Journal of Manufacturing Processes最新文献

Review of augmented reality maintenance and registration in aerospace industry 航空航天工业增强现实维护与注册综述

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-31 DOI: 10.1016/j.jmapro.2025.07.063

Xin Zhao , Kangli Liu , Hongyong Fu , Yue Wang

引用次数: 0

The effect of T6 and hot isostatic pressure thermal treatments on the crack fatigue growth and fracture toughness of AlSi10Mg produced by additive manufacturing T6和热等静压热处理对增材制造AlSi10Mg裂纹疲劳扩展和断裂韧性的影响

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-31 DOI: 10.1016/j.jmapro.2025.07.065

Busisiwe J. Mfusi , Ntombizodwa R. Mathe , Londiwe Motibane , Daniel Glaser , Omar E. Lopez-Botello , Patricia A.I. Popoola

{"title":"The effect of T6 and hot isostatic pressure thermal treatments on the crack fatigue growth and fracture toughness of AlSi10Mg produced by additive manufacturing","authors":"Busisiwe J. Mfusi , Ntombizodwa R. Mathe , Londiwe Motibane , Daniel Glaser , Omar E. Lopez-Botello , Patricia A.I. Popoola","doi":"10.1016/j.jmapro.2025.07.065","DOIUrl":"10.1016/j.jmapro.2025.07.065","url":null,"abstract":"<div><div>Fatigue in metal components during application is a vital factor that currently affects the development of additive manufacturing technologies such as laser powder bed fusion (LPBF). It is assumed that the initial cracks that propagate and eventually lead to component failure are found inside the sample. Therefore, samples should be designed to withstand fatigue by subjection to cyclic loads in various environments. The precise knowledge of the fatigue crack growth rate (FCG) is important for the component to be replaced in time before complete failure. In this study, the AlSi10Mg samples produced by LPBF were tested for fatigue properties after thermal treatment with T6 and HIP treatment and was compared to as-built and cast conditions. It was observed that after HIP and T6, fatigue resistance improved successfully. Other mechanical characteristics, such as hardness, tensile strength, and residual stress measurements, showed significant improvement compared to stress-relieved samples.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 1042-1057"},"PeriodicalIF":6.8,"publicationDate":"2025-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144738829","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Planetary laser welding of medium-thickness aluminum alloys: microstructure, texture, and performance enhancement 中厚铝合金行星激光焊接：显微组织、织构和性能增强

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-30 DOI: 10.1016/j.jmapro.2025.07.021

Libo Wang , Zhijia Hua , Xiuquan Ma , Jingyu Chao , Gaoyang Mi , Lin Zhang

{"title":"Planetary laser welding of medium-thickness aluminum alloys: microstructure, texture, and performance enhancement","authors":"Libo Wang , Zhijia Hua , Xiuquan Ma , Jingyu Chao , Gaoyang Mi , Lin Zhang","doi":"10.1016/j.jmapro.2025.07.021","DOIUrl":"10.1016/j.jmapro.2025.07.021","url":null,"abstract":"<div><div>Degradation of post-weld mechanical properties in medium-thickness aluminum alloys limits their broader application. In this study, a planetary laser welding (PLW) system was employed to butt-weld 2024 aluminum plates, combining a high-speed planetary beam with a oscillating satellite beam. With a single laser, welds exhibit an I-shape profile (2.1 mm width) with pronounced internal cracks and porosity. In contrast, PLW expands the upper molten pool region and enhances melt circulation, effectively reducing crack formation. Increasing the oscillation amplitude from 0.5 to 1.5 mm, progressively separated the planetary and satellite keyholes, concentrating energy at the base (0.5 mm), enlarging and stabilizing the keyhole opening (1.0 mm), and ultimately inducing instability and collapse at full separation (1.5 mm). Higher oscillation frequencies disrupt the temperature gradient, accelerate the columnar-to-equiaxed transformation, refine grain size, disperses texture, and increase grain boundary density. However, at 500 Hz, oscillations drive oxygen ingress and form oxygen-rich precipitates that act as crack-initiation sites. Optimally, at 1.0 mm amplitude and 200 Hz frequency, tensile strength reached 376 MPa and elongation was 3.18 %. These results demonstrate that PLW precisely controls molten pool dynamics and microstructural evolution, producing high-performance welds in medium-thickness aluminum alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 930-945"},"PeriodicalIF":6.8,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Mechanisms of variable polarity alternating arc based directed energy deposition with feedforward control of mass transfer and droplet kinetics 具有前馈传质和液滴动力学控制的变极性交变电弧定向能沉积机理

