Journal of Manufacturing Processes最新文献_第2页

Correlating dimensionless enthalpy, pyrometry, and melt pool geometry within the laser powder bed fusion energetic regime: A path to in-situ melt pool control demonstrated on tungsten

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.03.033

Janko Stajkovic , Manuel Kahl , Lukas Kaserer , Jakob Braun , Sophie Scheuringer , Bernhard Mayr-Schmölzer , Benedikt Distl , Gerhard Leichtfried

{"title":"Correlating dimensionless enthalpy, pyrometry, and melt pool geometry within the laser powder bed fusion energetic regime: A path to in-situ melt pool control demonstrated on tungsten","authors":"Janko Stajkovic , Manuel Kahl , Lukas Kaserer , Jakob Braun , Sophie Scheuringer , Bernhard Mayr-Schmölzer , Benedikt Distl , Gerhard Leichtfried","doi":"10.1016/j.jmapro.2025.03.033","DOIUrl":"10.1016/j.jmapro.2025.03.033","url":null,"abstract":"<div><div>In the realm of laser powder bed fusion (LPBF), controlling the melt pool in situ represents a critical challenge, as numerous defects are associated with its dynamics. This research demonstrates the utility of pyrometric signals in gaining insights into the depth of vapor capillaries during LPBF processes. By establishing a correlation between a semi-empirical enthalpy model and pyrometric data, gathered on a powder-free substrate, a pathway towards the in-situ control of melt pool geometry is unveiled. The study introduces a dimensionless enthalpy model designed for predicting the aspect ratio of melt pools in LPBF.A linear relationship between the depth of melt pools, pyrometric signals, and dimensionless enthalpy is established through correlation with this model and measurements from metallographic cross sections. Histographic analysis of pyrometric data reveals unique signatures that correlate with conduction and keyhole mode melting, suggesting that these distinct histogram forms are indicative of keyhole stability. The findings confirm that the relationships defined in this study are applicable across varying spot sizes and hatch distances, allowing for the inference of optimal parameters directly from pyrometric signals. This research lays the groundwork for real-time control of melt pool geometry, marking a significant advancement towards enhancing the quality and consistency of LPBF and holds potential applications to laser welding processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1310-1323"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644942","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}

引用次数: 0

Evaluation of radially polarized femtosecond laser drilling of film cooling holes

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-18 DOI: 10.1016/j.jmapro.2025.02.080

Zhengjie Fan , Peng Shen , Xiaomao Sun, Tao Sun, Liangtian Yi, Jianlei Cui, Xuesong Mei

{"title":"Evaluation of radially polarized femtosecond laser drilling of film cooling holes","authors":"Zhengjie Fan , Peng Shen , Xiaomao Sun, Tao Sun, Liangtian Yi, Jianlei Cui, Xuesong Mei","doi":"10.1016/j.jmapro.2025.02.080","DOIUrl":"10.1016/j.jmapro.2025.02.080","url":null,"abstract":"<div><div>The low efficiency of femtosecond (fs) laser processing remains a significant obstacle to its application particularly in the field of film cooling holes of aero-engines. This paper aims to provide an understanding of the energy coupling mechanism in femtosecond vector laser drilling. In this paper, the polarization dependence of penetration efficiency in femtosecond laser drilling was investigated. Experimental results reveal that the radially polarized laser has the highest penetration efficiency in deep drilling. The penetration efficiency of the radially polarized laser can be improved by 35.2 % and 33.0 % compared with the linearly polarized laser on samples of 3 mm and 5 mm thick. At the same time, the on-line monitoring system can effectively monitor the penetration time, and the combination of ultrafast transient absorption spectroscopy (UTAS) and laser-induced breakdown spectroscopy (LIBS) further proves that the radially polarized laser has higher absorptivity and ablation efficiency. The impact of laser drilling on the morphology and microstructure evolution of the hole wall was investigated. The results indicate that the radially polarized laser exhibits superior performance compared to the other two lasers in stimulating the electronic system of the material, leading to penetration efficiency enhancement. This study provides new insights into the mechanism of femtosecond vector laser drilling and provides a basis for the application of vector laser in high aspect ratio film cooling hole machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1296-1309"},"PeriodicalIF":6.1,"publicationDate":"2025-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644940","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

