Journal of Manufacturing Processes最新文献

{"title":"Dissimilar ultrasonic spot welding of AA6016 alloy-to-DP800 steel: The role of a novel AlSi(Fe) PVD coating","authors":"D. Bajaj ,&nbsp;V.V. Nemade ,&nbsp;N. Stöcker ,&nbsp;D. Sulik ,&nbsp;X.F. Fang ,&nbsp;N.S. Ma ,&nbsp;D.Y. Li ,&nbsp;D.L. Chen","doi":"10.1016/j.jmapro.2025.07.022","DOIUrl":"10.1016/j.jmapro.2025.07.022","url":null,"abstract":"<div><div>Lightweighting in the automotive industry often involves joining dissimilar materials, while ensuring the safety and durability of load-bearing components. However, the joining of dissimilar materials presents significant challenges due to differences in their physical and chemical properties. In this study, a novel AlSi(Fe) physical vapor deposition (PVD) coating was applied on DP800 steel to enhance its compatibility with AA6016 aluminum alloy during solid-state ultrasonic spot welding (USW). The AA6016-to-coated DP800 steel joints, fabricated at welding energies around 1250 J, surpassed the tensile lap shear load requirements specified in the AWS D17.2 standard. The presence of the PVD coating not only enhanced the tensile lap shear strength by 23 % (i.e., from 69 MPa to 85 MPa), but also reduced the welding energy required to achieve optimal joint performance by 37.5 % (i.e., from 2000 J to 1250 J). This reduction in energy consumption further contributed to improved welding efficiency. The AA6016-to-uncoated DP800 steel joints at a welding energy of 2000 J exhibited button pullout failure under tensile loading and high-stress cyclic loading, largely due to excessive thinning of the AA6016 alloy. In contrast, the AA6016-to-coated DP800 steel joints welded at 500 J showed adhesive failure caused by defects at the weld interface. However, at a welding energy of 1250 J, these joints demonstrated superior intermixing between the Al sub-layer of PVD coating and the AA6016 alloy, resulting in a combination of cohesive and adhesive failure modes. The findings reveal the effectiveness of the AlSi(Fe) PVD coating in improving the mechanical properties of the joints while enhancing the energy efficiency of the welding process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 103-119"},"PeriodicalIF":6.1,"publicationDate":"2025-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144623761","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":"Fabrication of smooth and deep microchannels on soft polymer by stretching enhanced cryogenic assisted micro milling","authors":"Partha Sarathi Mallick ,&nbsp;Ashwani Pratap ,&nbsp;Karali Patra","doi":"10.1016/j.jmapro.2025.07.038","DOIUrl":"10.1016/j.jmapro.2025.07.038","url":null,"abstract":"<div><div>Soft viscoelastic polymer is typically difficult –to-machine up to larger depth by cryogenic assisted micro milling (CAMM) process. Stretching enhanced cryogenic assisted micro milling (SECAMM), a single stage and unfilled processing method for soft polymer, is proposed in this study. Tensile stress is initially generated in bulk polymer by uniaxial stretching; then CAMM is performed to fabricate microchannel. To investigate the impact of structural change by directional stretching on deformation response, SECAMM is performed at different stretching ratio (1, 1.1, 1.25, 1.5, and 2) and cutting directions (0°, 45°, and 90°). Further to evaluate the changes in mechanical properties of bulk polymer under cryogenic environment, a scratch based method is used to determine coefficient of dynamic friction (CODF) and fracture toughness under different cutting condition. The study highlights that increase in stretch ratio reduces CODF and fracture toughness with minimum value along 90° direction. Results showed that SECAMM process helps to reduce surface roughness value of machined surface to 2.30 μm for 100 μm depth microchannel. Compared to CAMM, SECAMM along 90° direction reduces the material recovery percentage by 45–55 %, improves the microchannel dimensional accuracy, and enhance surface flatness.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 120-141"},"PeriodicalIF":6.1,"publicationDate":"2025-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144623762","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":"Enhancing heating uniformity of radio frequency additive manufacturing via functional grading","authors":"Hongtao Song ,&nbsp;Ali Sohaib ,&nbsp;Jared Allison ,&nbsp;Christopher Tuck ,&nbsp;Richard Hague ,&nbsp;John Pearce ,&nbsp;Joseph Beaman ,&nbsp;Carolyn Seepersad","doi":"10.1016/j.jmapro.2025.07.013","DOIUrl":"10.1016/j.jmapro.2025.07.013","url":null,"abstract":"<div><div>Radio Frequency Additive Manufacturing (RFAM) is an additive manufacturing process that utilizes Radio Frequency (RF) radiation as the sole heat source to heat and sinter an entire object simultaneously. Parts are fabricated selectively from powders, similarly to powder bed fusion but with RF radiation replacing laser or electron beams as the energy source. Typical polymer powders, such as nylon 11 or 12, are relatively transparent to RF energy sources, but polymer powders that are doped with conductive additives selectively absorb RF energy. By depositing electrically conductive dopants into selective regions of an insulating polymer powder bed, those regions of the powder