In this study, weldability of ultrasonic welding of 4-mm-thick fiber carbon/nylon 66 composite in lap configuration was investigated. Ultrasonic welding tests were performed, and the weld appearance, microstructure, and fractography of the welded joints were examined using optical and scanning electron microscope. The transient temperatures near the faying surfaces and horn-workpiece interfaces were recorded to understand the weld growth mechanism. It was found that it is feasible to join 4-mm-thick lapped carbon fiber reinforced nylon 66 composite with ultrasonic welding. Under the ultrasonic vibration, the weld initiated and grew at the faying surfaces, while the weld indentation developed at the horn-workpiece interface. The pores observed in the regions between the heat-affected-zone (HAZ) and the fusion zone (FZ), and the severe weld indentation on the surface of upper workpieces decreased the loading capacity of the ultrasonic welded (UW) joints and caused the welded carbon/nylon 66 composite fractured prematurely. The strengths of the ultrasonic welds were determined by the balance of positive effect of the weld area and negative effects of the weld indentation and porosity near the FZ. To ensure the joint strength, it is necessary to apply the proper weld schedules (i.e., welding time and horn pressure) in ultrasonic welding of 4-mm-thick carbon fiber reinforced nylon 66 composite, which were developed based on the joint strength criterion.

The ultrasonic welding (UW) technique is a fast-joining process; it is very suitable for the carbon fiber reinforced thermoplastic (CFRTP) composite. For improving the consistency of the welded joint quality, a new pre-pressing ring clamp (PPRC) was designed for ultrasonic welding carbon fiber reinforced nylon composites in this paper. The effects of the PPRC on the weld quality of the ultrasonic welding welded 4.0 mm thick 30% mass short carbon fiber reinforced Nylon 6 composite was investigated and compared with that of normal clamp weld joint. The weld strength, microstructure, and temperature evolution of the joint were analyzed by tensile test, scanning electron microscope, and temperature measurement. The results showed that the PPCR UW joints had larger central weld nugget size (478 mm² vs. 300 mm²), thicker stable fusion region thickness (1.10 mm vs. 0.96 mm), resulting in a higher joint strength (6.86 kN vs. 6.21 kN) compared with the normal clamp UW joints under the same welding parameters. The real-time monitor curve of the horn displacement and temperature at the faying interface showed that the PPRC increased the heat rating at the faying interface during instable melting stage. The PPRC could improve the contact condition between workpieces and the utilization efficiency of ultrasonic energy, which boosted the melting rate of materials at faying interface and consequently the formation of a sound joint with enough weld size (i.e., 433 mm²) in a shorter welding time (i.e., 1.3 s). Therefore, the flexibility of component assembly would be increased by the use of this sort of clamps.

Ti65 high-temperature titanium alloy, known for its exceptional high-temperature mechanical properties and oxidation resistance, demonstrates considerable potential for aerospace applications. Nevertheless, conventional manufacturing techniques are often inadequate for achieving high design freedom and fabricating complex geometries. This study presents a systematic investigation into the process optimization, microstructure characterization, and mechanical performance of Ti65 alloy produced by laser powder bed fusion (LPBF). Via meticulously designed single-track, multi-track, and bulk sample experiments, the influences of laser power (P), scanning speed (V), and hatch spacing (h) on molten pool behavior, defect formation, microstructural evolution, and surface roughness were thoroughly examined. The results indicate that under optimized parameters, the specimens attain ultra-high dimensional accuracy, with a near-full density (>99.99%) and reduced surface roughness (Ra = 3.9 ± 1.3 μm). Inadequate energy input (low P or high V) led to lack-of-fusion defects, whereas excessive energy (high P or low V) resulted in keyhole porosity. Microstructural analysis revealed that the rapid solidification inherent to LPBF promotes the formation of fine acicular α′-phase (0.236–0.274 μm), while elevated laser power or reduced scanning speed facilitated the development of coarse lamellar α′-martensite (0.525–0.645 μm). Tensile tests demonstrated that samples produced under the optimized parameters exhibit high ultimate tensile strength (1489 ± 7.5 MPa), yield strength (1278 ± 5.2 MPa), and satisfactory elongation (5.7 ± 0.15%), alongside elevated microhardness (446.7 ± 1.7 HV_0.2). The optimized microstructure thereby enables the simultaneous achievement of high density and superior mechanical properties. The fundamental mechanism is attributed to precise control over volumetric energy density, which governs melt pool mode, defect generation, and solidification kinetics, thereby tailoring the resultant microstructure. This study offers valuable insights into defect suppression, microstructure control, and process optimization for LPBF-fabricated Ti65 alloy, facilitating its application in high-temperature structural components.

High resistance to tempering and extended service life are pivotal research directions for cutting tools utilized in the machining of industrial machine tool. The design of alloys and their manufacturing processes have become methods for the development of cutting tool materials. Carbon-free Fe-Co-Mo steel (FCM) has garnered attention due to its excellent magnetic properties and high-temperature performance, as well as its superior thermal conductivity, making it an ideal choice for applications in high-temperature and high-pressure environments. The µ-phase within this alloy exhibits exceptional high-temperature stability and resistance to aggregation. Its characteristics suggest that it has the potential to replace carbide reinforcement phases, which are prone to coarsening, in high-temperature applications of powder high-speed steel. This application of the µ-phase could lead to an enhancement in the resistance to tempering and the service life of powder metallurgy high-speed steel cutting tools. However, there is a relative scarcity of published research regarding the preparation of carbon-free high-speed steel via hot isostatic pressing (HIP) technology and the subsequent heat treatment processes. In this study, Fe-Co-Mo alloys reinforced with the intermetallic compound µ-phase were prepared at hot isostatic pressing sintering temperatures of 1200 °C, 1250 °C, and 1350 °C. Furthermore, to investigate the influence of the solid-solution treatment temperature on the microstructure and macroscopic properties of the alloy, the as-prepared materials were subjected to solution annealing treatment at different temperatures (1120 °C, 1150 °C, 1180 °C, and 1210 °C). The results demonstrate that by moderately reducing the sintering temperature, the segregation phenomenon of the reinforcing µ-phase was significantly reduced, leading to an optimization of the microstructural uniformity of the prepared sample, with the micro-scale µ-phase being uniformly dispersed within the α-Fe matrix. As the temperature of the solid-solution annealing increased, the microstructural uniformity was further enhanced, accompanied by a reduction in the quantity of the reinforcing phase and refinement of the grain size. Notably, after solid-solution annealing at 1180 °C, the hardness of the samples reached a peak value of 500.4 HV, attributed to the decrease in the reinforcing phase and grain refinement during the annealing process. Aging treatment at 600 °C for 3 h facilitated the uniform precipitation of the nano-scale µ-phase, resulting in a significant increase in sample hardness to approximately 900 HV. The prepared material exhibited excellent resistance to tempering, indicating its potential for application in high-temperature service environments.