Roll-stamp forming of circular tubes

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.036

Zhiheng Zhang , Tianxia Zou , Dayong Li , Yinghong Peng , Hua Xiao , Lei Shi

{"title":"Roll-stamp forming of circular tubes","authors":"Zhiheng Zhang , Tianxia Zou , Dayong Li , Yinghong Peng , Hua Xiao , Lei Shi","doi":"10.1016/j.jmapro.2025.03.036","DOIUrl":"10.1016/j.jmapro.2025.03.036","url":null,"abstract":"<div><div>Circular tubes are important structural components and generally processed by roll forming technique. In this work, roll-stamp forming is developed as an alternative to roll forming to form circular tubes. A three-pass roll-stamp forming process is designed and implemented, and a corresponding die design criterion is proposed. The finite element model of tube roll-stamp forming is established and forming quality is quantitatively evaluated through simulation and experiment. The deformation process from a flat blank to a circular tube is analyzed, as well as the regularities in the distribution and evolution of stress and strain. In tube roll-stamp forming, no significant thinning or thickening of wall thickness occurs. Finally, the effects of key process parameters on the final forming quality are numerically investigated, and the optimal parameter settings are determined. Forming experiments are conducted and good forming quality is achieved with the optimized process design. Preliminary multi-pass forming experiments are further implemented, successfully enabling the continuous production of tubes. This work makes the first attempt to develop roll-stamp technique as an effective forming approach for profiles of closed cross-sections.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1119-1134"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637417","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

Rapid acquisition of a unique combination of strength and ductility in La-Fe-Co-Si magnetocaloric alloy: Eutectic interface construction by selective laser melting

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.058

Ruochen Zhang , Bo Yuan , Mingfang Qian , Xuexi Zhang , Zhengxian Liu

{"title":"Rapid acquisition of a unique combination of strength and ductility in La-Fe-Co-Si magnetocaloric alloy: Eutectic interface construction by selective laser melting","authors":"Ruochen Zhang , Bo Yuan , Mingfang Qian , Xuexi Zhang , Zhengxian Liu","doi":"10.1016/j.jmapro.2025.03.058","DOIUrl":"10.1016/j.jmapro.2025.03.058","url":null,"abstract":"<div><div>In this work, La,Cu,Si-rich eutectic interfaces consisting of the refined α-Fe and LaCuSi phases are primarily constructed via adding Cu by selective laser melting to rapidly acquire a combination of strength and ductility in La-Fe-Co-Si alloy. As a result, the ingot exhibits a decreased porosity from 2.52 vol% to 1.84 vol%. It is also the lowest porosity that has been reported among the La-Fe-Si-based ingots fabricated by laser additive manufacturing until now compared to those without eutectic interfaces， so these as-built ingots exhibit the enhanced hardness. More importantly, due to the ductility of α-Fe and LaCuSi phases, the ductility of the ingot is significantly increased to 6 % and a yield stage is first discovered with a yield strength 549.43 MPa and ductility 6 % in the as-built ingot. Simultaneously, the compression strength is as large as 583.88 MPa. After a short annealing process at 1323 K for 12 h, large amounts of the refined magnetocaloric La(Fe,Co,Si)<sub>13</sub> phases are formed. The interfacial phases are transformed to LaCu<sub>2</sub> phases semi-coherent to La(Fe,Co,Si)<sub>13</sub> phases and ductile LaCuSi phases. It causes an extra 36 % enhancement of compression strength to 918.98 MPa without any ductility sacrifice thanks to the combined impact of the refinement and second-phase strengthening. It is the highest strength that has ever been reported in this material. Simultaneously, a wide working temperature interval 300 K–340 K with high magnetocaloric cyclicity is obtained.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1098-1108"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637415","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

Anisotropy study of the microstructure, phase composition and properties of 321 stainless steel additively manufactured by laser powder bed fusion

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.038

Liang Zou , Yang Huang , Yun Tan , Yueting Wang , Tong Wang , Yue Ma , Tiechui Yuan , Ruidi Li

