Journal of Manufacturing Processes最新文献

{"title":"Effect of shielding gas on keyhole stability and pores in laser-CMT hybrid welding of ultra-high strength steel","authors":"Yuhui Zhang ,&nbsp;Cong Chen ,&nbsp;Changjian Wang ,&nbsp;Ran Xiong ,&nbsp;Ke Zhang","doi":"10.1016/j.jmapro.2024.11.042","DOIUrl":"10.1016/j.jmapro.2024.11.042","url":null,"abstract":"<div><div>Laser-CMT hybrid welding (LCHW) is a highly efficient and high-quality welding technique, showing promise for welding ultra-high strength steel (UHSS) in the aerospace industry. However, the presence of pores significantly limits its application in this field. It has been observed that using an argon-rich gas can effectively stabilize the keyhole and prevent the formation of pores. Therefore, this study aims to investigate the effect of different shielding gases on keyhole stability and porosity. The weld profile, pores, electrical signal, droplet transfer, and molten pool internal flow were carefully characterized and compared with various shielding gases. The results show that increasing the CO₂ content gradually reduces weld porosity. The optimal weld formation and porosity were achieved at a CO₂ content of 25 %. With the CO₂ content increases, the droplets shift from off-axis upwards to downwards. This shift increases the distance between the droplet and the keyhole, reducing the time for droplet growth and promoting droplet transfer. Furthermore, the surface tension pressure gradually decreases from 3.86 Kpa to 1.1 Kpa, and at Ar + 25 % CO₂, itpromote the opening of keyhole and further suppress the formation of the protrusion on the keyhole rear wall. In addition, when the CO₂ content reaches 25 %, the top metal of the molten pool changes from counterclockwise flow to clockwise flow, reducing the likelihood of keyhole collapse. These effects stabilize the keyhole and suppress the formation of pores.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 948-962"},"PeriodicalIF":6.1,"publicationDate":"2024-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142706001","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":"Formation of functionally graded steel by laser powder bed fusion via in-situ carbon doping","authors":"McKay G. Sperry ,&nbsp;Tracy W. Nelson ,&nbsp;Nathan B. Crane","doi":"10.1016/j.jmapro.2024.11.015","DOIUrl":"10.1016/j.jmapro.2024.11.015","url":null,"abstract":"<div><div>Additive Manufacturing (AM) enables functional integration by combining multiple components into a single part to shorten assembly time, reduce weight, and improve performance. Laser Powder Bed Fusion (LPBF) is an important AM method due to excellent spatial resolution, surface finish, and material properties without the need for extensive post-processing. Functional integration could be enhanced by spatial tuning of properties, but LPBF cannot readily vary material composition. This paper addresses a method to add spatial composition control by printing small quantities of dopants via liquid carrier prior to laser fusion. The impact of carbon black suspension added to select regions of a Stainless Steel 316 L powder bed on melt pool dimension, hardness, and porosity is reported. The distribution of the carbon between the doped and plain layers and the resulting spatial variation in hardness is measured. Optical microscopy and composition analysis show that the carbon dispersed uniformly within the layer of deposition and diffused as little as 50 μm in the build direction. Keyhole conditions dramatically increase the inter-layer transport of the dopant. The added carbon increased hardness by &gt;50 %. Porosity increased in doped regions but remained below 1.5 % for the best processing parameters. These results demonstrate that the composition of LPBF parts could be controlled in 3-dimensions using a dopant that is soluble in the melt pool. Additional work will be required to evaluate different dopant materials and optimize processing conditions for full density, but microalloying with soluble dopants appears to be a plausible solution to enhance functional integration with LPBF.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 878-890"},"PeriodicalIF":6.1,"publicationDate":"2024-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705545","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 the superplastic deformation capabilities of the Ti-6Al-4V alloy using superimposed oscillations","authors":"Zackary Fuerth ,&nbsp;Mohammad Shirinzadeh Dastgiri ,&nbsp;Daniel Green ,&nbsp;Eugene Ryzer ,&nbsp;William Altenhof","doi":"10.1016/j.jmapro.2024.11.025","DOIUrl":"10.1016/j.jmapro.2024.11.025","url":null,"abstract":"<div><div>This study investigates the effect of imposing low frequency, low amplitude oscillations during uniaxial tensile tests on the mechanical behaviour of the Ti-6Al-4V alloy under a typical superplastic temperature of 900 °C. Different material models were used to simulate these tests with the finite element software ABAQUS. A creep strain power model fit through an iterative FEA process yielded a high correlation to the force/displacement and thinning results from uniaxial tensile tests. The developed material models with and without