Journal of Manufacturing Processes最新文献

{"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}

{"title":"Study on the WC structural evolution and wear behavior of the cemented carbide coatings by laser directed energy deposition","authors":"Chenguang Guo ,&nbsp;Shengli Xue ,&nbsp;Haitao Yue ,&nbsp;Weibing Dai ,&nbsp;Ning Lv ,&nbsp;Jianhua Zhai ,&nbsp;Qiang Li ,&nbsp;Jinhua Li","doi":"10.1016/j.jmapro.2025.07.035","DOIUrl":"10.1016/j.jmapro.2025.07.035","url":null,"abstract":"<div><div>At present, laser directed energy deposition (LDED) of cemented carbide faces critical problems, such as WC melting, porosity, and cracks, which severely affect the mechanical properties of cemented carbide. In this study, WC-NiFeCr cemented carbide coatings were prepared using the LDED technique at various laser powers (1800 W, 2100 W, 2400 W, and 2700 W) to investigate the evolution of the WC particles, crack formation, and wear behavior. The results show that the WC particles gradually melted (unmelted WC → slightly melted WC → completely melted WC) through two erosive effects: edge melting and internal infiltration of the nickel-based solvent. Microcracks initiate in the edge melting and internal infiltration regions of the WC particles, whereas fine eutectic carbides help prevent crack extension. When the laser power increased from 1800 W to 2400 W, the microhardness and wear resistance of the cemented carbide coating gradually increased. The maximum microhardness of the coating is 1457.19 HV_0.5, and the minimum wear-profile area is 2801.48 μm². When the power is further increased to 2700 W, owing to the increase in internal pore defects, the microhardness and wear resistance decrease slightly. The main wear mechanisms are three-body abrasive wear and brittle spalling, as well as a small amount of adhesive wear. The results provide a new method for optimizing the wear resistance of cemented carbide coatings by changing the process parameters to regulate the evolution of the WC structure.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 54-65"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604679","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":"Rolled-flatness deviation evolution mechanism induced by transverse inhomogeneous deformation resistance during tandem cold rolling","authors":"Xiaohua Li ,&nbsp;Xu Li ,&nbsp;Qinglong Wang ,&nbsp;Lei Cao ,&nbsp;Hao Yuan","doi":"10.1016/j.jmapro.2025.06.103","DOIUrl":"10.1016/j.jmapro.2025.06.103","url":null,"abstract":"<div><div>Frequent occurrences of flatness defects during cold rolling have emerged as a significant bottleneck limiting the production of wide-thin high-strength strip. Conventional flatness simulation methods, typically based on idealized and homogeneous material models, fail to capture defects caused by distribution in transverse mechanical properties inherent to the strip itself. In this study, an analytical approach of strip shape, which addresses the limitations of existing models by incorporating actual transverse mechanical property distributions, is pioneered. Compared with conventional methods, the proposed finite element model demonstrates improved accuracy and stability, as validated by industrial production data. The relative error between the calculated and measured rolling force is maintained within 7 %, and the absolute error of the center thickness of the rolled strip is less than 5 μm. It is observed that there is a strong correlation between flatness defects and the initial transverse property distribution, which significantly increases the complexity of flatness deviations control. Furthermore, the influence of transverse property distribution on the evolution of the elastic deflection, inter-roll pressure and 3D pressure distribution is comprehensively analyzed, and the control efficiency of strip shape under relevant conditions is also evaluated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 24-40"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604677","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":"Investigation of thermal behavior and mechanical properties in hot stamping of aluminized 30MnB5 with an integrated process window design","authors":"Jea-Myoung Park,&nbsp;Kye-Jeong Park,&nbsp;Je-Youl Kong,&nbsp;Seung-Chae Yoon","doi":"10.1016/j.jmapro.2025.06.105","DOIUrl":"10.1016/j.jmapro.2025.06.105","url":null,"abstract":"<div><div>Hot stamping technology has emerged as an essential process for manufacturing lightweight and ultra-high-strength automotive components, particularly with the increasing adoption of electric