Dislocation dynamics and thermal softening during laser-assisted orthogonal cutting γ-TiAl: Molecular dynamics simulation for laser parameter optimization

ZH Hou and ZQ Liu and YQ Tang and B Wang and XC Wang and CY Lu, MATERIALS TODAY COMMUNICATIONS, 49, 114320 (2025).

DOI: 10.1016/j.mtcomm.2025.114320

The laser-assisted machining significantly alters material mechanical properties, exerting complex influences of machining-induced surface damage. This study employs molecular dynamics simulations to investigate the effects of laser-assisted cutting on the surface quality of single- crystal gamma-TiAl alloys, which focuses on analyzing the laser power and laser-tool spacing influences the dislocation evolution, cutting temperature profiles, cutting forces, von-mises stress distributions, and shear strain patterns. The mechanisms driving surface damage are systematically elucidated. The research results demonstrate that the laser assistance enhances surface quality and reduces subsurface damage in gamma-TiAl alloys through a nonlinear relationship between surface integrity and laser power, which is governed by competing thermal softening and work hardening effects. At approximately 80 eV/ ps, optimal coordination between plastic material removal, dislocation dynamics, cutting forces, and thermal conditions achieves superior surface quality. The moderate laser-tool spacing further improves surface integrity by preventing thermal inhomogeneity and energy dissipation. The findings provide critical theoretical guidance for laser-assisted precision machining of titanium aluminides in aerospace applications, establishing a foundation for optimizing thermal- mechanical interactions to achieve high-performance surface quality.

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