Journal of Manufacturing Processes最新文献

{"title":"Evolution law of trace element precipitated phases, strengthening mechanism of IMC in joints, and mechanical properties of AZ31B/6061 heterogeneous oscillating laser welded joints","authors":"Xianlong Wu,&nbsp;Kaihan Zhou,&nbsp;Boshi Jiang,&nbsp;Guangyu Sun,&nbsp;Qingning Xue,&nbsp;Zhe Wu","doi":"10.1016/j.jmapro.2025.09.066","DOIUrl":"10.1016/j.jmapro.2025.09.066","url":null,"abstract":"<div><div>Efficient joining of dissimilar metals is a current research focus, and an in-depth understanding of the strengthening mechanism of dissimilar joints is of great significance for improving joint performance. In this study, the infinite-shaped oscillating laser welding method was adopted, and the evolution law of precipitated phases of trace elements in AZ31B/6061 heterogeneous joints was explored in depth using SEM-EDS-TEM characterization techniques. The mechanism of joint IMC strengthening was clarified, and the influence of oscillation parameters on the mechanical properties of AZ31B/6061 heterogeneous joints was investigated. The results show that the oscillating frequency and amplitude affect the precipitated phases of the joints by influencing the stirring intensity of the molten pool. The introduction of trace elements such as Si, Fe, and Cu in the alloy joints leads to the precipitation of nanoscale strip - shaped <span><math><msub><mi>Mg</mi><mn>2</mn></msub><mi>Si</mi></math></span>, dot-shaped and strip-shaped <span><math><msub><mi>Al</mi><mn>13</mn></msub><msub><mi>Fe</mi><mn>4</mn></msub></math></span>, and dot-shaped <span><math><msub><mi>Al</mi><mn>2</mn></msub><mi>Cu</mi></math></span> in the joints. The <span><math><msub><mi>Al</mi><mn>2</mn></msub><mi>Cu</mi></math></span> and the α-<em>Al</em> matrix are in a coherent interface relationship: <span><math><msub><mfenced><mn>0</mn><mover><mn>1</mn><mo>¯</mo></mover><mn>0</mn></mfenced><mrow><msub><mi>Al</mi><mn>2</mn></msub><mi>Cu</mi></mrow></msub><mo>∥</mo><msub><mfenced><mover><mn>1</mn><mo>¯</mo></mover><mover><mn>1</mn><mo>¯</mo></mover><mn>1</mn></mfenced><mrow><mi>α</mi><mo>−</mo><mi>Al</mi></mrow></msub><mo>,</mo><msub><mfenced><mn>1</mn><mn>1</mn><mn>2</mn></mfenced><mrow><msub><mi>Al</mi><mn>2</mn></msub><mi>Cu</mi></mrow></msub><mo>∥</mo><msub><mfenced><mn>2</mn><mn>0</mn><mn>0</mn></mfenced><mrow><mi>α</mi><mo>−</mo><mi>Al</mi></mrow></msub></math></span>. The precipitation of <span><math><msub><mi>Mg</mi><mn>2</mn></msub><mi>Si</mi></math></span>, <span><math><msub><mi>Al</mi><mn>13</mn></msub><msub><mi>Fe</mi><mn>4</mn></msub></math></span>, and <span><math><msub><mi>Al</mi><mn>2</mn></msub><mi>Cu</mi></math></span> not only achieves precipitation strengthening but also preferentially precipitates before the γ-phase, thereby consuming Al atoms near the interface, reducing the effective concentration of Al, and inhibiting the nucleation driving force for γ-phase formation. By regulating the oscillation parameters, the joint strength can be increased by approximately 94.9 %. This study provides an important theoretical basis and practical guidance for further improving the performance of AZ31B/6061 heterogeneous joints.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 109-121"},"PeriodicalIF":6.8,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223312","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 study on the anisotropic machinability of as-printed and heat-treated additive manufactured Ti6Al4V titanium alloys in micro-hole drilling","authors":"Zhongwei Chen ,&nbsp;Xian Wu ,&nbsp;Jiafu Ruan ,&nbsp;Xigui Wang ,&nbsp;Meng Zhao ,&nbsp;Zhiping Xue ,&nbsp;Laifa Zhu","doi":"10.1016/j.jmapro.2025.09.073","DOIUrl":"10.1016/j.jmapro.2025.09.073","url":null,"abstract":"<div><div>Additive manufactured (AMed) titanium alloy components fabricated by Selective Laser Melting (SLM) process are pivotal in the upgrading and transformation of industrial products to precision and complexity. However, different heat treatment processes and surface states can directly affect the machinability of SLM-formed (SLMed) titanium alloys. In this research, samples extracted from the upper and side surfaces of both as-printed and heat-treated SLMed Ti6Al4V materials were selected for micro-hole drilling experiments. The anisotropic machinability of four samples was compared using indicators such as thrust force, micro-hole wall quality, and exit burr. The findings indicate that thrust force and exit burr size of the as-printed SLMed Ti6Al4V