vehicles. Among advanced materials, aluminized 30MnB5 steel, with tensile strengths exceeding 1.8 GPa, provides a compelling combination of crash safety enhancement and weight reduction. However, its mechanical properties are highly sensitive to processing conditions, necessitating systematic optimization. This study introduces an integrated Process Window (PW) that incorporates heating, transfer, and cooling stages to ensure efficient and reliable manufacturing. Experimental results identified 870 °C as the optimal heating temperature for 30MnB5 steel. At this temperature, the steel achieved a tensile strength exceeding 1.8 GPa, a yield strength of approximately 1.2 GPa, and an elongation of 6.8 %. Additionally, the interdiffusion layer thickness in the Al-Si coating was reduced to approximately 3.8 μm, the prior austenite grain size was refined to 9.6 μm, and hydrogen absorption was suppressed by about 45 % compared to higher heating temperatures. These conditions collectively enhance weldability and ensure consistent mechanical performance. The sheet thickness was shown to significantly influence thermal behavior, impacting heating times, ambient exposure, and die-cooling. The derived temperature-time relationship functions enable tailored process adjustments to achieve consistent strength and formability across varying sheet thicknesses. Unlike conventional PW, which primarily addresses heating conditions, the proposed integrated PW encompasses the entire hot stamping process. It aims to reduce inefficiencies and improve process stability. By quantitatively linking process parameters to microstructural evolution and mechanical properties, this study establishes a robust framework for the production of lightweight, ultra-high-strength automotive components. The findings also contribute to advancing sustainable manufacturing practices by optimizing energy consumption and process efficiency.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1216-1227"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596954","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":"Resistance welding of thermoplastic composites using novel heating element of graphite film","authors":"Jixiao Han ,&nbsp;Hongchuan Zhang ,&nbsp;Yifan Liu ,&nbsp;Jianhui Su ,&nbsp;Xueyan Zhang ,&nbsp;Caiwang Tan ,&nbsp;Huatao Wang ,&nbsp;Xiaoguo Song","doi":"10.1016/j.jmapro.2025.07.026","DOIUrl":"10.1016/j.jmapro.2025.07.026","url":null,"abstract":"<div><div>The application of thermoplastic composites has advanced structural lightweight, necessitating effective methods for achieving stable joints. In this study, a laser-ablated graphite film was developed as a novel heating element, introducing an innovative approach to the resistance welding of carbon fiber-reinforced polyamide 66 (CF/PA66) thermoplastic composites. Systematic experiments and analyses verified the performance of the graphite heating element in providing uniform heat and efficient welding during the process. Through systematic experiments and analysis, the graphite heating element demonstrated uniform heat generation and high welding efficiency. The use of this heating element enhanced resin flow and improved the temperature distribution uniformity at the welding interface. Moreover, it eliminated the need for dissimilar metallic materials, thereby reducing stress concentrations and minimizing edge effects during the welding process. This novel heating element shows great potential for resistance welding of thermoplastic composites, offering a groundbreaking solution for joining high-performance and lightweight structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 41-53"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604678","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":"Ultrafast laser processing of shaped film cooling holes for aero-turbine blades: Surface integrity, parameter influence and forming mechanism","authors":"Meng Li ,&nbsp;Zhixun Wen ,&nbsp;Ping Wang ,&nbsp;Yuxing Liu ,&nbsp;Zhufeng Yue","doi":"10.1016/j.jmapro.2025.07.017","DOIUrl":"10.1016/j.jmapro.2025.07.017","url":null,"abstract":"<div><div>Shaped film cooling holes (FCHs) can effectively improve the film cooling efficiency of turbine blades, but due to their complex structure and precision requirements, there is currently no reliable and high-quality machining method. In this paper, a segmented processing method of fan-shaped FCHs is proposed, which realizes high-quality processing of fan-shaped FCHs. The effects of processing parameters on the machining efficiency, geometric accuracy and surface morphology of