Journal of Manufacturing Processes最新文献

{"title":"Impact variation of workpiece stiffness on drilling of CFRP/Ti thin stacks","authors":"Changlin Du,&nbsp;Rao Fu,&nbsp;Wenhao Zhai,&nbsp;Jinlong Liu,&nbsp;Guanping Cui,&nbsp;Meng Zhao,&nbsp;Fuji Wang","doi":"10.1016/j.jmapro.2025.03.001","DOIUrl":"10.1016/j.jmapro.2025.03.001","url":null,"abstract":"<div><div>High-quality drilling Carbon Fiber Reinforced Polymer (CFRP)/Titanium alloy (Ti) stacks is a significant challenge in the aerospace industry, especially for thin stacks. This study investigates the drilling behavior of CFRP/Ti thin stacks under various stiffness conditions and reveals the impact of stiffness variation. Various quantified stiffness conditions were set for drilling tests and analysis. The results indicate that when the drill bit fully penetrates CFRP and still cuts Ti, an interlayer gap will be formed between CFRP and Ti layers, and lower stiffness will enlarge the interlayer gap. The maximum thrust force was found to decrease linearly by 3–4 % with every 70 % increase in clamping length, even though the thrust force increased over a longer period in low-stiffness cases. Ti cutting chips were consistently extruded into the interlayer in low stiffness cases, which consequently caused scratching and damaged the interlayer surface. In addition, the extruded chips lead to a reverse deformation of CFRP, which enlarges the gap and further aggregates chip extrusion and interlayer damage. Meanwhile, three additional CFRP removal phenomena caused by deformation and Ti chip scratching were observed, chip scratching was the most serious, and the mechanism of hole-shape formation was revealed. Compared to the CFRP hole, the shape of the Ti hole was barely affected by its deformation, but its position error was enlarged due to in-suit changing deformation and the position-based cylindricity errors of the stacks were also affected. More importantly, the beginning of Ti chip extrusion was proposed as a critical condition for low-stiffness stack drilling when the gap exceeds the Ti chip curl height, which has been proved by integrated simulation and experiment analyses. This critical condition and its correlated clamping distribution could be adopted as free interlayer damage drilling instruction for low stiffness CFRP/Ti stack.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 627-637"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578255","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":"Numerical modelling of material fracture caused by the Mannesmann effect","authors":"Zbigniew Pater","doi":"10.1016/j.jmapro.2025.03.035","DOIUrl":"10.1016/j.jmapro.2025.03.035","url":null,"abstract":"<div><div>This paper relates to the problem of modelling material fracture caused by the so-called Mannesmann effect, a phenomenon that frequently occurs in cross and skew rolling processes. First, previous studies on numerical modelling fracture in rotary tube piercing and cross wedge rolling processes are described. The literature review shows a lack of studies investigating the propagation of cracks due to the Mannesmann effect. To fill this knowledge gap, a study involving both numerical analyses and experiments was undertaken. The study used a test based on rotary compression of a cylindrical specimen; the test is used for material damage function calibration. Rotary compression was performed under cold forming conditions for aluminium alloy Al99.7 and under hot forming conditions for steel C45. Based on results of the rotary compression test for aluminium, a new method was developed for determining the critical value of damage using cylindrical specimens with initiated fracture. Following the establishment of the critical damage value for alloy Al99.7, the rotary compression process was simulated numerically, which consisted of 3D modelling the axial crack propagation caused by the Mannesmann effect. In addition to that, the effect of the formed crack on the state of stress in the workpiece was determined. After that, the critical damage of steel C45 in the temperature range 950 °C–1100 °C was determined. The obtained critical damage value was validated by simulating material fracture in a cross wedge rolling process that was earlier conducted under laboratory conditions. The numerical and experimental results of material fracture showed very high agreement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 650-666"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578256","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":"Synchronously tailoring of residual stress and surface