{"title":"Anisotropy study of the microstructure, phase composition and properties of 321 stainless steel additively manufactured by laser powder bed fusion","authors":"Liang Zou , Yang Huang , Yun Tan , Yueting Wang , Tong Wang , Yue Ma , Tiechui Yuan , Ruidi Li","doi":"10.1016/j.jmapro.2025.03.038","DOIUrl":"10.1016/j.jmapro.2025.03.038","url":null,"abstract":"<div><div>This study investigates the microstructure, phase composition evolution, and mechanical anisotropy of 321 stainless steel (SS) fabricated via laser powder bed fusion (LPBF). The influence of volume energy density on the morphology of molten pool and characteristics was investigated through experiments and simulations. Experimental results indicate that LPBF 321 SS predominantly consists of austenite with trace amounts of martensite. Through parameter optimization, nearly-fully-dense specimens with a relative density of ~99.9 % were prepared. It exhibits an excellent strength-plasticity balance surpassing that of castings/forgings. The ultimate tensile strength and elongation along the transverse direction reached 704 MPa and 61.5 %, respectively, while the longitudinal values were 625 MPa and 73.2 %. Grains oriented perpendicular to the building direction exhibit finer grains, higher proportion of low-angle grain boundaries and a lower Schmidt factor, all of which contribute to enhanced strength. Two substructures, cellular and columnar, were observed within the grains. During plastic deformation, the cellular substructure with dislocation walls effectively pinned dislocations and suppressed deformation twin propagation, while columnar substructures showed weaker blocking ability depending on their alignment. The higher cellular substructure content in the transverse direction contributed to greater tensile strength. These findings provide valuable insights for expanding the industrial production applications range of 321 stainless steel.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1135-1150"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637418","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

Defects response to precoated adhesive in Al/steel friction stir welded joint

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.042

Weiben Huang , Zhijie Ding , Peng Li , Peng Zhao , Dianwu Zhou , Yongxian Huang , Xiangchen Meng , Yongbing Li , Yunwu Ma , Honggang Dong

{"title":"Defects response to precoated adhesive in Al/steel friction stir welded joint","authors":"Weiben Huang , Zhijie Ding , Peng Li , Peng Zhao , Dianwu Zhou , Yongxian Huang , Xiangchen Meng , Yongbing Li , Yunwu Ma , Honggang Dong","doi":"10.1016/j.jmapro.2025.03.042","DOIUrl":"10.1016/j.jmapro.2025.03.042","url":null,"abstract":"<div><div>Friction stir welding (FSW) has been applied for welding dissimilar materials in advanced manufacturing industries such as shipbuilding, automotive and aerospace. For the broad popularization of adhesive in FSW, the innovative coupling method of friction stir welding-adhesive bonding (FSW-AB) technology was designed to join 5A06 aluminum alloy to 304 stainless steel. The joints were fabricated using a single-component structural adhesive applied manually in the pre-lap zone. The joints were then cured by the heat generated from FSW. Macrostructure, defect generation and tensile shear performances of the joints obtained using three different rotation speeds and different adhesive thickness were studied. The adhesive prevented direct plate contact, but the FSW-AB joint showed more flash. Adhesive expansion occurred on the advancing side due to structural asymmetry and uneven heat dissipation. Compared to conventional FSW, the joints produced by FSW-AB exhibited significantly reduced hook defects in the pin-affected zone, a smoother distribution of hardness across the weld cross-section, and notably elevated hardness on the retreating side of the base metal outside the shoulder. It is attributed to the difference in the degree of crystallization between the two caused by the difference in heat dissipation rate. The ultimate tensile shear load of the FSW-AB joint reached 93.3 % of the conventional FSW joint at 1200 rpm stirring speed and 0.25 mm adhesive thickness. Furthermore, the fracture modes of FSW-AB joints were mainly normal fracture and shear fracture.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1109-1118"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637416","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

Investigation of kerf width in CO2 laser fabrication of microchannels on aluminium-coated polymethyl methacrylate (PMMA) using adaptive neuro-fuzzy inference system (ANFIS)

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.02.086

Job Lazarus Okello , Ahmed M.R. Fath El-Bab , Masahiko Yoshino , Hassan A. El-Hofy