oscillation materials were also used to simulate a free-bulge forming process within the strain rate range of 0.0003 to 0.01 s⁻¹ under constant strain rate testing. Within the domain of the parts formed in this study, the improvement in the forming time ranged from a 120 % reduction at elevated strain rates and reduced part complexity to 520 % in the most complex part geometry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 863-877"},"PeriodicalIF":6.1,"publicationDate":"2024-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705544","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":"Effect of laser powder bed fusion gas flow rate on microstructure and mechanical properties of 316 L stainless steel","authors":"Chen Qingpeng ,&nbsp;Yu Jiachen ,&nbsp;Lu Xiangyu ,&nbsp;Yang Zihan ,&nbsp;Zhang Guoqing ,&nbsp;Dong Fang ,&nbsp;Sheng Liu","doi":"10.1016/j.jmapro.2024.11.024","DOIUrl":"10.1016/j.jmapro.2024.11.024","url":null,"abstract":"<div><div>The inert protective gas flow rate during laser powder bed fusion (LPBF) molding is an important environmental condition. The protective gas not only prevents parts from being oxidizing, but also significantly affects spatter particle removal and particle migration on the powder bed surface. There are relatively few systematic comparative studies reported on the effect of gas flow rate on the movement of two types of powders. Therefore, in this study, three flow rate environments, low, medium and high, were designed for multi-scale experimental analysis of the quality, microstructure, mechanical properties and defects of molded samples. It was observed that the movement of the powder that dominated the sample defects was different in the three environments as the gas flow velocity was adjusted. Under low flow conditions, spatter particles are the main contributor to the creation of defects such as porosity, resulting in poor surface quality (TOP: Sq = 14.023, Side: Sq = 22.006), elevated surface oxygen content (Wt. = 1.7 %), increased grain size, and i a higher number of pores and spatter particles. Consequently, this led to the lowest density, microhardness, and mechanical properties among the three sample groups. High flow rates increased the removal of spatter particles compared to low flow rates, resulting in the highest surface quality (top: Sq = 11.528, Side: Sq = 14.051) and the lowest surface oxygen content (Wt. = 0.88 %). However, under the influence of high flow rates, surface particle migration becomes an important factor in defects, leading to an increase in grain size, porosity, and unfused particles compared to medium flow rates. This leads to a decrease in density, microhardness and elongation. This study reveals, through multi-scale experimental characterization, the mechanism by which varying air flow rates affect powder movement, and hence the microstructure and properties of parts. These findings provide new insights for device development and coupled multi-physics field computational studies.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 850-862"},"PeriodicalIF":6.1,"publicationDate":"2024-11-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705334","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":"A comparative study on machinability of ceramics with different mechanical properties in diamond wire sawing","authors":"Jun-yong Zeng ,&nbsp;Feng-lin Zhang ,&nbsp;Chuang-jie Zheng ,&nbsp;Kai-jiang Li ,&nbsp;Yu-mei Zhou ,&nbsp;Shang-hua Wu ,&nbsp;Yanjun Lu","doi":"10.1016/j.jmapro.2024.11.030","DOIUrl":"10.1016/j.jmapro.2024.11.030","url":null,"abstract":"<div><div>Ceramics thin substrates are widely used in electronic devices due to their excellent physical and mechanical properties. Diamond wire sawing is one of promising manufacturing route to prepare thin ceramic substrates from sintered ceramics block. In present paper, a comparative study on diamond wire sawing of Al₂O₃, AlN, ZrO₂ and Si₃N₄ ceramics was carried out. The material removal rate (MRR), wire sawing force and surface integrity of different ceramics as well as the wear characteristics of diamond wire were examined. A finite element model (FEM) for the single-grain cutting of different ceramic materials was developed to elucidate the influence of the mechanical properties of these ceramics on both surface morphology and the cutting force. The results show that mechanical properties of ceramic materials have great influence on diamond wire sawing performance. The Al₂O₃ and AlN with lower fracture toughness exhibit better machinability than that of ZrO₂ and Si₃N₄. AlN has the highest MRR (0.128 mm³/min) and the smallest tangential sawing force (0.0255 N), while Si₃N₄ presents the lowest MRR (0.101 mm³/min) and ZrO₂ owns the largest wire sawing force (0.238 N) under wire speed of 1.3 m/s. For the sawn surface of ceramics, Si₃N₄ shows the lowest surface roughness (Ra 0.23 μm), followed by ZrO₂ (Ra 0.44 μm) and AlN (Ra 0.57 μm), while Al₂O₃ exhibits the highest surface roughness (Ra 0.62 μm). In sawing of ZrO₂ and Si₃N₄, the electroplated diamond grits tend to flatten or fall-off, producing severer wear of diamond wire than that of Al₂O₃ and AlN, and deteriorating the sawing capability of the diamond wire.