material on upper surface sample are both smaller than those on side surface sample. Between the upper and side surfaces, the maximum deviation rates of the two indicators reached 6.02 % and 33.52 %, respectively. Furthermore, micro-hole wall surface quality on the upper surface sample is inferior to that observed on the side surface sample, with the maximum deviation rate between different surfaces reaching 30.36 %. The interaction between the micro-drill feed direction and grain extension orientation affects the generation of cutting force and material removal mode, which is the key reason for the anisotropic behavior observed in machining. The anisotropy of heat-treated SLMed Ti6Al4V material on different surfaces has been greatly alleviated. After heat treatment, the average thrust force deviation rate between different surface samples decreased from 1.66 % to 1.09 %, the average micro-hole wall surface roughness deviation rate dropped from 19.22 % to 3.51 %, and the average exit burr height deviation rate was reduced from 25.97 % to 6.68 %. This study provides theoretical support for micro-hole drilling parameter design of SLMed Ti6Al4V components, facilitating the manufacturing application of high-precision titanium alloy parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 94-108"},"PeriodicalIF":6.8,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223373","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":"Automated segmentation and analysis of microscopy images of laser powder bed fusion melt tracks","authors":"Aagam Shah ,&nbsp;Reimar Weissbach ,&nbsp;David A. Griggs ,&nbsp;A. John Hart ,&nbsp;Elif Ertekin ,&nbsp;Sameh Tawfick","doi":"10.1016/j.jmapro.2025.09.043","DOIUrl":"10.1016/j.jmapro.2025.09.043","url":null,"abstract":"<div><div>With the increasing adoption of metal additive manufacturing (AM), researchers and practitioners are turning to data-driven approaches to optimise printing conditions. Cross-sectional images of melt tracks provide valuable information for tuning process parameters, developing parameter scaling data, and identifying defects. Here we present an image segmentation neural network that automatically identifies and measures melt track dimensions from a cross-section image. We use a U-Net architecture to train on a data set of 62 pre-labelled images obtained from different labs, machines, and materials coupled with image augmentation. After tuning the neural network hyperparameters, the learned model has a pixelwise accuracy of over 99% and an F1 score over 90%. The neural network exhibits robustness when tested on images captured by various users, printed on different machines, and acquired using different microscopes. A post-processing module extracts the height and width of the melt pool, and the wetting angles. We discuss opportunities to improve model performance and avenues for transfer learning, such as extension to other AM processes such as directed energy deposition.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 61-70"},"PeriodicalIF":6.8,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223237","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":"The potential of PTT-CFD coupling for isothermal 3D thermoplastic extrudate swelling simulations","authors":"Chiara Fiorillo ,&nbsp;Tom Van Waeleghem ,&nbsp;Mariya Edeleva ,&nbsp;Dagmar R. D'hooge","doi":"10.1016/j.jmapro.2025.09.058","DOIUrl":"10.1016/j.jmapro.2025.09.058","url":null,"abstract":"<div><div>To speed-up polymer processing design, it is worthwhile to enhance the applicability of our polymer melt computational fluid dynamics (CFD) tools. Essential is the more representative embedding of the rheological first principles in the CFD mesh via an appropriate constitutive model. In the present work, we highlight that the Pan-Thien-Tanner (PTT) constitutive model, with its viscoelastic parameters tuned to rotational and capillary rheometric data, can be coupled to the Ansys Polyflow finite element solver, to simulate 3D isothermal extrudate swell, out of a slit die for a wide variety of thermoplastic polymers. We differentiate between commercial polypropylene (PP), acrylonitrile butadiene styrene polymer (ABS), poly(lactic acid) (PLA), and polyethylene terephthalate glycol (PETG), spanning a wide range of slip (<span><math><mi>ξ</mi></math></span>), extensional (<span><math><mi>ϵ</mi></math></span>), and relaxation time (<span><math><mi>λ</mi></math></span>) PTT parameters. We additionally include mock materials of which the (<span><math><mi>ξ</mi></math></span>, <span><math><mi>ϵ</mi><mo>,</mo><mi>λ</mi><mo>)</mo><mspace></mspace></math></span>PTT parameters are (slight) modifications with respect to the PTT parameters of the 4 materials studied to test mathematical boundaries. We highlight that normal stress difference data are critical for the PTT parameter tuning, and computational challenges can be avoided in case the elongational viscosities and mode dependent Weissenberg numbers are not too extreme, i.e. specific combinations of (<span><math><mi>ξ</mi></math></span>, <span><math><mi>ϵ</mi><mo>,</mo><mi>λ</mi><mo>)</mo><mspace></mspace></math></span>PTT parameters are avoided. The present work contributes to a better linkage of rheological data recording and finite element framework developments toward model-driven process intensification of extrusion-based equipment, including conventional extrusion and additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 43-60"},"PeriodicalIF":6.8,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223236","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":"The influence of femtosecond laser surface texturing on the microstructure and mechanical properties of sapphire-ZrO₂ brazed joints","authors":"Yao Du ,&nbsp;Shuye Zhang ,&nbsp;Jiayi Xu ,&nbsp;Bingxu Guo ,&nbsp;ShuWei Li ,&nbsp;Fuqiang Ye ,&nbsp;Hong Li ,&nbsp;Shujun Chen ,&nbsp;Tiesong Lin ,&nbsp;Peng He ,&nbsp;Erika Hodúlová ,&nbsp;Rui Pan","doi":"10.1016/j.jmapro.2025.09.052","DOIUrl":"10.1016/j.jmapro.2025.09.052","url":null,"abstract":"<div><div>When faced with challenges such as poor wettability of the brazing filler metal and low joint strength in the brazing of dissimilar ceramics, femtosecond laser surface treatment offers a new solution. In this study, we used a femtosecond laser to create periodic patterns on the sapphire surface, applied AgCuTi metal paste to form a metallization layer, and then completed the brazing process with AgCuZnSn filler metal. Following laser texturing, periodic microcone arrays were formed on the sapphire surface. Subsequent cladding on this laser-textured sapphire surface resulted in a more homogeneous microstructure within the joint, along with a reduction in the quantity of brittle intermetallic compounds. The shear strength of the treated joint reached 158 MPa, representing a 50 % increase over the untreated joint. This enhancement is attributed to the microstructures generated by laser processing, which increased the density of reactive sites between Ti and sapphire. This enabled more Ti to react with the sapphire surface, rather than forming brittle Ti-Cu compounds within the joint. On the other hand, when cracks spread along the microstructures, their paths change, which uses up energy. Additionally, the mechanical interlocking effect of the laser-pre-treated periodic microstructures at the interface also contributes to increasing the strength. We hypothesize that this study offers a novel design strategy for joining dissimilar ceramics, with direct applicability to brazing pretreatment of optical windows and microelectronic components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 31-42"},"PeriodicalIF":6.8,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223240","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":"Burr formation mechanisms and parameter effects in high-speed micro-milling of aviation-grade soft metals","authors":"Yang Cao ,&nbsp;Bo Deng ,&nbsp;Chunjin Li ,&nbsp;Songsong Lu ,&nbsp;Yang Tang ,&nbsp;Shuang Deng ,&nbsp;Liping Wang ,&nbsp;Yang Xie","doi":"10.1016/j.jmapro.2025.09.049","DOIUrl":"10.1016/j.jmapro.2025.09.049","url":null,"abstract":"<div><div>Aerospace-grade soft metal communication devices have a large number of array micro-milled grooves. High-speed milling tends to generates fine, hard-to-remove burrs, which significantly impairs the signal reception performance of communication devices. In order to reduce burr formation during micro-milling and improve the machining quality, this study conducted simulation and experimental research on the formation mechanism of burrs during the micro-machining of aerospace soft metals, and explored the fundamental mechanisms of typical burr formation in soft metals. First, by comparing among different samples in micro-milling experiments, the effects of process parameters on the overall burr size was analyzed. Then, the finite element analysis method was employed to reveal the dynamic process of burr formation in the micro-milling of soft