fan-shaped FCHs were analyzed. And the microstructure, composition, surface roughness and residual stress of the hole wall under specific processing parameters were characterized. The influence mechanism of processing parameters on the processed results is clarified by laser overlap rate and laser energy density of the processing area. The important role of focus compensation in the segmented machining method is discussed. The formation mechanism of microstructures was explained by the plasma exciton theory and the energy shielding effect. Furthermore, the process method is promoted through expansion section model segmentation and processing attitude adjustment to realize the processing of cat-ear-shaped and bat-face-shaped FCHs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1194-1215"},"PeriodicalIF":6.1,"publicationDate":"2025-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144596952","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":"Managing thermal states in multi-material additive manufacturing of polymer-ceramic structures","authors":"Olorunfemi J. Esan ,&nbsp;Christopher J. Hansen ,&nbsp;Alireza Amirkhizi ,&nbsp;Ian M. McAninch ,&nbsp;Stephen R. Cluff ,&nbsp;Pauline M. Smith ,&nbsp;Amy M. Peterson","doi":"10.1016/j.jmapro.2025.06.102","DOIUrl":"10.1016/j.jmapro.2025.06.102","url":null,"abstract":"<div><div>Multi-material additive manufacturing (MMAM) enables the fabrication of components with a wide range of properties and functionalities. However, integrating materials such as ceramics, known for their high strength, chemical and wear resistance, with polymers, exhibiting toughness and ductility, remains challenging due to their vastly different processing temperatures. In this work, we modeled the dissimilar thermal processing of polymers and ceramics in a single AM platform. Ceramic processing was simulated using powder bed fusion (PBF), while polymer processing can be achieved using material extrusion, vat photopolymerization, material jetting, and PBF for powder-based polymers. Physical gaps between polymer and ceramic were designed to reduce heat transfer to the polymer during ceramic sintering. A range of common thermoplastic and thermosets polymers were studied. Results showed that increased laser power and scan speed raised actual processing temperatures. Thermoplastic polymers exhibited a narrow processing window, melting with increased laser power and scan speed, particularly at smaller gap sizes. In contrast, thermosets, due to their crosslinked nature, were less sensitive to laser power and scan speed, offering a wider processing window with less degradation. Multiple scans increased heat absorption in polymers, such that all polymers degraded below a gap size of 0.5 mm. This study provides insights into preserving polymers during integrated processing with ceramic components, expanding the design possibilities for dissimilar materials in MMAM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1153-1163"},"PeriodicalIF":6.1,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144588666","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental and data-driven exploration of surface topography and tribological properties of additively manufactured polymers using fused filament fabrication (FFF)","authors":"Samsul Mahmood ,&nbsp;Emily Guo ,&nbsp;Abdullah Al Nahian ,&nbsp;Shoumik Sadaf ,&nbsp;Zhihua Jiang ,&nbsp;Lauren Beckingham ,&nbsp;Kyle Schulze","doi":"10.1016/j.jmapro.2025.06.088","DOIUrl":"10.1016/j.jmapro.2025.06.088","url":null,"abstract":"<div><div>Additive manufacturing (AM) has revolutionized rapid prototyping and manufacturing. However, limited research has been done on the effect of build orientation and surface roughness on AM parts’ frictional and wear characteristics. This study examines how different print and system parameters influence the surface topography and tribological behavior of 3D printed PLA. The samples were printed in three orientations and tested under varying normal loads (50–100 N). The vertically printed samples resulted in the best wear performance compared to the other two build orientations (<span><math><mo>∼</mo></math></span> 26.75% and 18.47%, respectively, at 100 N normal load). The coefficient of friction also showed dependency on the orientation of the print. The effect of surface topography parameters on tribological properties was also investigated. Skewness, <span><math><msub><mrow><mi>S</mi></mrow><mrow><mi>s</mi><mi>k</mi></mrow></msub></math></span>, and maximum valley depth, <span><math><msub><mrow><mi>S</mi></mrow><mrow><mi>v</mi></mrow></msub></math></span>, exhibited