Journal of Manufacturing Processes最新文献

{"title":"An unsupervised welding quality detection method based on high-quality condition-guided diffusion reconstruction","authors":"Xin Chen ,&nbsp;Bin Zi ,&nbsp;Kai Tang ,&nbsp;Wenjun Tang ,&nbsp;Yuan Li","doi":"10.1016/j.jmapro.2026.01.059","DOIUrl":"10.1016/j.jmapro.2026.01.059","url":null,"abstract":"<div><div>Radiographic testing of welds plays a critical role in ensuring the quality of welded manufacturing, because X-ray imaging technology can clearly reveal the internal structure of the weld area. However, existing mainstream detection methods rely on manual inspection or supervised detection, both of which are susceptible to limitations imposed by subjective factors and model generalization capabilities, respectively. Therefore, this paper proposes a two-stage unsupervised detection framework based on reconstruction to achieve fast and accurate detection of welding quality. First, an algorithm for generating simulated defects based on real welding defect characteristics is designed. A dataset encompassing multiple defect types is constructed, and image quality is further optimized through data augmentation algorithms. Second, a high-quality diffusion model (H-DiffuM) based on residual learning is proposed, which achieves accurate reconstruction of weld defect images through a residual-guided noise scheduling mechanism. Finally, by combining the gated mechanism with frequency domain features of X-ray images, a multi-scale frequency domain attention fusion module (MFDAFM) is designed and embedded into the discriminative network (Seg-net), thereby enhancing detection accuracy. The final experimental results demonstrated that the proposed method achieved 97.80% in pixel-level AUROC and 93.34% in AP, which surpassed the current state-of-the-art unsupervised detection approaches. Meanwhile, the inspection method described in this paper offers the advantages of rapid detection speed and high precision, demonstrating its potential for application in the rapid assessment of welding quality.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 429-441"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080427","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":"Filament-assisted combined pulse laser ablation of metal targets: Mechanistic insights, efficiency enhancement, and spatial tolerance","authors":"Zhou Li ,&nbsp;Junyang Xu ,&nbsp;Yuyang Chen ,&nbsp;Kai Li ,&nbsp;Lu Zhang ,&nbsp;Xianshi Jia ,&nbsp;Cong Wang ,&nbsp;Ji'an Duan","doi":"10.1016/j.jmapro.2026.01.050","DOIUrl":"10.1016/j.jmapro.2026.01.050","url":null,"abstract":"<div><div>Filament-assisted combined pulse laser (CPL) ablation, coupling a millisecond laser with a nanosecond-laser-induced air filament, is demonstrated to achieve high-efficiency metal ablation under near-on-target power densities of 10³-10⁴ W/cm². An integrated diagnostic system, combining transient temperature measurement and time-resolved imaging, enables direct identification of the coupled processes of melting and filament-driven expulsion, with the assistance of post-process three-dimensional morphology analysis. The filament assistance yields nearly an order-of-magnitude enhancement in ablation volume and material removal rate compared with millisecond laser irradiation alone. Crater depth is increased by more than a factor of two, while smaller and more stable laser-supported combustion waves are maintained. Moreover, CPL exhibits pronounced spatial tolerance, sustaining significant efficiency gains even under deliberate lateral misalignment and thereby confirming its robustness for non-ideal and long-range conditions. These findings highlight both mechanistic insight and performance advancement, consolidating filament-assisted CPL as a robust and scalable strategy for efficient, stable, and spatially tolerant ablation in high-energy laser damage.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 371-388"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080396","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":"Machining performance and mechanism of surface-active-media-assisted milling for 18Ni300","authors":"Xufeng Tang ,&nbsp;Zhongpeng Zheng ,&nbsp;Tianhao Cheng ,&nbsp;Xinyi Li ,&nbsp;Jiancheng Zhao ,&nbsp;Yan Wang ,&nbsp;Xiaoming Yin ,&nbsp;Xin Jin ,&nbsp;Chaojiang Li ,&nbsp;Wenhui Li","doi":"10.1016/j.jmapro.2026.01.042","DOIUrl":"10.1016/j.jmapro.2026.01.042","url":null,"abstract":"<div><div>18Ni300 maraging steel is difficult to machine, commonly exhibiting high cutting forces, degraded surface integrity, and accelerated tool wear. To address these issues, this study investigate surface-active media (SAM) assisted milling using DYKEM High Purity 44 marker ink to activate the Rehbinder effect, in