aluminum alloys, and the consistency of the experimental conclusions was verified. Finally, the burr formation mechanism and the influence of process parameters on the formation of inward-curved burrs were analyzed by combining simulation and experiments. The results show that the error between the experimental and simulation results of external milling burrs is &lt;8 %. Among the process parameter combinations within the allowable machining range, the smaller the feed rate and axial depth of cut, and the higher the spindle speed, the smaller the burr size. The minimum average burr width is 0.11265 mm. Under machining conditions with lower feed rate, the clustered burrs produced during machining are easier to remove than the flat flag-shaped burrs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 13-30"},"PeriodicalIF":6.8,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145223239","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":"Defect in-situ monitoring of bump during the bonding process of 3D packaging based on active thermography","authors":"Bin Zhou ,&nbsp;Jianxin Qiao ,&nbsp;Wentao Huang ,&nbsp;Longqiu Li","doi":"10.1016/j.jmapro.2025.09.065","DOIUrl":"10.1016/j.jmapro.2025.09.065","url":null,"abstract":"<div><div>A three-dimensional(3D) package using a micro bump is a key technique to achieving high-density integration, fine spacing and smaller size. However, duo to the increase of bump density and chip layer, monitoring internal defects within the bump has become increasingly challenging. In this paper, the active thermography is used for in-situ monitoring of inside defects during the bonding process of a 3D package. The two-dimensional heat resistance thermal resistance network is constructed and heat conduction of different defects in the bonding process is analyzed. An experimental investigation is carried out to inspect the inside defect, such as bump missing and bridge at the top, intermediate, and bottom, respectively. The temperature curve of the bump is acquired, and results show that the maximum temperature of the missing bottom bump is 18.05 °C lower than the normal. The maximum temperature of the bottom bumps bridge is 16.61 °C higher than the normal. The void of top is lower than that of the normal, and the temperature difference is 3.325 °C. The support vector machines (SVM) is used to defect classification of bumps. The Computed Tomography (CT) is used to verify the method. This work introduces a new method for the inside defect in-situ monitoring of bumps while providing valuable inspiration for future research on 3D package online repair.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"154 ","pages":"Pages 1-12"},"PeriodicalIF":6.8,"publicationDate":"2025-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145157099","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":"Feedforward-adjusted temperature field: A multiphysics protocol for process-structure co-optimization in GF/PPS ultrasonic welding","authors":"You Wu ,&nbsp;Zhiwu Xu ,&nbsp;Zhengwei Li ,&nbsp;Zhongwei Ma ,&nbsp;Junjie Gao ,&nbsp;Jiuchun Yan","doi":"10.1016/j.jmapro.2025.09.055","DOIUrl":"10.1016/j.jmapro.2025.09.055","url":null,"abstract":"<div><div>Ultrasonic welding is a promising joining technique for thermoplastic composites, but its application faces with non-uniform interfacial temperature distribution, resulting in poor joint mechanical performance. To overcome the limitation, this study evaluates the use of preheating in ultrasonic welding of glass fiber polyphenylene sulfide (GF/PPS) composites using both experimental and numerical methods. The cross-sectional morphologies, mechanical properties, fracture modes, and temperature distribution were systematically characterized. These results revealed that moderate preheating can significantly improve resin fusion at different interfacial locations, enhancing joint mechanical performance by homogenizing the interfacial temperature distribution. Numerical simulations were firstly used to confirm this improvement, of which mechanism was proved to be derived from transitioning localized frictional heating toward distributed viscoelastic heating at the welding interface, resulting in smaller interfacial temperature gradients. The maximum lap shear strength of the joints reached 23.1 MPa with 90 °C preheating, which is 10.5 % higher than the joints without preheating (22.6 MPa). These findings offer a comprehensive understanding of preheating effects in GF/PPS ultrasonic welding