quality of high-strength titanium alloy tube using magnetic field-assisted finishing","authors":"Dong Wei ,&nbsp;Heng Yang ,&nbsp;Jingchao Yang ,&nbsp;Jiagang Xue ,&nbsp;Pei Zhang ,&nbsp;Heng Li","doi":"10.1016/j.jmapro.2025.02.085","DOIUrl":"10.1016/j.jmapro.2025.02.085","url":null,"abstract":"<div><div>High-strength titanium alloy tubes are widely used as key materials in hydraulic and fuel systems in aeronautic industries, which are subjected to harsh conditions such as alternating loads and oil erosion during the service process. The residual stress state and the surface quality of the tubes are crucial to their service performance. However, these tubes are primarily prepared through a cold pilgering process, and the finished tube exhibits significant residual tensile stress on the outer surface, which cannot be changed with the variation of the process parameters. Moreover, the conventional shot peening process can only achieve the outer surface treatment while causing surface roughening, thereby reducing the fatigue strength and stress corrosion resistance. Accordingly, this study aims to achieve the synchronous tailoring of the residual stress and surface quality of high-strength titanium alloy tubes by introducing magnetic field-assisted finishing (MAF) technology, as well as to investigate the residual stress evolution mechanisms during the MAF process. The effects of MAF parameters on the residual stress and surface quality of the tubes are revealed firstly. With the increase in magnetic needle diameter and disk rotational speed, the residual compressive stresses exhibit a gradually increasing trend on the inner and outer surfaces of the tubes, with the maximum residual compressive stress reaching −600 MPa. While the surface roughness of the inner and outer surfaces of the tubes firstly decreases and then increases, with the lowest Ra values of 0.24 μm and 0.52 μm for the outer and inner surfaces, respectively. Secondly, the residual stress evolution mechanisms during the MAF process are elucidated. During the MAF process, significant plastic deformation occurs in the region near the surface of the tube with a depth of approximately 90 to 100 μm. The dislocation densities along the wall thickness direction show gradient distribution characteristics, with a gradual decrease trend from the surface to the middle layer. The increase in the difference in dislocation density between the area near the surface and the middle layer results in the distribution characteristics of residual compressive stress on the surface of the tubes after MAF. It can be concluded that MAF can effectively tailor the residual stress on the outer and inner surfaces of high-strength titanium tubes by adjusting the magnetic needle diameter and disk rotational speed, without reducing the surface quality of the tubes, and is of great significance for improving the fatigue service performance of the tubes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 638-649"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577757","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":"Microstructure evolution and grain refinement mechanism of ultrasonic-assisted low-frequency pulse VPPA welded joint of AA2195-T8 Al-Cu-Li alloy","authors":"Guihan Cui,&nbsp;Chunli Yang","doi":"10.1016/j.jmapro.2025.03.026","DOIUrl":"10.1016/j.jmapro.2025.03.026","url":null,"abstract":"<div><div>Variable polarity plasma arc welding is a widely utilized welding technique for the AA2195-T8 alloy. However, coarse grains adversely affect the weld's mechanical properties. This study integrates ultrasonic-assisted and low-frequency pulse welding processes to achieve grain refinement and enhance mechanical properties. The results indicated that high-amplitude ultrasound produced a superior grain refinement effect. However, this method also introduced numerous microscopic defects in the weld, compromising the mechanical properties. In contrast, low-frequency pulse welding exhibited less effective grain refinement than ultrasonic assistance without microscopic defects. The optimal grain refinement was achieved when low-amplitude ultrasound was combined with the high-difference pulse welding process, resulting in the best grain refinement effect. The weld grain morphology primarily consisted of refined equiaxed grains, with an average size reduction of 82 % (18.8 μm). The coarse second phase near the grain boundary was the Al-Cu-Mg-Ag eutectic phase. T1 and σ phases, along with dislocation lines, were prevalent in the grains. Compared to conventional welds, the tensile and yield strengths