Journal of Manufacturing Processes最新文献

{"title":"Monitoring of Argon plasma in a coating manufacturing process by utilising IR imaging techniques","authors":"David Miller ,&nbsp;V. Viswanathan ,&nbsp;Divya Tiwari ,&nbsp;Windo Hutabarat ,&nbsp;Saurav Goel ,&nbsp;Beth Muthoni Irungu ,&nbsp;Allan Matthews ,&nbsp;Ashutosh Tiwari","doi":"10.1016/j.jmapro.2025.01.093","DOIUrl":"10.1016/j.jmapro.2025.01.093","url":null,"abstract":"<div><div>Atmospheric plasma spray is a complex multivariable manufacturing process used in a wide range of industries. Deviations in the process parameters have been shown to affect the coating quality. Currently, the quality analysis is performed at the end of the process rather than checking for defects during the process. However, monitoring for these deviations during a coating process is difficult due to environmental hazards such as UV radiation, dusty environment, and excessive noise generation. A commercially available thermal imaging camera was integrated into this space to directly monitor the atmospheric plasma heat distribution and its influence on the in-flight particle trajectories during spraying. A novel metric called asymmetric angle is proposed to monitor the asymmetry of the plasma heat distribution. This is an important metric as a symmetric heat distribution is required to heat all the particles adequately to form a good quality coating. Further metrics of Gaussian Aspect Ratio (GAR) and contour area were found to have a relationship with the plasma gas flow rate and are discussed. The spray angle of the material is also tracked by fitting a 1D line to the regional Shannon entropy of the thermal image. The limitations of these metrics are discussed with possible avenues of further investigation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 79-89"},"PeriodicalIF":6.1,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378541","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Sandwich printing of PLA and carbon fiber reinforced-PLA for enhancing tensile and impact strength of additive manufactured parts","authors":"Madheswaran Subramaniyan ,&nbsp;Sivakumar Karuppan ,&nbsp;Anandhamoorthy Appusamy ,&nbsp;Nagarajan Pitchandi","doi":"10.1016/j.jmapro.2025.02.001","DOIUrl":"10.1016/j.jmapro.2025.02.001","url":null,"abstract":"<div><div>The tensile and impact strength of the additively fabricated polylactic acid (PLA)-based components are enhanced by adding reinforcements like carbon fiber, glass fiber, ceramics, etc. Reinforcing PLA with short carbon fiber enhances the mechanical properties to a limited range. The fused deposition modeling (FDM) fabricated from composite materials often exhibits weak bonding between layers. This article focuses on enhancing the interlayer bonding by employing a novel sandwich printing technique while also aiming to reduce the amount of reinforcement material required. The FDM dual-extruder printer is used to prepare samples with reinforcement volumes of 20 %, 40 %, 60 %, 80 %, and 100 %, consisting of alternating layers of PLA‑carbon fiber (CF) and PLA. Thermal and mechanical characterizations were conducted, and failure surfaces were evaluated using field emission scanning electron microscopy (FESEM). The results demonstrate that sandwich printing with 80 % PLA-CF and PLA increases tensile strength by 17.06 %, tensile modulus by 27.48 %, impact strength by 8.01 %, and hardness by 38.53 % compared to full PLA-CF reinforcement. The penetration of carbon fibers and the reduction of voids at layer junctions are responsible for the enhancement in mechanical properties. The alignment and orientation of fibers along the printing direction improve bonding and load-bearing capacity of the printed specimens. Compared to full reinforcement, the flexural strength for 60 % sandwich layers of PLA-CF and PLA increased by 18.76 %. These results confirm that sandwich printing enhances mechanical strength.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 425-436"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143377191","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}

