature gradient and cooling rate on the coating structure and the residual stress distribution. The results showed that a good coating quality could be achieved using a laser power of 2400 W, a cladding rate of 20 m/min, and a powder feeding rate of 20.32 g/min. The coatings’ cross-sectional morphology corresponded well with the temperature distribution predicted by numerical modeling of the melt pool. The microstructure of the molten coatings is affected by the temperature gradient and cooling rate, which vary greatly from the bottom to the middle to the top. Maximum residual stress appears between the bonding region of the coatings and the substrate, and the coatings themselves have significant residual stress in the form of tensile strains that are mostly distributed in the direction of the laser cladding speed.