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-30 DOI: 10.1016/j.jmapro.2025.07.077

Zhaoyang Yan , Feng Liang , Jun Xiao , Hao Yi , Runsheng Li , Shujun Chen

{"title":"Mechanisms of variable polarity alternating arc based directed energy deposition with feedforward control of mass transfer and droplet kinetics","authors":"Zhaoyang Yan , Feng Liang , Jun Xiao , Hao Yi , Runsheng Li , Shujun Chen","doi":"10.1016/j.jmapro.2025.07.077","DOIUrl":"10.1016/j.jmapro.2025.07.077","url":null,"abstract":"<div><div>Conventional DED-Arc processes suffer from heat and mass transfer instability due to thermomechanical coupling in an arc. This paper proposes a real-time feedforward control method using a variable-polarity alternating arc. The method decouples arc thermomechanical transmission and utilizes electrical signals of the arc to trigger piezoelectric ceramic forces. By combining droplet inertia with arc forces, it synergistically regulates droplet necking and detachment for stable deposition. The paper designed two control modes, M1 (falling-edge triggering) and M2 (rising-edge delayed triggering). A comparative analysis of droplet transfer under the two control modes at varying welding parameters revealed that at 80 A current, stable droplet transfer was achieved using the M2 control mode. The droplet transfer frequency underwent linear fitting with a determination coefficient (R<sup>2</sup>) of 0.99946, indicating a high linear correlation and stable droplet transfer frequency. In the M2 control mode under high-current conditions (≥100 A), the inertial driving effect became more pronounced, and the droplet transfer frequency increased significantly. Under low-current conditions (≤80 A), uniform and stable droplet transfer was maintained even with reduced wire feed speed. Compared to the original stable process window, the M2 control mode expanded the viable parameter range by 50 %. Formation experiments demonstrated that under the M2 control mode, single-pass formation continuity and uniformity were significantly superior to conventional modes, with deposition layer surface flatness improved by approximately 80 %. This paper provided both theoretical and practical foundations for droplet dynamics regulation and process optimization in variable-polarity arc additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 946-968"},"PeriodicalIF":6.8,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724508","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

The formation mechanism of surface roughness and the realization of ultra-smooth surface in controllable spiral magnetorheological finishing (CSMRF) 可控螺旋磁流变精加工（CSMRF）中表面粗糙度的形成机理及超光滑表面的实现

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-30 DOI: 10.1016/j.jmapro.2025.07.072

Bo Wang , Ci Song , Feng Shi , Wanli Zhang , Xing Peng , Guipeng Tie , Shuo Qiao

引用次数: 0

Mechanistic study of anisotropy elimination in DWAAM-deposited TA15 alloy through coupling of La2O3 addition and low-frequency pulsing strategies La2O3加入与低频脉冲耦合消除dwaam沉积TA15合金各向异性的机理研究

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-30 DOI: 10.1016/j.jmapro.2025.07.078

Zhenyu Yu , Shengfu Yu , Zhenyong Feng , Fangbin Deng , M.W. Fu

{"title":"Mechanistic study of anisotropy elimination in DWAAM-deposited TA15 alloy through coupling of La2O3 addition and low-frequency pulsing strategies","authors":"Zhenyu Yu , Shengfu Yu , Zhenyong Feng , Fangbin Deng , M.W. Fu","doi":"10.1016/j.jmapro.2025.07.078","DOIUrl":"10.1016/j.jmapro.2025.07.078","url":null,"abstract":"<div><div>The wire arc additive manufacturing (WAAM) process is considered suitable for the fabrication of large-scale components. However, titanium alloys fabricated via this method have been observed to exhibit pronounced mechanical anisotropy. To address this issue, this study used a dual wire arc additive manufacturing (DWAAM) method to quantitatively introduce La<sub>2</sub>O<sub>3</sub> particles into the titanium alloy, coupled with low-frequency pulsing strategies to refine the size of the columnar grains in the alloy. From the results, the anisotropic mechanical properties of the titanium alloys deposited by using this coupled strategy were mitigated. The mechanism behind this anisotropy reduction was further investigated. The results reveal that the anisotropic yielding strength is correlated with the orientation distribution of α laths, while the anisotropy in elongation is associated with the spatial arrangement of the α colonies along the columnar grain boundaries. The refinement of the columnar grains of the alloy effectively modified α-lath orientations and balanced the distribution of α colonies, which served as the critical factor in the reduction of mechanical anisotropy. This study provides insights into microstructure regulation for optimizing the isotropic performance of WAAMed titanium alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 969-987"},"PeriodicalIF":6.8,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724509","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Thermal field model driven by heat anisotropy and computational stability analysis in grinding of MgF2 crystals MgF2晶体磨削中热各向异性驱动的热场模型及计算稳定性分析