bed can be sintered quickly and volumetrically via RF radiation into engineered parts. Previous work demonstrated that heating uniformity is a challenge related to the dopant density and the geometry of the part, but simulations suggested that it can be addressed by functionally (spatially) grading the dopant density. In this work, those simulation-based, functionally graded designs are fabricated for the first time via a combination of binder jetting additive manufacturing and sintering in an RF heating apparatus. The heating uniformity and geometric accuracy of the functionally graded samples are evaluated and compared to that of uniformly doped samples. The results show that functionally graded samples exhibit enhanced heating uniformity and improved geometric accuracy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 142-159"},"PeriodicalIF":6.1,"publicationDate":"2025-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144623763","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":"Pi-TabNet: An explainable physics-informed deep learning method for flatness prediction in cold-rolled copper strips","authors":"Bowei Duan ,&nbsp;Dongcheng Wang ,&nbsp;Guodong Wang ,&nbsp;Yexin Hu ,&nbsp;Yanghuan Xu ,&nbsp;Hongmin Liu","doi":"10.1016/j.jmapro.2025.06.090","DOIUrl":"10.1016/j.jmapro.2025.06.090","url":null,"abstract":"<div><div>Flatness is a critical quality indicator for high-end cold-rolled strip products. In industrial applications, flatness is automatically measured and controlled through flatness measurement and control systems. Traditional mechanistic models for flatness prediction face challenges, including low accuracy, lengthy development cycles, and slow computational speeds. Although deep learning-based intelligent models show potential, their industrial adoption remains limited due to poor explainability, insufficient incorporation of physics-informed knowledge from the rolling domain, and low-quality training data. Furthermore, flatness prediction for cold-rolled copper strips remains an underexplored research area. To address these challenges, this study proposes an explainable, physics-informed deep learning method for flatness prediction at the exit stage of cold-rolled copper strips. Using industrial big data, actual operating conditions, and data mining techniques, two flatness datasets were constructed for cold-rolled copper strips under representative industrial scenarios. Guided by prior physical knowledge from the rolling domain, a novel deep neural network architecture, Physics-informed TabNet (Pi-TabNet), was developed. The training process incorporates physical constraints, ensuring that flatness predictions comply with physical laws, which improves the model's explainability and robustness. The results on the test set indicate that the proposed method achieves higher prediction accuracy than other classical algorithms and demonstrates strong generalization performance. Furthermore, transfer learning experiments indicate that the proposed physics-informed model possesses strong feature extraction capabilities and adapts well to varying data distributions across different scenarios. Additionally, the SHapley Additive exPlanations (SHAP) method, an explainable artificial intelligence (XAI) technique, was employed to elucidate the model's decision-making process, which improves the transparency and reliability of the predictions. Finally, a physical consistency analysis method based on Legendre basis functions is proposed to systematically verify the model's physical consistency and interpretability under perturbations of key process parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1260-1281"},"PeriodicalIF":6.1,"publicationDate":"2025-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605991","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":"Accelerating design for additive manufacturing: Experimental investigation and theoretical assessment on microstructure evolution of Al-Yb alloy","authors":"Yihao Wang ,&nbsp;Lei Hu ,&nbsp;Yang Li ,&nbsp;Zeyu Bian ,&nbsp;Mingliang Wang ,&nbsp;Zhe Chen ,&nbsp;Haowei Wang","doi":"10.1016/j.jmapro.2025.07.031","DOIUrl":"10.1016/j.jmapro.2025.07.031","url":null,"abstract":"<div><div>Eutectic systems are widely used in additive manufacturing to suppress hot tearing, despite their unsatisfactory mechanical properties. The Al-Yb system demonstrates exceptional potential for high-strength aluminum alloys due to its coherent eutectic/matrix interface and superior age-hardening response. Given the paucity of systematic investigations in Al-Yb system, a detailed investigation of its microstructure under rapid solidification is crucial for accelerating its development. This investigation systematically evaluates the potential microstructure of the compositional-process space via single-track laser remelting experiments. By optimizing the phase-competitive growth model based on non-linear phase diagram, the eutectic coupling zone and the morphology of primary Al and eutectic structure are quantitatively discussed using the experimental results as inputs and corrections. During the process, a new divorced eutectic criterion is proposed by coupling the dendrite and eutectic growth models, suggesting that eutectic Al grows epitaxially on primary Al and the eutectic Al₃Yb phase exhibits complete segregation when the intercellular spacing is equal to the eutectic lamellar spacing. These discoveries are comprehensively mapped within a three-dimensional composition-growth velocity-temperature gradient (<em>C</em>_<em>0</em><em>-V-G</em>) microstructural selection framework. The proposed methodology provides transformative insights for accelerating alloy development cycles through computational-experimental co-optimization of composition and processing parameters in Al-Yb systems.