{"title":"Investigation of kerf width in CO2 laser fabrication of microchannels on aluminium-coated polymethyl methacrylate (PMMA) using adaptive neuro-fuzzy inference system (ANFIS)","authors":"Job Lazarus Okello , Ahmed M.R. Fath El-Bab , Masahiko Yoshino , Hassan A. El-Hofy","doi":"10.1016/j.jmapro.2025.02.086","DOIUrl":"10.1016/j.jmapro.2025.02.086","url":null,"abstract":"<div><div>Kerf width affects the quality of microfluidic devices. For highly accurate results, kerf width should be minimum. It is challenging to attain minimum kerf width with laser micromachining. Relating the inputs to the outputs is also a critical challenge. Accordingly, an intelligent system with adaptive neuro-fuzzy inference system (ANFIS) has been built to attain the desired kerf widths of microchannels in CO<sub>2</sub> laser fabrication of polymethyl methacrylate (PMMA). The work samples were coated with a 1 μm layer of aluminium of purity 99.5 %. The inputs were speed (10, 15, and 20 mm/s), pulse rate (800, 900, and 1000 pulses/in.), and power (1.5, 3.0, and 4.5 W). The experiments were designed using response surface methodology. The total number of experiments was 54. The ANFIS toolbox was used for generating the ANFIS model in MATLAB R2022a. The model was trained and examined using the experimental results. The chosen membership function was Gaussian (gaussmf). The significance of all the inputs was examined using analysis of variance (ANOVA). Power was found to be the most significant. Speed was second in significance and pulse rate was the last. Mean relative error (MRE), correlation coefficient (R), and mean absolute error (MAE) were used to investigate how accurate the model was. MRE, R, and MAE were 0.003799, 0.99997116 (coefficient of determination, R<sup>2</sup> = 0.99998558) and 0.582 respectively. The training data had the root mean square error (RMSE) of 0.623405 while RMSE was 1.08345 for the checking data. The accuracy of the ANFIS model was high.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1235-1244"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143644874","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

Multi-directional hydraulic loading for high-precision calibration of additively manufactured aluminum alloy thin-walled tube

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.064

Xinlong Zhang, Xiaodong Xie, Chenxi Zheng, Jiang Xiao, Xueyan Liu

{"title":"Multi-directional hydraulic loading for high-precision calibration of additively manufactured aluminum alloy thin-walled tube","authors":"Xinlong Zhang, Xiaodong Xie, Chenxi Zheng, Jiang Xiao, Xueyan Liu","doi":"10.1016/j.jmapro.2025.03.064","DOIUrl":"10.1016/j.jmapro.2025.03.064","url":null,"abstract":"<div><div>Metal additive manufacturing, due to its unique process characteristics, tends to produce deformation defects in thin-walled tubular components. This study proposes a multi-directional composite loading hydraulic calibration method to improve the geometric accuracy and mechanical properties of additively manufactured tubes. Using AlSi10Mg tubes fabricated by Selective Laser Melting (SLM) as the research subject, theoretical models describing dent flattening and axial compression instability were established based on the energy method and Cao-Boyce criterion. The influence of tube geometric parameters and material properties on calibration pressure was analyzed. Results indicate that the material's strain hardening exponent and strength coefficient significantly affect the critical flattening pressure and critical instability pressure. Through finite element analysis and experimental validation, the influence mechanisms of process parameters, including dent flattening pressure, corner forming pressure, and axial compression pressure, on calibration effectiveness were investigated. Under optimal process parameters (dent flattening pressure of 14 MPa, corner forming pressure of 130 MPa, axial compression pressure of 7 MPa, and axial boundary displacement of 20 mm), the method effectively eliminated the initial 1.82 mm dent in the straight edge region and controlled the inner and outer radius deviations of corners within 1.85 % and 0.83 %, respectively, achieving a maximum wall thickness increase rate of 20.53 %. Furthermore, the multi-directional composite loading hydraulic calibration induced a triaxial compressive stress state, which favorably enhanced microstructural homogeneity and mechanical properties. This research provides theoretical guidance and engineering reference for precise calibration of additively manufactured tubular components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1177-1194"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637550","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}

引用次数: 0

Accurate at-line measurement of deposition rate for aerosol jet printing for the fabrication of 3D patterns and resistors with high precision