a strong positive correlation with the coefficient of friction, indicating that tribological behaviors are more sensitive to extreme surface topography features than average surface roughness (<span><math><msub><mrow><mi>S</mi></mrow><mrow><mi>a</mi></mrow></msub></math></span>). A data-driven approach was employed to predict wear rate and coefficient of friction using four machine learning models: Support Vector Regression (SVR), Artificial Neural Network (ANN), Random Forest (RF), and Extreme Gradient Boosting (XGBoost), where decision tree-based models outperformed others. The RF model achieved an <span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> value of 0.98 in predicting the wear rate and the coefficient of friction, where surface roughness parameters and operational parameters (normal loads, sliding distance) played critical roles.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1132-1152"},"PeriodicalIF":6.1,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144580398","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 novel method for suppressing clogging of nozzle and stopper rod by electric current pulse during continuous casting of ultra-low carbon steel","authors":"Kaiwang Chen ,&nbsp;Dongxue Wang ,&nbsp;Lei Yuan ,&nbsp;Qiang Gu ,&nbsp;Guoqi Liu ,&nbsp;Hongxia Li","doi":"10.1016/j.jmapro.2025.07.029","DOIUrl":"10.1016/j.jmapro.2025.07.029","url":null,"abstract":"<div><div>The effect of electric current pulse (ECP) on the clogging behavior of submerged entry nozzle (SEN) and stopper rod was studied during the continuous casting process of ultra-low carbon steel. Compared to normal treatment of SEN, ECP effectively prevented the deposition of alumina (Al₂O₃) inclusions at the nozzle outlet and stopper rod tip. Specifically, the application of ECP reduced the clogging thickness by more than 21 %, and the adhesion at the tip was mainly the tundish covering flux. Under ECP, the clogging density increased, which reduced the detachment of large-sized inclusions. Notably, the lattice distortions and dislocations of Al₂O₃ on the surface of the auxiliary electrode (negative electrode) increased its conductivity at high temperature. Furthermore, the mold level fluctuation and the change in inclusion size in the slab also showed that ECP could effectively suppress the clogging behavior, thereby enhancing the slab quality. This novel study provides important reference value and practical significance for applying external fields to suppress clogging of SEN and stopper rod.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"151 ","pages":"Pages 1-23"},"PeriodicalIF":6.1,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144604811","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":"Properties of composite micro-textured surface on YG8 cemented carbide prepared by laser peening and ablation","authors":"Yang Lu ,&nbsp;Xiangqian Liu ,&nbsp;Jing Guo ,&nbsp;Changan Zhou","doi":"10.1016/j.jmapro.2025.07.015","DOIUrl":"10.1016/j.jmapro.2025.07.015","url":null,"abstract":"<div><div>This paper proposes a novel method for fabricating composite micro-textured surfaces using a combined laser processing technique. The method integrates laser peening without coating and laser ablation texturing in the air to create composite micro-textured surfaces on YG8 cemented carbide. The study examines the microstructure, roughness, hardness, residual stress, friction-wear performance, and cutting performance of composite micro-textured surfaces. Experimental results indicate that laser treatment significantly alters the microstructure and surface properties of cemented carbide. In particular, the composite micro-textured surface (LP-T) achieved by combining laser peening and ablation, demonstrated the highest surface hardness (1579 HV). It also shows an improved surface contact ratio and a balanced residual stress distribution (231.8 MPa). The average friction coefficient was the lowest, reduced by 19.4 % compared to traditional polished surfaces. Additionally, the composite treatment significantly lowers cutting force and temperature at higher cutting speeds, improving adhesive wear on the cutting face. In conclusion, the laser composite treatment substantially enhances the performance of cemented carbide by optimizing its surface characteristics.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"150 ","pages":"Pages 1118-1131"},"PeriodicalIF":6.1,"publicationDate":"2025-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144580396","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}