Journal of Manufacturing Processes最新文献_第4页

Synergistic strengthening mechanism of zirconia-reinforced alumina ceramics through additive manufacturing and sintering 氧化锆增强氧化铝陶瓷增材制造和烧结的协同强化机理

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-17 DOI: 10.1016/j.jmapro.2025.04.045

M. Irfan Hussain , Min Xia , Changchun Ge , Zhen Shen , Zhangwei Chen

{"title":"Synergistic strengthening mechanism of zirconia-reinforced alumina ceramics through additive manufacturing and sintering","authors":"M. Irfan Hussain , Min Xia , Changchun Ge , Zhen Shen , Zhangwei Chen","doi":"10.1016/j.jmapro.2025.04.045","DOIUrl":"10.1016/j.jmapro.2025.04.045","url":null,"abstract":"<div><div>Fabricating high-strength ceramics with high precision intricate shapes from photosensitive ceramic slurry is an exciting yet challenging due to limited control over sub-grain structures, performance and sustainable manufacturing. Herein, to address these issues, a high solid content 50 vol% zirconia-reinforced alumina (ZRA) ceramic suspension with printable built-in functionality is proposed, enabling customizable target recognition, and enhanced flexural strength performance. Using stereolithography 3D printing with an optimized low shear rate suspension, precise printing control over tuned physical properties, morphology engineered structures and significantly enhanced performance with different holding time were obtained. With the ZrO<sub>2</sub> reinforcement strategy, this study not only demonstrates high flexural strength and hardness but also minimization of shrinkage. After sintering at 1550 °C for 6 h, the density reached a maximum of 98.7 % with shrinkage 7.57 % along the XY direction and 16.33 % along Z direction. Remarkably, the sintered ZRA ceramic exhibited a flexural strength of 371.8 ± 5 MPa, Vickers hardness of 1198. 2 ± 1.6 HV, and compressive strength of 33.54 MPa. Microscopic and tomographic analysis revealed a two-phase microstructural nature that enhances toughness and promotes good distribution. Benchmark strength is enhanced because of the improved interfacial bonding and fine-grained structure, which is the most dominant contributor to the mechanical properties. The findings set a guideline for high strength property-structure relationship of DLP-3D printed alumina reinforced composites in the field of advanced ceramic industry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 227-242"},"PeriodicalIF":6.1,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143839240","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

A 3D preform design method based on a generative artificial intelligence algorithm 一种基于生成式人工智能算法的三维预制件设计方法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-16 DOI: 10.1016/j.jmapro.2025.04.013

Donghwi Park, Joonhee Park, Naksoo Kim

{"title":"A 3D preform design method based on a generative artificial intelligence algorithm","authors":"Donghwi Park, Joonhee Park, Naksoo Kim","doi":"10.1016/j.jmapro.2025.04.013","DOIUrl":"10.1016/j.jmapro.2025.04.013","url":null,"abstract":"<div><div>This study introduces a novel 3D preform design method that leverages generative artificial intelligence to optimise complex forging geometries. The 3D preform shape is simplified by expressing it in a two-dimensional manner based on the geometric features of the forged shape. A beta-variational autoencoder (<span><math><mi>β</mi></math></span>-VAE) serves as the generative model, paired with a surrogate model using deep neural networks (DNN) to explore and optimise preform geometries efficiently. The initial training dataset for the generative model is created using isosurfaces derived from Laplace’s equation. A multi-objective optimisation framework is developed to minimise forging load and flash volume and mitigate underfill and lap defects. Preforms were designed using this method and validated through forging experiments on two target geometries: a brake calliper and an electric vehicle (EV) manifold. The forging results of the optimised preforms were compared with traditional isosurface methods, demonstrating that the proposed method reduces forging load and flash volume while preventing underfill and lap defects. This integrated approach combines advanced computational techniques with practical validation, offering a systematic and adaptable solution for the challenges associated with 3D preform design in forging processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 190-208"},"PeriodicalIF":6.1,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834739","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

Application of novel soft solid lubricant coatings on turning tools for sustainable and high-performance machining of INC 718 alloy: A new efficient fluid-free method 新型软固体润滑涂层在车刀上的应用，以实现INC 718合金的可持续和高性能加工：一种新的高效无流体方法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-16 DOI: 10.1016/j.jmapro.2025.04.017