which polar molecules adsorb on the workpiece surface, reduce surface energy, and promote near-surface dislocation motion and microcrack initiation, thereby lowering local fracture toughness. Comparative milling experiments were conducted, and a corresponding ABAQUS/Explicit FEM model was developed by representing the R-effect via reduced fracture energy. Experimentally, SAM reduced average cutting forces by ~25%, while improving surface integrity (suppressed tearing and reduced roughness) and decreasing tool wear under identical conditions. FEM results corroborate the trend, predicting a 39.59% reduction in specific cutting force with SAM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 317-331"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036785","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":"Vat photopolymerization of high solid-content SiC slurry for near-net-shape high performance ceramic components via selective powder oxidation","authors":"Shuyu Zhou ,&nbsp;Shan Li ,&nbsp;Chuanqi Hu ,&nbsp;Qingfeng Jia ,&nbsp;Rihan Zhang ,&nbsp;Yuzhen Zhang ,&nbsp;Congcong Cui ,&nbsp;Wei Li ,&nbsp;Ge Zhang ,&nbsp;Xiaodong Liu ,&nbsp;Bingshan Liu ,&nbsp;Gong Wang","doi":"10.1016/j.jmapro.2026.01.052","DOIUrl":"10.1016/j.jmapro.2026.01.052","url":null,"abstract":"<div><div>This study presents a method for producing high-performance SiC ceramics with low sintering shrinkage using vat photopolymerization (VPP) of high-solid-content slurry, followed by carbothermal reduction and reactive melt infiltration (RMI). Systematic research of SiC powder surface oxidation parameters revealed and precisely controlled the temperature-time synergy mechanism, achieving over 40% reduction in ultraviolet (UV) absorption. Furthermore, implementation of “selective oxidation of fine particles coupled with coarse particle gradation” strategy enabled formulation of a slurry with 57 vol% solid content and 160 μm curing depth. The debinding shrinkage rate was reduced to less than 2%. Research of carbothermal reduction at 1500 °C transformed SiO₂ into SiC nanowire conversion, successfully improving flexural strength of 308.86 MPa. This technique effectively addresses UV-shielding challenges and impurity formation in pre-oxidized SiC systems, demonstrating significant potential for near-net-shape manufacturing of high-strength RB-SiC components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 270-284"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036900","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":"Snaking chatter: Mechanism and mitigation","authors":"Luke Rimac,&nbsp;Philip Koshy,&nbsp;Mohamed Elbestawi","doi":"10.1016/j.jmapro.2026.01.037","DOIUrl":"10.1016/j.jmapro.2026.01.037","url":null,"abstract":"<div><div>This research investigated snaking chatter in grooving blades that causes an inconsistent increase in groove width relative to the tool width, often exceeding tolerance limits in precision applications. Contrary to the suggestion in the literature attributing snaking chatter to mode coupling, this study proposed and verified the hypothesis that it arises instead from regenerative effects on the side walls of the machined groove. With the application of a conventional stability-based process design shown infeasible in addressing snaking chatter, a counterintuitive mitigation strategy that concomitantly delivers a 450% increase in the material removal rate over the state of the art is demonstrated.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 134-141"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036894","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 numerical investigation of shape asymmetry in slit die foam extrusion","authors":"Claudio Esposito,&nbsp;Marco Trofa,&nbsp;Daniele Tammaro,&nbsp;Lorenzo Lombardi,&nbsp;Gaetano D’Avino,&nbsp;Pier Luca Maffettone","doi":"10.1016/j.jmapro.2026.01.073","DOIUrl":"10.1016/j.jmapro.2026.01.073","url":null,"abstract":"<div><div>Foam extrusion through slit dies often suffers from shape asymmetry that compromise product quality and increase waste. This work combines experiments and computational fluid dynamics simulations to investigate the influence of die geometry and pulling velocity on foam board morphology. Two slit dies with different central heights are tested at varying pulling speeds using low-density polyethylene with isobutane as a blowing agent. Experiments show that dies with a large central height promote nearly rectangular boards with uniform bubble morphology, whereas those with a small gap produce pronounced N-shaped distortions and surface irregularities. Higher pulling velocity mitigates asymmetry of the extrudate shape but reduces expansion and leads to smaller, more elongated bubbles due to rapid quenching. Despite employing a simplified Newtonian rheology and a reduced computational domain, simulations qualitatively reproduce the experimental trends, elucidating the contribution of the velocity and pressure gradients at the die exit that drive asymmetric expansion.