{"title":"Experimental investigation of hydrodynamic flexible spindle polishing of metal additively manufactured channels","authors":"Patrick Chernjavsky,&nbsp;Rohit Dey,&nbsp;Jack Shanks,&nbsp;Yihao Zheng","doi":"10.1016/j.jmapro.2025.01.087","DOIUrl":"10.1016/j.jmapro.2025.01.087","url":null,"abstract":"<div><div>Metal additive manufacturing enables fabrication of internal channels with complex geometries, including small diameters and high aspect ratios, optimized for thermal and fluid transfer efficiency. Polishing these channels to improve internal surface finishing is critical to fatigue life, corrosion resistance, and fluid flow efficiency. Existing internal polishing methods are challenged by these complex channels and struggle to produce consistent internal surface roughness improvement, limiting their applicability. A novel hydrodynamic flexible spindle (HydroFlex) polishing process is introduced. HydroFlex uses a high-speed fixed-abrasive grinding wheel driven by a flexible spindle to navigate through complex internal channels for fast, uniform, and controllable material removal for surface improvement. HydroFlex polishing performance depends on process parameters including workpiece material, channel diameter, grinding wheel diameter, rotational speed, and coolant which are interdependent with limited understanding. In this study, Taguchi statistical method was employed to evaluate the influence of HydroFlex process parameters on the polishing performance, with surface roughness, polish uniformity, and maintenance of channel dimension characterized. The grinding forces and wheel motion were measured for mechanistic understanding. As results, grinding wheel orbital motion around the internal surface of the specimen was found to strongly correlate with polishing performance, with more stable wheel motion resulting in better surface finish. The sensitivity analysis indicated that the wheel rotational speed and specimen material had the largest effect on grinding wheel motion and polishing performance. In performance testing, HydroFlex was able to reduce the surface roughness of a 100 mm long additively manufactured AlSi10Mg channel by 86 % to 1.58 μm in five minutes of polishing. The sample surface finish uniformity and channel circularity were improved by 24.7 % and 43 %, respectively, with the channel diameter widening by only 1.2 %. These results suggest that HydroFlex is an effective, efficient polishing process for additive manufactured internal channels with inherent controllability and adaptability for surface uniformity and dimensional integrity.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 24-37"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378538","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}

{"title":"Interface micro-structure via ultrafast laser ablating in diamond/Cu joint to achieve high strength bonding and high efficiency heat conduction","authors":"Xinfei Zhang ,&nbsp;Panpan Lin ,&nbsp;Ye Ding ,&nbsp;Shuye Zhang ,&nbsp;Rui Xu ,&nbsp;Xin Sun ,&nbsp;Fugang Lu ,&nbsp;Peng He ,&nbsp;Tiesong Lin","doi":"10.1016/j.jmapro.2025.01.078","DOIUrl":"10.1016/j.jmapro.2025.01.078","url":null,"abstract":"<div><div>The high strength and efficient heat transfer of diamond/Cu cooling plate pose significant challenges for cutting-edge technologies, such as thermal management of electronics. In this paper, we reported a method to simultaneously enhance the mechanical properties and heat transfer performance of diamond/Cu joint by utilizing diamond interface micro-structures prepared by picosecond laser. The ablation behavior of picosecond laser on diamond surface and the effect of diamond graphitization on the properties of joints were analyzed. Meanwhile, by characterizing the shear strength and thermal diffusivity of diamond/Cu joints, the strengthening mechanism on the joint performance was explored. Compared to the flat interface in the original joint, laser-treated joints exhibited an increase in shear strength of up to 29 %, reaching 213 MPa, and an increase in thermal diffusivity of up to 11 %, reaching 212.1 mm²/s. These excellent properties were affiliated with designed interface micro-structure and distribution of interface layers. This study aims to provide novel insights into achieving efficient heat transfer and high strength at diamond/metal plates for heat management.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 50-61"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378539","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}

{"title":"Improving the surface quality of maraging 300 parts produced via laser powder bed fusion through powder distribution selection and optimized laser remelting","authors":"Mirko Sinico,&nbsp;Ann Witvrouw,&nbsp;Wim Dewulf","doi":"10.1016/j.jmapro.2025.02.014","DOIUrl":"10.1016/j.jmapro.2025.02.014","url":null,"abstract":"<div><div>This work examines the impact of powder particle size distribution (PSD) on the surface finish of maraging 300 steel parts produced by laser powder bed fusion (LPBF). After an initial selection of two suitable powder raw materials, Mar 10–30 and Mar 15–45, the study demonstrates that finer powders lead to significantly smoother upfacing surfaces, with up to a 50 % reduction in surface roughness (Ra). The Mar 10–30 distribution not only produces superior surface quality but also allows for more advanced LPBF processing strategies. These strategies combine small layer thicknesses with laser remelting, demonstrating that top surface roughness can be reduced to as low as 1.5 μm Ra. Finally, an outlook is given, suggesting that properly engineered powders, together with optimized LPBF processing parameters, enable the fabrication of both vertical single-track ridges or thin-walls down to ~100 μm thickness and basic texturing patterns, offering a cost-effective in-situ LPBF alternative to post-processing texturing. These developments open new possibilities for the surface finish and functionalization of LPBF components while increasing the precision and feature resolution in LPBF parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 38-49"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378536","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}