and suggest that optimization of stress distribution at the interface can further improve fusion uniformity and mechanical performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 916-932"},"PeriodicalIF":6.8,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155049","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 wavelet convolutional network for monitoring interfacial bonding quality in LDED using AE signals","authors":"Jie Wang ,&nbsp;Zhifen Zhang ,&nbsp;Shuai Zhang ,&nbsp;Hao Qin ,&nbsp;Rui Qin ,&nbsp;Jing Huang ,&nbsp;Guangrui Wen ,&nbsp;Xuefeng Chen","doi":"10.1016/j.jmapro.2025.09.026","DOIUrl":"10.1016/j.jmapro.2025.09.026","url":null,"abstract":"<div><div>Laser cladding is widely used for surface modification and repair of metallic materials, where the interfacial bonding quality is critical, especially in dissimilar material cladding. However, existing evaluation methods rely on experience or destructive testing, lacking real-time and quantitative capabilities, which limits broader application. The strong interactions between laser, powder and substrate result in complex multimodal mixing within the acoustic emission (AE) signals, making it challenging for traditional purely data-driven deep learning methods. To address this, this paper proposes a wavelet deep learning framework with physical interpretability. First, a comprehensive descriptive label for the cladding layer was constructed based on two key forming indicators: flatness ratio and dilution rate. Then, a wavelet packet decomposition (WPD) layer adaptively decomposed the AE signals, reducing frequency aliasing. Based on this, a parallel wavelet convolution layer was designed to extract physical features from the decomposed sub-band information using wavelet convolution kernels. To further enhance the feature representation ability, an attention module was introduced to optimizing feature expression. Finally, multi-layer neural networks were used to map the features to the comprehensive forming labels, achieving accurate monitoring of interfacial quality. Experimental results demonstrate a 96.18 % accuracy in interfacial bonding quality identification. Moreover, feature visualization results confirm the significant role of the parallel wavelet convolution layer in improving the distinguishability, while the attention module can effectively perceive energy fluctuations within the frequency bands, promoting the aggregation of similar samples and alleviating the boundary overlap between easily confused categories.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 899-915"},"PeriodicalIF":6.8,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155050","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":"Modeling the effect of plate position on thermal, material flow and deposition during dissimilar friction stir welding between Al and Cu","authors":"Hao Su ,&nbsp;Ji Chen ,&nbsp;WenZhen Zhao ,&nbsp;Huan He ,&nbsp;ChuanSong Wu","doi":"10.1016/j.jmapro.2025.09.039","DOIUrl":"10.1016/j.jmapro.2025.09.039","url":null,"abstract":"<div><div>The effects of dissimilar Al/Cu plate position on thermal, material flow and deposition behavior in FSW are studied in detail based on computational fluid dynamics (CFD) simulation with bonding interface tracking by volume of fluid (VOF) technique. A novel 3D steady-state model is proposed to compare the coupled multi-physics fields between Type-I (Al-AS/Cu-RS) and Type-II (Al-RS/Cu-AS) positions. A 2D transient-state model with refined grid is established for the dynamic evolution of the periodic feature with Type-I position by considering tool eccentricity. It is found that the total heat input is identical with different plate positions, but the temperature around the pin is about 50–100 K higher with Type-II than that with Type-I. The flow streamline analyses indicate that direct-through flow pattern is dominated with Type-I, whereas both direct-through and multi-circle flow patterns are subsistent with Type-II. The tool eccentricity is confirmed to be the primary factor for the formation of the periodic feature in dissimilar Al/Cu FSW, since it changes velocity field around the tool and causes reciprocating block-open of the flow channel at the RS. The modeling results are in good agreements with abundant experimental observations.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 868-885"},"PeriodicalIF":6.8,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155324","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}