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 99-110"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036891","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":"Heterogeneous Al–Zn–Mg-Cu and Al–Cu–Li layered composite fabricated by friction deposition additive manufacturing","authors":"Shuwei Duan ,&nbsp;Yimeng Ye ,&nbsp;Yuyang Zou ,&nbsp;Tao Wang ,&nbsp;Xiaoyang Yi ,&nbsp;Zhongli Liu ,&nbsp;Kenji Matsuda ,&nbsp;Yong Zou ,&nbsp;Fuqiang Guo","doi":"10.1016/j.jmapro.2026.01.084","DOIUrl":"10.1016/j.jmapro.2026.01.084","url":null,"abstract":"<div><div>Solid-state additive manufacturing of high-strength aluminum composites offers a promising route to overcome performance trade-offs inherent in monolithic alloys. This study presents the fabrication of a layered Al–Cu–Li/Al–Zn–Mg–Cu composite via friction surfacing deposition additive manufacturing (FSD-AM). Microstructural and mechanical analyses reveal sound interfacial bonding achieved through materials plastic flow and transfer, without forming detectable intermetallic compounds or continuous diffusion layers. The Al–Zn–Mg–Cu layers exhibit a finer recrystallized grain structure and a high number density of η' (MgZn₂) precipitates, delivering a tensile strength exceeding 500 MPa. In contrast, the Al–Cu–Li layers, with coarser grains and sparse T₁ (Al₂CuLi) precipitates, provide superior ductility (&gt;18% elongation). This architecture, comprising alternating “high-strength/low-ductility” and “medium-strength/high-ductility” layers of dissimilar high-strength aluminum alloys, coupled with a balanced corrosion performance, demonstrates a possible strategy to synergistically tailor strength, ductility, and durability for next-generation aerospace structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 509-515"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080327","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 welding penetration prediction model for laser welding process based on self-supervised learning using physics-informed neural networks","authors":"Sen Li ,&nbsp;Xiaoying Liu ,&nbsp;Xiaojian Xu ,&nbsp;Chendong Shao ,&nbsp;Yaqi Wang ,&nbsp;Ling Lan ,&nbsp;Xinhua Tang ,&nbsp;Haichao Cui","doi":"10.1016/j.jmapro.2026.01.035","DOIUrl":"10.1016/j.jmapro.2026.01.035","url":null,"abstract":"<div><div>The laser welding full-penetration is of critical importance, as it constitutes one of the fundamental factors in achieving defect-free welded joints. Accurate prediction of the penetration state is therefore essential for ensuring weld quality. To this end, this paper introduces SimPhysNet, a novel algorithm that achieves high classification accuracy in laser welding penetration prediction using only a limited number of labeled images. This approach effectively overcomes the limitations of supervised learning classification algorithms, which are hindered in industrial applications by their dependence on extensive, high-quality labeled data. The core of SimPhysNet is a unique self-supervised learning paradigm that embeds physical priors into a contrastive learning framework. By incorporating a physics-informed neural network (PINN), the model is guided to extract physically meaningful features of the molten pool and keyhole from a large set of unlabelled data, while three image augmentation tasks further enhance its generalization capabilities. Subsequently, a few-shot learning strategy, based on prototypical networks, enables robust classification by constructing class representations from a minimal set of labeled images. Experimental results demonstrate that SimPhysNet achieves a classification accuracy of 96.06% using only 200 labeled images (approximately 5% of the total labeled dataset), which is comparable to the performance of conventional supervised learning algorithms that utilize the entire labeled dataset. This work presents a new, efficient, and highly accurate method, providing the way for the intelligent automation of laser welding.