{"title":"Unravelling the cracking mechanism in wire-based laser-directed energy deposition processing high-strength aluminum alloy","authors":"Mengjie Wang ,&nbsp;Nowfal Al-Hamdany ,&nbsp;Yujie Deng ,&nbsp;Emad Maawad ,&nbsp;Shengnian Luo ,&nbsp;Nikolai Kashaev","doi":"10.1016/j.jmapro.2025.01.046","DOIUrl":"10.1016/j.jmapro.2025.01.046","url":null,"abstract":"<div><div>High-strength aluminum alloys exhibit high cracking susceptibility in laser-based additive manufacturing. Understanding the mechanisms behind cracking and identifying the primary factors are crucial to preventing cracking, especially when dealing with difficult-to-process materials. Therefore, it is necessary to uncover the cracking mechanisms during successive deposition. In this study, the cracking mechanism is investigated in laser-directed energy deposition processing AA7075 alloy in terms of solidification conditions, microstructure, and residual stress. Based on the results, the cracking phenomenon observed during successive deposition is induced by insufficient backfilling to solidification shrinkage leading to solidification cracking. The melt-pool lifetime and the maximum melt-pool temperature are the primary factors determining the solidification cracking susceptibility. After the initiation, the cracks grow in two directions parallel to the building direction. The growth downwards is attributed to the liquation cracking mechanism, while the growth upwards results from the solidification cracking mechanism. The delayed cracking (cracking after a certain number of layers have been deposited) is identified as the consequence of the competitive growth between grains with preferential growth direction and highly misaligned grains.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 437-456"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143377192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing mechanical properties of AA6082 alloy by reinforcing graphite nanoplatelets using a novel continuous caster","authors":"Jagadish Nayak ,&nbsp;Prasenjit Biswas ,&nbsp;Archana Mallik ,&nbsp;Sanjeev Das","doi":"10.1016/j.jmapro.2025.02.012","DOIUrl":"10.1016/j.jmapro.2025.02.012","url":null,"abstract":"<div><div>This study employs a newly developed continuous casting setup (CCS) to fabricate a metal matrix nanocomposite (MMNC) by reinforcing graphite nanoplatelets (GNPs) within the aluminium 6082 (AA6082) alloy. Various volume percentages of GNPs, i.e., 0.3 %, 0.5 %, 0.7 %, and 1.2 % were selected for reinforcement. The incorporation of GNPs in MMNC was validated using X-ray diffraction (XRD), Raman spectroscopy, Field emission scanning electron microscopy (FE-SEM), and High-resolution Transmission electron microscopy (HR-TEM) techniques. Adding 1.2 % GNPs to the AA6082 alloy achieved a 183.90 % enhancement in micro-hardness, whereas incorporating 0.3 % GNPs resulted in a 71.02 % increase in the tensile strength of the MMNC relative to the base alloy. However, the MMNC, reinforced with 0.3 % GNPs, showed a significant decrease of 56.78 % in compressive yield strength compared to AA6082 alloy. Additionally, the negative elongation in compression was increased by 24.37 % up to the yield point. A detailed examination of the deformation process was performed utilizing the Finite Element Method (FEM) to explore the interaction of GNPs in AA6082. A good agreement between the simulated and experimental results for the tensile behaviour is observed, indicating the ability of the FEM model to predict the strength of GNPs reinforced MMNC. In conclusion, the advanced CCS method utilizing a rotor-stator device (RSD) and bottom-feeding technology has proven effective for synthesizing AA6082/GNPs MMNC.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 62-78"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378540","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}