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 837-849"},"PeriodicalIF":6.1,"publicationDate":"2024-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705339","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":"Surface modification by γ-electrochemical selective dissolution for improving nickel-based superalloy machinability","authors":"Xiaolin Shi,&nbsp;Xiaoguang Guo,&nbsp;Lin Niu,&nbsp;Renke Kang,&nbsp;Zhigang Dong","doi":"10.1016/j.jmapro.2024.11.017","DOIUrl":"10.1016/j.jmapro.2024.11.017","url":null,"abstract":"<div><div>A strategy to adjust mechanical properties and improve machinability of nickel-based superalloys by γ-electrochemical selective dissolution surface modification was proposed in this paper. Firstly, a new γ-electrochemical selective dissolution process using NaNO₃ electrolyte was developed through theoretical and experimental analyses. Then, the surface modification effect and mechanism of the new γ-electrochemical selective dissolution process were investigated. The results showed that during the γ-electrochemical selective dissolution process, γ' in nickel-based superalloy remained undissolved due to its stable protective film riched in Al₂O₃ and Al(OH)₃, while γ dissolved due to the broken of its protective film riched in Cr₂O₃ and Cr(OH)₃. The dissolution of γ caused the nickel-based superalloy surface layer to be modified into a porous structural layer, resulting in an effective reduction of material microhardness. Finally, the effect of γ-electrochemical selective dissolution surface modification on material machinability was studied by milling experiments. The results demonstrated that the γ-electrochemical selective dissolution surface modification can significantly reduce both cutting force and tool wear. The proposed γ-electrochemical selective dissolution surface modification strategy may have promising application prospects in the high-efficiency manufacturing of nickel-based superalloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 802-810"},"PeriodicalIF":6.1,"publicationDate":"2024-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705336","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":"Innovative insight for microstructural regulation of intermetallic compounds in Ti/Al dissimilar alloy laser welding: Micro-surface texturing via pulsed laser pretreatment","authors":"Jintian Zhao,&nbsp;Boan Xu,&nbsp;Ping Jiang,&nbsp;Minjie Song,&nbsp;Shaoning Geng","doi":"10.1016/j.jmapro.2024.10.052","DOIUrl":"10.1016/j.jmapro.2024.10.052","url":null,"abstract":"<div><div>The welding of dissimilar Ti/Al hybrid structures is recognized as a critical technology for the high-performance/lightweight fabrication of aerospace and high-speed transportation components. Laser brazing welding, a recognized method for Ti/Al joining, is challenged by the formation of brittle intermetallic compounds (IMCs), which significantly compromises joint mechanical. Herein, pulsed laser pretreatment (PLP) is employed to butt surface, effectuating a 40 % enhancement in tensile strength of Ti/Al dissimilar joint under laser brazing welding. The influence of PLP on evolution of IMCs is comprehensively understood by numerical simulation. PLP induces a turbulent flow at Ti/Al interface and enhances thermal diffusion on Ti side, resulting in alternating distribution and diverse crystallographic orientations of IMCs with an average thickness reduced to 2 μm. Thereupon, the fundamental relationship between IMCs structure and mechanical performance is illuminated by exploring joint fracture failure behavior. PLP promotes the stochastic distribution of Ti₃Al, curbing the cracking of brittle phase and its interfaces within IMCs layer, diverting crack propagation paths and markedly reducing extension rates, thereby effectively enhancing tensile strength. This article heralds a considerable advance in understanding the formation and fracture of IMCs for Ti/Al system. It further furnishes novel and unique insights into the improvement strategies for mechanical properties of Ti/Al dissimilar joint, based on surface texture “Riveting” and IMCs structure “Pinning”.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 824-836"},"PeriodicalIF":6.1,"publicationDate":"2024-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705337","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":"Electrode-embedded linear actuating enhanced resistance spot welding of aluminium alloy and dual phase steel","authors":"Chao Ding,&nbsp;Jun Xiao,&nbsp;Shengnan Gai,&nbsp;Shujun Chen","doi":"10.1016/j.jmapro.2024.11.038","DOIUrl":"10.1016/j.jmapro.2024.11.038","url":null,"abstract":"<div><div>Resistance spot welding (RSW) of aluminium/steel dissimilar materials has important application prospects in industries such as automobiles. However, the relatively poor mechanical properties of the welds due to the issue of brittle intermetallic compounds (IMCs) at the welding interface has been the major concerned by the welding community. A novel modified RSW process that utilizes relatively high-frequency linear actuator embedded in the electrode is proposed and experimentally verified. The linear actuator superimposes a pulsed electrode force to base force which is expected to facilitate the melt flow inside the aluminium nugget and modify the forming process of the IMCs. The experimental results demonstrate that the introduction of linear actuating could significantly increase the area of the aluminium nugget, which means more aluminium was melted. Further, it is observed that the thickness of the IMCs layer was reduced by 81.9 %, with a peak thickness of 1.48 μm. Therefore, 38.5 % improvement in the average peak tensile shear load of the welded joints was achieved. The involved mechanisms were discussed by thermal/force dynamic analysis.