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 642-662"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146189741","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":"Control of the centerline segregation by manipulating dendritic growth for slab casting of HSLA steel through roller-type electromagnetic stirring","authors":"Liang Chen ,&nbsp;Pu Wang ,&nbsp;Jinwen Jin ,&nbsp;Shengkai Hu ,&nbsp;Zhenjie Du ,&nbsp;Jiaquan Zhang","doi":"10.1016/j.jmapro.2026.01.067","DOIUrl":"10.1016/j.jmapro.2026.01.067","url":null,"abstract":"<div><div>Controlling centerline segregation in high-strength low-alloy (HSLA) steel slabs is essential for producing high-end automotive sheets, as this defect seriously compromises mechanical properties, fatigue resistance, and service life. Therefore, this study quantitatively investigates the mechanisms of dendrite deflection and fragmentation under roller-type electromagnetic stirring (R-EMS), and demonstrates how controlled dendritic growth can effectively mitigate centerline segregation in HSLA steel. The research shows that dendrite deflection exhibits a significant flow-aligned growth characteristic, with deflection primarily occurring in regions with a liquid fraction higher than 0.7, and is regulated by flow velocity: at low velocities, it is dominated by the asymmetry of the concentration boundary layer; at high velocities, it evolves into a competitive mechanism between fluid mechanical force and the solute field. The study further established a quantitative relationship between the critical flow velocity for dendrite fragmentation and its necking degree (characterized by the necking factor <em>β</em>), finding that the critical velocity is inversely proportional to <em>β</em>³, and the critical fragmentation velocity for a dendrite without necking is 0.582 m/s. Regarding process impact, the study found that although excessive stirring can provide a large number of heterogeneous nuclei by promoting dendrite fragmentation, thereby advancing the columnar-to-equiaxed transition (CET), it leads to coarsening of equiaxed crystals and aggravates centerline segregation. By optimizing the stirring configuration—deactivating the first pair of stirrers while maintaining a high current in the second pair—the massive nucleation of equiaxed grains was effectively delayed. This strategy yielded a suitable equiaxed grain ratio of 28.3% and stabilized centerline segregation at level C 0.5, providing a theoretical foundation and a practical strategy for producing HSLA steel slabs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 142-157"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036895","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":"Femtosecond laser bonding of transparent polycarbonate: a study on the weld seam quality and strength","authors":"Soheil Alee Mazreshadi ,&nbsp;Pol Vanwersch ,&nbsp;Tim Evens ,&nbsp;Sylvie Castagne","doi":"10.1016/j.jmapro.2026.01.070","DOIUrl":"10.1016/j.jmapro.2026.01.070","url":null,"abstract":"<div><div>Reliable bonding of transparent polymers is essential for microfluidic and biomedical devices. Ultrashort laser welding provides localized energy deposition with minimal heat-affected zones, but nonlinear absorption introduces challenges in achieving consistent weld quality. This study investigates femtosecond laser bonding of transparent polycarbonate using a 1030 <span><math><mi>nm</mi></math></span> source, focusing on the effects of fluence per pulse, scanning speed, and repetition rate. Two degradation mechanisms are identified: excessive cumulative fluence and high per-pulse fluence, both defining operational limits. At optimized fluence values, pre-focal absorption before the focus causes a focal offset between the intended and actual weld location. Even after refocusing on the interface, the gap between plates and the distorted beam profile produce a non-uniform fluence distribution, compromising weld quality. Simulations confirm that such offsets distort beam shape and fluence delivery. To overcome this, a low-fluence with high-overscan strategy is proposed, mitigating offset effects. Uniform welds are achieved at a repetition rate of 1 <span><math><mi>MHz</mi></math></span> with scanning speeds ranging from 10 to 30 <span><math><mi>mm</mi><mo>/</mo><mi>s</mi></math></span> and fluences of 0.08–0.17 <span><math><mi>J</mi><mo>/</mo><msup><mi>cm</mi><mo>²</mo></msup></math></span>, with more than five overscans. FTIR measurements are performed to monitor potential chemical changes in the bonded regions. The optimized process has a maximum shear strength of 30.2 ± 5 <span><math><mi>N</mi><mo>/</mo><msup><mi>mm</mi><mo>²</mo></msup></math></span>, corresponding to 48% of pristine polycarbonate. Weibull analysis identifies a highest modulus of 5.2, confirming process reliability. Devices withstand leakage tests up to 1 <span><math><mi>bar</mi></math></span>. This approach establishes a reproducible femtosecond welding strategy for transparent polymers, resulting in stronger, and more reliable fabrication of microfluidic and biomedical systems.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 413-428"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080393","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}