IF 6.8 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-29 DOI: 10.1016/j.jmapro.2025.07.066

Yinchuan Piao , Xichun Luo , Zhengjian Wang , Feihu Zhang , Chen Li

{"title":"Thermal field model driven by heat anisotropy and computational stability analysis in grinding of MgF2 crystals","authors":"Yinchuan Piao , Xichun Luo , Zhengjian Wang , Feihu Zhang , Chen Li","doi":"10.1016/j.jmapro.2025.07.066","DOIUrl":"10.1016/j.jmapro.2025.07.066","url":null,"abstract":"<div><div>Developing an accurate and efficient model of thermal field is crucial for optimizing process parameters and achieving high removal accuracy in grinding of difficult-to-machine materials, especially for brittle and anisotropic solids. However, ensuring both the accuracy and computational efficiency of the model remains challenging, as it is highly sensitive to computational stability, the selection of an appropriate heat flux model, and the anisotropic nature of heat conduction. In this work, a comprehensive thermal model of grinding of MgF₂ crystals was developed based on the principle of energy conservation and Fourier's Law of heat conduction, explicitly incorporating the anisotropy of heat conduction. Then, a rigorous computational stability analysis of the grinding thermal field was performed using the Gerschgorin circle theorem, enabling the determination of the optimal time step. Finally, the proposed model was compared with the traditional thermal field model and validated through grinding experiments. The results demonstrate a strong agreement between simulation and experiment, with the triangular heat flux model achieving an average simulation error of 10.37 %, outperforming other heat flux models. The results contribute to elucidating the sensitivity of thermal anisotropy to heat generation during the grinding of anisotropic solids, thereby providing a theoretical basis for optimizing process parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 916-929"},"PeriodicalIF":6.8,"publicationDate":"2025-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724240","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Thermokinetics-driven evolution of grain morphologies during laser direct energy deposition 激光直接能量沉积过程中晶粒形貌的热力学驱动演化

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-26 DOI: 10.1016/j.jmapro.2025.07.070

Shashank Sharma , Saikumar Dussa , Sameehan S. Joshi , K.V. Mani Krishna , Raj Banerjee , Narendra B. Dahotre

{"title":"Thermokinetics-driven evolution of grain morphologies during laser direct energy deposition","authors":"Shashank Sharma , Saikumar Dussa , Sameehan S. Joshi , K.V. Mani Krishna , Raj Banerjee , Narendra B. Dahotre","doi":"10.1016/j.jmapro.2025.07.070","DOIUrl":"10.1016/j.jmapro.2025.07.070","url":null,"abstract":"<div><div>The additive manufacturing of non-rare-earth permanent magnetic alloys such as Alnico-8H using laser directed energy deposition has consistently exhibited equiaxed grain morphologies, despite columnar structures being more desirable for enhanced coercivity. This necessitates a process induced thermokinetics–microstructure modeling framework to elucidate the governing mechanisms underlying equiaxed grain formation. The present study addresses this gap by integrating an experimentally validated high-fidelity thermo-fluidic model with CALPHAD-informed analytical Kurz-Giovanola-Trivedi model and Hunt's columnar-to-equiaxed transition criterion. Emphasis is placed on the physical interpretation of constitutional undercooling and nucleation volume density, which significantly influence morphology transitions but are challenging to quantify experimentally. Through this integrated approach, the influence of Marangoni-driven melt convection and rapid thermokinetics on spatial variations in thermal gradients and cooling rates is examined. A comparative analysis with conventionally studied alloys, SS316L and IN718, reveals that the grain morphology in Alnico is governed by markedly different threshold conditions due to its complex multi-component solidification behavior. The study highlights the dominant role of nucleation density in predicting microstructural evolution and provides a thermokinetic based rationale for the persistent equiaxed morphologies observed in Alnico. These findings offer valuable insight into tailoring grain morphology through process control in additive manufacturing of compositionally complex alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 895-915"},"PeriodicalIF":6.1,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144704602","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Computational investigations of the formation of intermetallic compounds in Al/Cu joints Al/Cu接头中金属间化合物形成的计算研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-25 DOI: 10.1016/j.jmapro.2025.07.061