{"title":"Research on the arc stability of dry hyperbaric GMAW from the perspective of arc energy and electrical conductivity","authors":"Liwei Guo ,&nbsp;Jiqiang Huang ,&nbsp;Long Xue ,&nbsp;Ruiying Zhang","doi":"10.1016/j.jmapro.2025.01.090","DOIUrl":"10.1016/j.jmapro.2025.01.090","url":null,"abstract":"<div><div>As the environmental pressure increases, the arc plasma of dry hyperbaric gas metal arc welding (DH-GMAW) contracts. This phenomenon leads to decreased arc stability or even arc extinguishment, which severely affects the welding quality. In essence, the dynamic behaviour of arc plasma is influenced by its electrical conductivity. Furthermore, changes in electrical conductivity depend on changes in arc energy transport. To study changes in arc energy transport, the energy dissipated from the arc to the external environment was measured. The arc voltage drop was measured, and the arc conductivity was calculated. A water heat exchange system was used to collect the energy dissipated from the arc to the external environment. A double passive tungsten probe was used to measure the voltage drop of the arc column. Comparative research on arc energy dissipation and conductivity under different environmental pressures was conducted to analyse their effects on arc stability. The experimental results show that as the environmental pressure increases, the arc energy dissipation increases, and the arc column voltage drop decreases. The electrical conductivity decreases with increasing environmental pressure, indicating that the internal energy of the arc decreases. The conductivity can be improved by increasing the welding current. However, this improvement gradually diminishes with increasing pressure. The energy dissipation near the cathode increases with pressure, leading to further contraction of the arc. The reverse plasma jet force increases with pressure. This phenomenon increases instability in the welding process. Clearly, changes in arc energy transport and conductivity have crucial effects on arc stability. In conclusion, increasing the arc energy input or reducing the arc energy dissipation is beneficial for suppressing arc contraction and improving arc stability.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 14-23"},"PeriodicalIF":6.1,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378537","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}

{"title":"PETG-silk biocomposite for additive manufacturing and biomedical applications","authors":"Vijayasankar K N ,&nbsp;Sumanta Mukherjee ,&nbsp;Ashis Kumar Bera ,&nbsp;Falguni Pati","doi":"10.1016/j.jmapro.2025.01.045","DOIUrl":"10.1016/j.jmapro.2025.01.045","url":null,"abstract":"<div><div>Natural fiber-reinforced biocomposites are suitable for the fabrication of biomedical products, including scaffolds, implants, prostheses, and orthoses due to their mechanical and biological properties as well as high availability, low cost, and sustainability. This study explores the mechanical properties, biocompatibility, biodegradability, and thermal stability of a short silk fiber reinforced PETG composite with various silk fiber ratios (2–10 % by weight) for potential tissue engineering scaffolds as well as external supportive biomedical devices like braces and splints using 3D printing. The composites were successfully prepared with a homogeneous distribution of fibers in the matrix without fiber agglomeration or any voids/cracks in the matrix. The prepared composites were found to be thermally stable up to 390 °C. The addition of the reinforcement helped to improve the mechanical properties of the material, and the composite with 10 % silk was observed to have a tensile modulus of 564 MPa, which is almost five times that of pure PETG (97 MPa). Specific strength of composite was also improved by 56.02 % compared to pure PETG. Silk content in composites significantly increased the biocompatibility as well, evidenced by the increased level of cellular metabolic activities in the composites. In terms of processability, the developed composite could be 3D printed with common FDM 3D printers without any significant challenges. Therefore, this material would be suitable for fabricating complex shapes like scaffolds with high strength-to-weight ratio and improved biomedical functionalities.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 1-13"},"PeriodicalIF":6.1,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378535","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}

{"title":"Adaptive process parameters decision-making in robotic grinding based on meta-reinforcement learning","authors":"Jie Pan ,&nbsp;Fan Chen ,&nbsp;Dan Han ,&nbsp;Shuai Ke ,&nbsp;Zhiao Wei ,&nbsp;Han Ding","doi":"10.1016/j.jmapro.2025.02.005","DOIUrl":"10.1016/j.jmapro.2025.02.005","url":null,"abstract":"<div><div>In robotic grinding, the variability of workpiece characteristics, uneven machining allowances and nonlinear tool wear collectively pose challenges for consistent material removal. To address these dynamic grinding conditions and achieve high-accuracy material removal, this paper presents an adaptive decision-making model for grinding process parameters based on the meta-reinforcement learning. The proposed approach accurately adjusts grinding process parameters under a wide range of coating characteristics, multiple grinding tool types and progressive tool wear, with few-shot training samples. First, we develop an enhanced proximal policy optimization algorithm with better experience (PPO_BE) to optimize process parameters for a specific grinding task, improving material removal accuracy. Subsequently, building on the PPO_BE framework, we integrate model-agnostic meta-learning (MAML) to form MAML-PPO_BE algorithm, enabling fast adaptation across heterogeneous grinding tasks while preserving high accuracy. Comprehensive experiments on 16 distinct grinding tasks demonstrate a 51.4 %–68.9 % improvement in material removal deviation relative to the MAML, PPO_BE, SAC and FLC algorithms, respectively. This paper presents an adaptive parameters decision-making method with high accuracy in changing and complex grinding process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"137 ","pages":"Pages 376-396"},"PeriodicalIF":6.1,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143350379","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}