Javad Hashemi Khosrowshahi, Maryam Aramesh

{"title":"Application of novel soft solid lubricant coatings on turning tools for sustainable and high-performance machining of INC 718 alloy: A new efficient fluid-free method","authors":"Javad Hashemi Khosrowshahi, Maryam Aramesh","doi":"10.1016/j.jmapro.2025.04.017","DOIUrl":"10.1016/j.jmapro.2025.04.017","url":null,"abstract":"<div><div>This study introduces the application of a novel class of soft solid metallic lubricant coatings on hard-coated cutting tools to enable high-performance, fluid-free machining of Inconel 718. By employing a novel in-situ coating technique, the Al-Si lubricant coating was applied to commercially available AlTiN-coated tools within a CNC machine in just seconds. The Al-Si-coated tools demonstrated significantly improved performance in dry machining compared to conventional wet and dry methods. The deposition of a top layer of Al-Si on AlTiN-coated tools resulted in significantly lower cutting forces and enhanced tool life compared to both dry and wet machining conditions, achieving a 64 % increase in tool life over dry conditions. Analysis of worn tools via FIB-SEM revealed that the Al-Si coating preserved the underlying AlTiN layer, which was otherwise depleted under harsh dry conditions. Surface analysis also revealed considerably improved surface integrity compared to wet and dry machining with TiAlN tools, with the Al-Si layer reducing surface defects and minimizing machining-induced microstructural changes. EBSD analysis demonstrated less microstructural deformation and misorientation in the workpiece, indicating better preservation of material properties. This innovative coating approach not only enhances tool performance and durability but also supports sustainable machining by eliminating the need for fluid-based lubricants, reducing waste, and minimizing environmental impact. Overall, the findings support the effectiveness of the Al-Si coating in facilitating the dry machining of challenging materials like Inconel 718, offering a new solution for reducing waste and promoting more sustainable machining practices.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 387-398"},"PeriodicalIF":6.1,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834037","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

Enhanced support structures in conformal additive manufacturing for improved geometric accuracy 增强了保形增材制造中的支撑结构，提高了几何精度

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-16 DOI: 10.1016/j.jmapro.2025.04.005

Emre Günaydın, Erkan Gunpinar

引用次数: 0

Additive manufacturing of continuous fiber reinforced polymer composites: Process planning and intelligent control 连续纤维增强聚合物复合材料的增材制造：工艺规划与智能控制

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-16 DOI: 10.1016/j.jmapro.2025.04.015

Donghua Zhao, Xinmeng Zha, Limin Zhou, Yi Xiong

{"title":"Additive manufacturing of continuous fiber reinforced polymer composites: Process planning and intelligent control","authors":"Donghua Zhao, Xinmeng Zha, Limin Zhou, Yi Xiong","doi":"10.1016/j.jmapro.2025.04.015","DOIUrl":"10.1016/j.jmapro.2025.04.015","url":null,"abstract":"<div><div>In the evolving additive manufacturing (AM) field, fiber-reinforced composites—particularly those with continuous fibers—are recognized for their superior mechanical properties. However, Continuous Fiber-Reinforced Polymer Composites (CFRPCs) produced via Material Extrusion (MEX) often exhibit limited structural complexity, restricting their performance potential. This limitation arises primarily from significant challenges in process planning, including fragmentation from intricate design features, excessive cutting points caused by complex geometries, disrupted fiber continuity from fiber cutting, and unfavorable fiber orientation due to sharp contours. This study reviews the process planning and control strategies for CFRPCs-MEX, focusing on overcoming manufacturing constraints and addressing the research gap in slicing and path planning. Initially, CFRPCs-MEX is introduced, highlighting the importance of process planning in mitigating these challenges. Key constraints are identified and categorized, including fiber orientation, continuity, warpage, bonding, and quality-related challenges, followed by a discussion of their impacts on the printing process. This review systematically presents strategies for optimizing dimensional accuracy, enhancing mechanical properties, and enabling multifunctional design. Furthermore, applications, challenges, and emerging trends are explored, including advances in slicing software, multi-axis system planning, AI-enhanced strategies, and process monitoring and control. This review advances process planning techniques by addressing these challenges, paving the way for more efficient, cost-effective, and intelligent production in the CFRPCs-MEX industry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 170-189"},"PeriodicalIF":6.1,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834738","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