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 75-88"},"PeriodicalIF":6.1,"publicationDate":"2025-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604609","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":"Theoretical and experimental analysis of temperature distribution in variable-depth reciprocating grinding process","authors":"Yuanqiang Luo,&nbsp;Weihua Liao,&nbsp;Weidong Tang,&nbsp;Xiaoran Wang,&nbsp;Cong Mao,&nbsp;Mingjun Zhang,&nbsp;Kun Tang,&nbsp;Wentao Wang,&nbsp;Bo Cheng,&nbsp;Abdur Razzak","doi":"10.1016/j.jmapro.2025.07.014","DOIUrl":"10.1016/j.jmapro.2025.07.014","url":null,"abstract":"<div><div>Grinding is widely utilized in minimally invasive surgery due to its handleability and high precision. However, the substantial heat generated during the grinding process can lead to localized temperature increases, which cause thermal damage to surrounding healthy tissues. This study investigates the temperature distribution in the variable-depth reciprocating grinding process by developing a heat flux density model for the spatially irregular grinding contact surface. A User Defined Function (UDF) subroutine was developed to numerically simulate temperature distribution based on this heat flux density model. To validate the model, bone grinding experiments were conducted under various spindle speeds and cutting depths, with temperature measurements taken from the bone. The simulation results demonstrated high accuracy in experimental temperatures. Additionally, numerical simulations were performed to visualize the thermal damage range during bone grinding. The findings indicate that, under specific grinding conditions—such as a cutting depth of 0.2 mm at 10,000 rpm and 0.1 mm at 30,000 rpm—the thermal damage depth is relatively shallow, measuring only 0.07 mm. These results provide valuable insights for orthopedic surgeons regarding the influence of grinding parameters on bone temperature and establish a solid foundation for selecting optimal grinding parameters in orthopedic robotic systems for clinical applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 89-102"},"PeriodicalIF":6.1,"publicationDate":"2025-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604610","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":"EMPR equipment development and research on EMPR process of titanium threaded hollow rivets","authors":"Mengchen Yu ,&nbsp;Xiao Lin ,&nbsp;Lu Yan ,&nbsp;Minghao Zhang ,&nbsp;Zengqiang Cao ,&nbsp;Lubin Huo","doi":"10.1016/j.jmapro.2025.06.099","DOIUrl":"10.1016/j.jmapro.2025.06.099","url":null,"abstract":"<div><div>To prevent the occurrence of substandard riveting, a handheld electromagnetic pull riveting (EMPR) device is developed based on electromagnetic technology for riveting titanium or titanium alloy rivets in closed/semi-closed structures to achieve high consistency connection quality. Installation process experiments were conducted using the device at different riveting voltages to get the forming conditions of titanium threaded hollow rivets, and the voltage range for forming without riveting defects using flat anvil and right-angle anvil riveting was obtained. Finally, through numerical simulation with ABAQUS and in conjunction with the riveting force waveform obtained through tests, the stress field distribution inside the rivet, and the failure risk area, the relationship between riveting voltage and riveting quality is established. The forming process of the rivet and the reasons for head failure and fracture during the forming process were analyzed. The results indicate that the numerical simulation results correspond well with the experimental results. The device has excellent riveting consistency, just like other types of electromagnetic riveting equipment, and can achieve high-quality single-direction forming in both conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1228-1240"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596955","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":"Chatter-free process parameter optimization for robotic machining of pockets with the spiral tool path","authors":"Tengyu Hou,&nbsp;Yang Lei,&nbsp;Ye Ding","doi":"10.1016/j.jmapro.2025.07.018","DOIUrl":"10.1016/j.jmapro.2025.07.018","url":null,"abstract":"<div><div>Pocket machining is widely used in manufacturing industries such as aerospace, mold, and automotive. Pocket machining with the spiral tool path has become an effective method for efficient pocket machining. The current primary means of pocket machining, CNC machine tools, face challenges in adaptability, machining mode, and production cost, while industrial robots provide a new approach to achieving efficient and cost-effective