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.067

Zhenxiang Xiong , Chenglin Yi , Yuan Li , Yingjie Niu , Teng Ma , Ao Li , Hui Cheng , Kaifu Zhang

{"title":"Accurate at-line measurement of deposition rate for aerosol jet printing for the fabrication of 3D patterns and resistors with high precision","authors":"Zhenxiang Xiong , Chenglin Yi , Yuan Li , Yingjie Niu , Teng Ma , Ao Li , Hui Cheng , Kaifu Zhang","doi":"10.1016/j.jmapro.2025.03.067","DOIUrl":"10.1016/j.jmapro.2025.03.067","url":null,"abstract":"<div><div>Aerosol jet (AJ) printing has gained significant attention in printed electronics for its high resolution and non-contact capabilities. However, batch-to-batch variations in printed products due to the difficulty of precisely controlling the amount of ink deposited have prevented its widespread use in production. A major challenge is to achieve direct, precise, and ink-unrestricted at-line measurement of the deposition rate (DR). By incorporating a photoetched inkwell and a mechanical shutter system with a high-pressure air-blowing device, a direct and precise at-line DR measurement during the printing process is established. A pneumatic shutter is used to briefly interrupt the printing process and enable multiple at-line measurements during printing. Utilizing this approach, three printable inks, including polyurethane acrylate, silver nanoparticles, and conductive carbon black, were employed to fabricate three-dimensional (3D) patterns with predetermined geometries or resistors with specific target resistances. Precise at-line DR control enabled the crafting of polymer structures with height deviations of just 3.48 % from the design specifications. Each group of 18 resistors, with target values of 1 Ω, 10 Ω, 1 kΩ, and 10 kΩ without postprocessing, achieved average errors of 2.49 %, 2.32 %, 2.94 %, and 2.34 %, respectively. This methodology offers a crucial tool for addressing precise fabrication challenges, as demonstrated here for both 3D patterns and passive components of conformal electronics using AJ printing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1151-1160"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637419","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

Enhancing wire arc directed energy deposition for challenging printing tasks: A VR-based skill-learning approach

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-03-17 DOI: 10.1016/j.jmapro.2025.03.051

Lei Yuan , Fengyang He , Donghong Ding , Huijun Li , Zengxi Pan

{"title":"Enhancing wire arc directed energy deposition for challenging printing tasks: A VR-based skill-learning approach","authors":"Lei Yuan , Fengyang He , Donghong Ding , Huijun Li , Zengxi Pan","doi":"10.1016/j.jmapro.2025.03.051","DOIUrl":"10.1016/j.jmapro.2025.03.051","url":null,"abstract":"<div><div>The recent development of wire arc directed energy deposition (WA-DED) has made the additive manufacturing of medium to large-sized metal parts possible with acceptable cost. However, the current WA-DED system commonly uses a fixed set of parameters for each weld bead, which results in a uniform weld bead geometry that fall short of meeting the demands of high-challenging tasks such as fabricating complex parts with intricate geometries. In contrast, experienced human welders can control the weld bead shapes during the deposition process by flexibly adjusting deposition parameters, thus realizing the fabrication of components with more complex geometries. This study aims to bridge this gap by distilling human skills and applying them to WA-DED system for the fabrication of metal parts with complex geometry. To learn the skills of experienced human welders, a skilled welder was asked to execute a series of predefined welding tasks, and a virtual reality (VR) based human motion capture system was developed to capture data on the real-time torch pose and welding parameters. The data collected from the human welder, after being processed through the developed data processing module, was utilized in the proposed PSO-BPNN-based predictive models. The inputs to the developed predictive model include travel speed (TS), welding angles (WAs), and the contact tip to workpiece distance (CTWD), while the outputs are the bead width (BW) and bead height (BH) of the two segments of a geometry-varying weld bead. The model can predict a great number of continuous parameter combinations for complex weld bead deposition with high precision. Then, the accuracies of the forward and backward were validated through experimentation. Finally, a real-world case study demonstrates the effectiveness of the proposed strategy, addressing its potential to broaden the applicability of WA-DED technologies significantly.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 1161-1176"},"PeriodicalIF":6.1,"publicationDate":"2025-03-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143637549","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