improved. However, the presence of some microcracks led to a reduction in elongation. The cavitation and acoustic streaming effects induced by ultrasonic assistance facilitated liquid convection and oscillation, resulting in more uniform second phases and disrupting coarse dendritic structures. Furthermore, the chilling effect of the pulse current promoted grain nucleation and accelerated molten pool flow, compensating for the limited grain refinement effect associated with low-amplitude ultrasound. At the late stage of solidification, the plasticity of the intercrystalline liquid film decreased, while the ultrasonic oscillation increased the strain, contributing to the formation of microscopic defects.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 679-693"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578258","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 gradient polishing depth on material removal mechanism of silicon wafer polishing by silicon dioxide abrasive based on molecular dynamics","authors":"Jianbo Le ,&nbsp;Juan Liu ,&nbsp;Miao Mei ,&nbsp;Hu Chen ,&nbsp;Hong Jiang ,&nbsp;Dongling Yu","doi":"10.1016/j.jmapro.2025.03.022","DOIUrl":"10.1016/j.jmapro.2025.03.022","url":null,"abstract":"<div><div>To study the effect of gradient polishing depth on the material removal mechanism of silicon wafers, the LAMMPS molecular dynamics method is utilized, combined with Lennard-Jones (LJ), Tersoff, and Stillinger-Weber (SW) potential functions. The nano-polishing process is investigated through gradient depth polishing experiments, with five different polishing depths of 2.2 <em>nm</em>, 2.4 <em>nm</em>, 2.6 <em>nm</em>, 2.8 <em>nm</em>, and 3.0 <em>nm</em> selected for analysis. By analyzing physical quantities such as polishing force, crystal structure, dislocation, radial distribution function, and coordination number, the effect of gradient polishing on material removal is revealed. The results show that at a polishing depth of 2.6 <em>nm</em>, the polishing force is stable, and the surface roughness reaches its minimum value (S<em>a</em> = 8.109 <em>nm</em>). Subsurface damage is minimized, and the Si-I phase structure remains intact, avoiding amorphization and phase transformation. This depth effectively removes material while preserving surface quality, making it the ideal polishing depth for enhanced processing efficiency. At polishing depths of 2.2–2.4 <em>nm</em>, shear strain begins to concentrate, and surface roughness starts to decrease. When the polishing depth increases to 2.4 <em>nm</em>, subsurface damage intensifies, and the roughness value becomes S<em>a</em> = 10.01 <em>nm</em>. At polishing depths of 2.8–3.0 <em>nm</em>, roughness reaches its highest value (S<em>a</em> = 11.843 <em>nm</em>), and the original silicon wafer structure Si-I transforms into Si-II phase, bct5-Si phase, and an amorphous state due to extrusion and shearing, resulting in decreased surface quality. This study provides an important theoretical foundation and practical guidance for optimizing the polishing process of silicon wafers and improving material removal efficiency and surface quality.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 746-759"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577756","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":"Inverse modeling of process parameters from data to predict the cooling behavior in injection molding","authors":"Manuel Wenzel ,&nbsp;Sven Robert Raisch ,&nbsp;Christian Hopmann ,&nbsp;Mauritius Schmitz","doi":"10.1016/j.jmapro.2025.02.057","DOIUrl":"10.1016/j.jmapro.2025.02.057","url":null,"abstract":"<div><div>AI methods, especially Deep Learning Methods (DLMs), present an excellent opportunity for the surrogate modeling of complex processes, like the injection molding process, based on simulation or measurement data. To overcome the need for large data sets DLMs usually require, the integration of domain knowledge into the learning process e.g., in the form of Partial Differential Equations (PDEs), is rising in popularity. In this study, an inverse approach based on Physics Informed Neural Networks (PINNs) is explored for parameterizing the influence of material and process parameters on the cooling behavior of an injection molded part. With the proposed method, the PDE, Initial Condition (IC), and Boundary Condition (BC) of the underlying physical process can be automatically parameterized based on data. To reduce modeling effort, a simplified generic representation of the physical process description is used. The effectiveness of the method is demonstrated by