pocket machining. However, as industrial robots are less rigid than machine tools, they are more prone to chatter vibrations. To achieve efficient and stable robotic machining of pockets with the spiral tool path, this paper proposes a new chatter-free process parameter optimization strategy. The feedrate optimization algorithm for pocket machining is first introduced. Further, this algorithm is extended to establish the chatter-free parameter optimization model for robotic machining of pockets with kinematics, cutting force, and milling stability constraints. The surrogate-based optimization (SBO) method is then employed to solve this optimization model efficiently. The effectiveness of the proposed chatter-free parameter optimization strategy for robotic machining of pockets is validated by analyzing optimization results and machining experiments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1241-1259"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596956","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":"Continuously layer-by-layer assembled multilayer coating to achieve excellent tribological properties and electrical contact stability","authors":"Dao-Yi Wu,&nbsp;Xue Zhou,&nbsp;Guo-Fu Zhai","doi":"10.1016/j.jmapro.2025.07.037","DOIUrl":"10.1016/j.jmapro.2025.07.037","url":null,"abstract":"<div><div>Balance between mechanical properties and electrical contact stability is one of the most important challenges in the field of electrical contact. In this study, multilayer coatings were designed based on alternating soft/hard layer strategy using magnetron sputtering technology. The main intention was to investigate the effect of the alternating structure of soft and hard layers on the mechanical, tribological properties and electrical contact behavior of multilayer coatings. The results demonstrated that as the number of heterogeneous interfaces in the multilayer coating increases, the hardness and yield strength raised to 5.1 GPa and 875 MPa, respectively, while the contact resistance was only 5.3 mΩ at a low contact force of 10 gf. The as-obtained multilayer coating maintained good structural integrity after 3000 wearing cycles at an ultra-high contact force of 8 N. The superior wear resistance is attributed to the high-density heterogeneous interfaces which served as a barrier to stress distribution, inhibiting the propagation of deformation carriers, shear bands and dislocations, thereby achieving an outstanding wear resistance. This finding provides a novel design strategy for developing high-quality coating.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 66-74"},"PeriodicalIF":6.1,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604815","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":"Impurity-induced phase transformations in AlMgZn(Cu) crossover alloys: Pathways to enhance recycling content and processability","authors":"Sebastian Samberger ,&nbsp;Irmgard Weißensteiner ,&nbsp;Matheus A. Tunes ,&nbsp;Lukas Stemper ,&nbsp;Christina Kainz ,&nbsp;Roland Morak ,&nbsp;Peter J. Uggowitzer ,&nbsp;Stefan Pogatscher","doi":"10.1016/j.jmapro.2025.06.106","DOIUrl":"10.1016/j.jmapro.2025.06.106","url":null,"abstract":"<div><div>Aluminum crossover alloys offer a broad property profile within a single composition, but due to the growing demand for recycling in the aluminium industry, they will be required to mitigate the impact of tramp elements such as Fe and Si. This study investigates the influence of Fe/Si ratios and cooling rates during solidification on phase transformations and microstructure evolution in AlMgZn(Cu) crossover alloys, aiming to increase recycling content and maintain processability. Thermodynamic simulations, coupled with experimental validation, reveal two critical phase transformations during homogenization: the 6-to-3 transformation (Al₆(Fe,Mn) → Al₁₃(Fe,Mn)₄) and the 6-to-α transformation (Al₆(Fe,Mn) → Al(Fe,Mn)Si). These transformations are governed by the Fe/Si ratio and cooling rate, significantly affecting intermetallic phase morphology. The 6-to-3 transformation can effectively decrease the size of intermetallic particles, facilitating processability in relevant industrial conditions. Higher cooling rates upon solidification (≈60 K/s) always result in small, spheroidized phases, ensuring rollability. In contrast, slow cooling rates (≤1 K/s) often promote coarse, stable phases that hinder processability. However, at cooling rates around 3 K/s the intermetallic phase morphology highly depends on the Fe/Si ratio. When Fe and Si levels are simultaneously high, the 6-to-α transformation yields hard-shell/soft-core structures that impair mechanical integrity, while a higher ratio governs a beneficial 6-to-3 transformation. This study provides new insights into impurity-induced phase transformations and their role in determining processability in industrially relevant conditions. By linking microstructural control to sustainable alloy design, the results serve as a foundation for the development of crossover aluminum alloys optimized for high scrap content.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1178-1193"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144588668","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}