Fundamental research on fatigue-resistant and low-stress welding repair technology through arc composite laser shock forging 电弧复合激光冲击锻造抗疲劳低应力焊接修复技术的基础研究

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-16 DOI: 10.1016/j.jmapro.2025.04.028

Chao Dai , Cailiang Zhang , Yuanqing Chi , Yong Chen , Zhijie Zhou , Yongkang Zhang , Ronghua Zhu

{"title":"Fundamental research on fatigue-resistant and low-stress welding repair technology through arc composite laser shock forging","authors":"Chao Dai , Cailiang Zhang , Yuanqing Chi , Yong Chen , Zhijie Zhou , Yongkang Zhang , Ronghua Zhu","doi":"10.1016/j.jmapro.2025.04.028","DOIUrl":"10.1016/j.jmapro.2025.04.028","url":null,"abstract":"<div><div>In order to reduce residual stresses during the repair process of fatigue damage, enhance repair quality, and improve fatigue life, this study introduces a novel in-situ repair technology called arc composite laser shock forging technology (Weld-LSF). The paper establishes a transient thermo-mechanical coupled model for Weld-LSF based on the finite element method. It analyzes the thermomechanical behavior of a circular tube during the Weld-LSF process. The research findings demonstrate that Weld-LSF technology can effectively improve the residual stress field in the repaired layer, with the peak tensile residual stress in the weld seam decreasing from 510 MPa to 417 MPa following Weld-LSF treatment. Furthermore, fatigue tensile tests on welded components produced by different repair methods demonstrate that the average fatigue cycle number for arc-welded (AW) components is 129,033 cycles, whereas for components treated with Weld-LSF, the average fatigue cycle number is 250,233 cycles, indicating a 93.9 % increase in fatigue life. This study delves into the impact of Weld-LSF technology on residual stress and fatigue life of the repaired layer, thereby providing a theoretical foundation for the application of Weld-LSF technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 399-410"},"PeriodicalIF":6.1,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834038","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

A coupled CPFEM-CA-based method for predicting single crystal superalloy machining-induced static surface recrystallization depth 基于cpfem - ca耦合的单晶高温合金加工诱导静态表面再结晶深度预测方法

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-15 DOI: 10.1016/j.jmapro.2025.04.020

Mingjun Liu , Xinpeng Zu , Yadong Gong , Liya Jin , Yao Sun , Jingyu Sun , Weijian Zhang , Jibin Zhao

{"title":"A coupled CPFEM-CA-based method for predicting single crystal superalloy machining-induced static surface recrystallization depth","authors":"Mingjun Liu , Xinpeng Zu , Yadong Gong , Liya Jin , Yao Sun , Jingyu Sun , Weijian Zhang , Jibin Zhao","doi":"10.1016/j.jmapro.2025.04.020","DOIUrl":"10.1016/j.jmapro.2025.04.020","url":null,"abstract":"<div><div>The aeroengine, the heart of the aircraft power system, is revered as the crown jewel of the aviation industry. As the material for aeroengine turbine blades, nickel-based single crystal (SX) superalloy leverages its single grain structure which is free from grain boundary defects, to enhance the aeroengine's power performance. During the manufacturing process of SX blades, the plastic deformation in machining process induces static surface recrystallization in high-temperature environment, accelerating fatigue crack propagation during service. Unfortunately, there is a lack of non-destructive methods for measuring or predicting the machining-induced recrystallization layer depth. In this paper, a simulation method based on the coupled crystal plasticity finite element and cellular automata (CPFEM-CA) approaches is proposed to predict the recrystallization layer depth in SX superalloys. The average error of the proposed method is 17.7 %. To the best of our knowledge, this method is the first to address the absence of SX superalloy machining-induced surface recrystallization non-destructive measurement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"144 ","pages":"Pages 136-156"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143834784","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

Asymmetric pore distribution in PBF-LB/M In718 thin-walled structures: Contour morphology and welding quality PBF-LB/M In718薄壁结构的不对称孔分布：轮廓形貌与焊接质量