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 811-823"},"PeriodicalIF":6.1,"publicationDate":"2024-11-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705998","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":"Preparation of Bouligand biomimetic ceramic composites and the effect of different fiber orientations on mechanical properties","authors":"Hailong Wu ,&nbsp;Anfu Guo ,&nbsp;Dekun Kong ,&nbsp;Jingwen Wu ,&nbsp;Peng Qu ,&nbsp;Shaoqing Wang ,&nbsp;Shuai Guo ,&nbsp;Xunjin Li ,&nbsp;Zhengyu Zhao ,&nbsp;Chang Liu ,&nbsp;Yongmei Zhu","doi":"10.1016/j.jmapro.2024.11.031","DOIUrl":"10.1016/j.jmapro.2024.11.031","url":null,"abstract":"<div><div>The multilevel helical arrangement of the Bouligand structure endows it with excellent mechanical properties when subjected to external stresses. In this study, Al₂O₃ ceramic scaffolds with Bouligand structures incorporated with continuous carbon fibers were prepared using vat photopolymerization (VPP) 3D printing technology. A series of biomimetic Bouligand–ceramic matrix composites with different fiber orientations were prepared using the epoxy penetration method. The flexural strength, fracture toughness, and work of fracture of the composites were evaluated at different fiber initiation and rotation angles. The effects of different fiber arrangements on the crack extension mode of the composites were revealed using the finite element method and peridynamics dynamics simulations. Molecular dynamics simulations, scanning electron microscopy, and energy-dispersive spectroscopy analyses revealed the material microstructure and interfacial bonding properties. The experimental results indicated that a specific combination of initiation and rotation angles can effectively promote crack twisting during the fracture process, thereby increasing the dissipation of fracture energy in the part and improving its fracture toughness. In this study, additive manufacturing technology was used to overcome the challenges of fabricating complex bionic structures through a simple and flexible production process. This method provides a practical solution for the development of lightweight, high-strength, and high-toughness bionic materials.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 789-801"},"PeriodicalIF":6.1,"publicationDate":"2024-11-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142705335","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":"Physics-informed inhomogeneous wear identification of end mills by online monitoring data","authors":"Guochao Li ,&nbsp;Shixian Xu ,&nbsp;Ru Jiang ,&nbsp;Yinfei Liu ,&nbsp;Leyi Zhang ,&nbsp;Hao Zheng ,&nbsp;Li Sun ,&nbsp;Yujing Sun","doi":"10.1016/j.jmapro.2024.11.020","DOIUrl":"10.1016/j.jmapro.2024.11.020","url":null,"abstract":"<div><div>Online tool wear monitoring is an important component of intelligent milling. Integral end mill is one of the typical high-value cutting tools which has been widely used in aerospace, automobile, mold and other industries. Its cutting edge may produce inhomogeneous wear after suffering variable cutting depth experience. The existing methods are mainly focused on monitoring the maximum value of the tool wear, which cannot identify the inhomogeneous wear state and results in insufficient accuracy and practicality. Therefore, a physics-informed method is proposed to online identify inhomogeneous tool wear state. Firstly, a milling force mechanism model considering tool wear is established. The force model are expressed with matrix formulation so that the time-domain signals of the forces considering inhomogeneous wear can be easily simulated. Then, a total of 11 groups of single-factor simulation experiments are carried out to provide data support. Accordingly, 48 features for each group are extracted, including time-domain and frequency-domain features. By analyzing the Mean Absolute Percentage Error (MAPE) of the extracted features, it is found that the inhomogeneous wear has significant effect on the feature of skewness. Finally, the conclusion is verified by practical experiments through comparing the extracted features in homogeneous and inhomogeneous wear state. The study will provide theoretical and experimental supplement to the engineering application and improve the online wear monitoring accuracy of end mill.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 759-771"},"PeriodicalIF":6.1,"publicationDate":"2024-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657323","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}