Hui Sun , Bo Pan , Shun-Li Shang , Allison M. Beese , Jingjing Li , Zi-Kui Liu

{"title":"Computational investigations of the formation of intermetallic compounds in Al/Cu joints","authors":"Hui Sun , Bo Pan , Shun-Li Shang , Allison M. Beese , Jingjing Li , Zi-Kui Liu","doi":"10.1016/j.jmapro.2025.07.061","DOIUrl":"10.1016/j.jmapro.2025.07.061","url":null,"abstract":"<div><div>Intermetallic compounds (IMCs) play a critical role in determining the performance of materials, particularly influencing mechanical properties and electrical conductivity. The present work elucidates the formation of IMCs in aluminum/copper (Al/Cu) joints using CALPHAD-based predictions of thermodynamic driving force and time-temperature-transformation (TTT) diagrams, benchmarked against experimental data from the literature. The analysis incorporates 90 experimental data points, encompassing various welding methods, peak temperatures, cooling rates, and chemical compositions. With collected from the literature, a good corroboration with the present simulations of thermodynamic driving forces and TTT diagrams is observed in terms of the types of IMCs formed and their formation sequence. However, the inability to predict metastable phases, attributed to incomplete thermodynamic and kinetic data, underscores the need for further research. Overall, the present work offers valuable insights into the formation of IMCs in Al/Cu joints across different welding processes and provides a systematic approach for understanding IMC formation mechanisms more broadly.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 885-894"},"PeriodicalIF":6.1,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703816","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Mechanism and experiment of magnetoelastic abrasive dual-disk passivation based on EDEM secondary development 基于EDEM二次开发的磁弹性磨料双盘钝化机理与实验

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-07-25 DOI: 10.1016/j.jmapro.2025.07.071

Yin Yuan , Xuefeng Zhao , Ke You , Yong Liu

{"title":"Mechanism and experiment of magnetoelastic abrasive dual-disk passivation based on EDEM secondary development","authors":"Yin Yuan , Xuefeng Zhao , Ke You , Yong Liu","doi":"10.1016/j.jmapro.2025.07.071","DOIUrl":"10.1016/j.jmapro.2025.07.071","url":null,"abstract":"<div><div>To address the challenge of uniform edge passivation for complex tools, this study proposes a magnetoelastic abrasive-based dual-disk magnetic passivation method. In this study, a finite-element model of the magnetic field of a dual-disk was established using Maxwell software. Then, the parameters influencing the dual-disk magnetic induction intensity, such as the disk diameter, thickness, magnetic direction and spacing, were studied. The accuracy of the mathematical model and simulation model of the magnetic field of the dual-disk was also verified. Subsequently, using the EDEM software of Visual Studio, a model for magnetic passivation was established and a method for calibrating the Archard wear coefficient was proposed. The magnetic tool passivation of magnetoelastic abrasives using a dual-disk was simulated and analysed, allowing the state of motion of magnetoelastic abrasives and the motion trajectory of individual particles to be studied. Finally, considering that the simulated magnetoelastic abrasives velocity cannot entirely represent the actual magnetoelastic abrasives velocity involved in tool passivation, a filter was added to the simulation results to filter out the active magnetoelastic abrasives velocity. The influence of passivation parameters on the active velocity, velocity probability density distribution and quantity was determined to verify the advantages of using magnetoelastic abrasives during tool passivation. Simulations identified magnetoelastic abrasives undergo three motion phases: adsorption, accumulation, and passivation, with active particle velocities ranging 60-1500 mm/s, showing active particle velocity increases with size and magnetic susceptibility, but decreases with disk spacing. Experimental validation confirmed 20 % extended tool life, increased edge radius, and eliminated micro-defects, demonstrating the efficacy of magnetoelastic abrasives for precision edge passivation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 858-884"},"PeriodicalIF":6.1,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144703815","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0