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-15 DOI: 10.1016/j.jmapro.2025.04.030

Kai Zhou , Deqiao Xie , Zansong Li , Dongsheng Wang , Lida Shen

{"title":"Asymmetric pore distribution in PBF-LB/M In718 thin-walled structures: Contour morphology and welding quality","authors":"Kai Zhou , Deqiao Xie , Zansong Li , Dongsheng Wang , Lida Shen","doi":"10.1016/j.jmapro.2025.04.030","DOIUrl":"10.1016/j.jmapro.2025.04.030","url":null,"abstract":"<div><div>Current research on In718 alloys produced by powder bed fusion-laser beam metals (PBF-LB/M) is mainly focused on the deformation challenges, while porosity has received less attention. This study focused on the porosity of the sub-surface of printed components, which is influenced by thickness, and the need to optimize the contour space to improve the print quality of thin-walled structures. The results illustrated that when the contour space was bigger than 0.04 mm, an asymmetry of contour melt tracks inevitably appeared for thin-walled structures, regardless of the placement angle. It was also found that asymmetric contour melt tracks were caused by the asymmetric hump effect of internal melt tracks. A localized collapse of one side of the internal melt tracks can cause breakage of the contour melt tracks. This is due to the lack of liquid metal at that location during contour melt track formation. Meanwhile, the contour melt track on the opposite side remains mostly undamaged. These broken contour melt tracks could cause asymmetric pore defects during the deposition process. Computational Fluid Dynamics (CFD) simulations were used to validate the contour scanning process. The results showed that a 0.04 mm contour space could significantly reduce the one-sided hump of the internal melt tracks and form a plump contour melt track, which would reduce the problem of local overthickness in the subsequent powder layer during powder spreading processes, thereby reducing the lack of fusion. This research provided valuable theoretical insights and practical guidance for optimizing the PBF-LB/M process for thin-walled In718 parts, with significant implications for engineering applications and academic innovation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 294-305"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829042","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

New cooling system with hollow mandrel in cold pilgering 新型空心芯棒冷镦冷却系统

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-15 DOI: 10.1016/j.jmapro.2025.04.033

Hideaki Abe

{"title":"New cooling system with hollow mandrel in cold pilgering","authors":"Hideaki Abe","doi":"10.1016/j.jmapro.2025.04.033","DOIUrl":"10.1016/j.jmapro.2025.04.033","url":null,"abstract":"<div><div>In cold pilgering, tube lubrication is critical to obtaining a high surface quality of the finished tube, long tool life, and high productivity, and addressing environmental concerns. To enhance lubrication, a new cooling system for the working tool was studied. The thermal balance between the heat generated and that removed during working was investigated, which is important for cooling the mandrel. The cooling system with a hollow mandrel and a coolant for the inner surface, which should have mechanical integrity and good cooling performance, is presented. The inner dimensions of the hollow mandrel were determined on the basis of mechanics of materials to prevent fissures on its inner surface. A fully developed turbulent flow in the inner coolant can remove the heat from the mandrel. The design procedure for the cooling system is described, including the determination of parameters, mechanical calculation, the calculation of heat transfer, and the determination of optimal designs. The mechanical integrity of the hollow mandrel was investigated by the finite element analysis of stress. The heat generated was calculated on the basis of the plastic deformation theory and the kinetics of cold pilgering, and heat transfer was calculated on the basis of the thermal conduction of the mandrel as well as the thermal convection of the inner coolant. The design results for a type 304 stainless steel tube indicated the feasibility of cold pilgering at mandrel temperatures below 100 °C. These findings indicate that the cooling system can be installed inside the tube for cold pilgering.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"143 ","pages":"Pages 335-350"},"PeriodicalIF":6.1,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829115","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

Coarse-grained molecular dynamics modelling of lithium-ion battery electrode drying: A sensitivity analysis 锂离子电池电极干燥的粗粒度分子动力学建模：灵敏度分析

IF 6.1 1区工程技术

Journal of Manufacturing Processes Pub Date : 2025-04-15 DOI: 10.1016/j.jmapro.2025.03.117

Xinxin Yao , Hasnain Hafiz , Lei Chen , Wayne Cai , Zirui Mao , Shenyang Hu

引用次数: 0