utilizing the inversely learned physical process model to regularize the surrogate model. When predicting the spatiotemporal temperature evolution dependent on different materials and process settings, a 25% lower Root-Mean-Squared-Error (RMSE) was achieved by the hybrid approach in comparison to a purely data-driven model. The use of the simplified process physics highlights the generalizability of the approach to other data types and processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 760-772"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143592621","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":"Microstructure evolution and plastic deformation behavior of DR-B2/ID-FCC phase lightweight high entropy alloy during improving thermal processing properties","authors":"Xueyu Jiang ,&nbsp;Xin Che ,&nbsp;Haoyu Zhang ,&nbsp;Siqian Zhang ,&nbsp;Xuelong Wen ,&nbsp;Ge Zhou ,&nbsp;Lijia Chen ,&nbsp;Peter K. Liaw","doi":"10.1016/j.jmapro.2025.03.041","DOIUrl":"10.1016/j.jmapro.2025.03.041","url":null,"abstract":"<div><div>This paper comprehensively benchmarks the aero-engine hot-end component material GH4169/Inconel718. A nickel-based lightweight high entropy alloy (HEA) with a nearly equimolar distribution of DR-B2 + ID-FCC was prepared using a multi-element non-equimolar design. And carry out hot compression experiments using XRD, TEM, and EBSD detection methods to study energy dissipation and redistribution (<em>η</em> value) as the starting point. The results indicate that heterostructure is beneficial for expanding the thermal processing window, and a machinable zone (900 °C/0.32 s⁻¹) also appears in the low <em>η</em> value interval. In the medium/high <em>η</em> value interval, the alloy has more machinable ranges due to the contribution of the dynamic response behavior of heterostructure and the evolution behavior of dislocations. The ID-FCC phase exhibits discontinuous dynamic recrystallization (DDRX), mainly forming {001} &lt; 0<span><math><mover><mn>1</mn><mo>¯</mo></mover></math></span>0 &gt; Cube texture. The DR-B2 phase is continuous dynamic recrystallization (CDRX) with no apparent preference for texture orientation. The volume fraction of FCC phase recrystallization (<em>X</em>_<em>rec</em>) is higher than that of the B2 phase (<em>X</em>_{<em>rec-FCC</em>}: <em>X</em>_{<em>rec-B2</em>} = 1.05–2.3), making it more prone to recrystallization. Meanwhile, the FCC/B2 phase deformation mechanism is mainly a dislocation climb creep mechanism (<em>n</em>₁ = 4.96). These research results guide designing lightweight heterostructure HEA with good thermal processing performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 725-745"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577755","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":"Multi-physical process simulation of resistance spot welding available for synthetic data generation","authors":"Tian-Le Lv ,&nbsp;Yu-Jun Xia ,&nbsp;Siva Prasad Murugan ,&nbsp;Fernando Okigami ,&nbsp;Hassan Ghassemi-Armaki ,&nbsp;Blair E. Carlson ,&nbsp;Yongbing Li","doi":"10.1016/j.jmapro.2025.03.024","DOIUrl":"10.1016/j.jmapro.2025.03.024","url":null,"abstract":"<div><div>Resistance spot welding (RSW) faces challenges when realizing online quality evaluation because of insufficient labeled data. Finite element (FE) models can generate synthetic databases, but their application is limited due to the reliability and generalization ability problem. This paper establishes an FE model that can digitally twin the welding gun characteristics, contact behavior, nugget growth process, and key process signals simultaneously. A multi-spring structure was designed to simulate the loading feature of a servo gun, and certain modifications in material properties were applied to the model. The simulation errors can be restricted to 2 % for the weld profile and 5 % for all process signals. A quick generalization method is also proposed to apply the FE model on different stack-ups, only needing modification in electrical contact resistance (ECR) parameters. The modeling and generalization methods were validated on 6 stack-ups consisting of three steels with different mechanical strengths, sheet thickness, and various chemical compositions, and also validated under different currents. The reliability and generalization ability of the proposed model are superior to traditional models, maintaining &lt;5 % and &lt;10 % errors in simulated nuggets and signals, respectively. ECR analysis shows that contact film resistivity is strength-related, and all stack-ups have similar electrical contact resistances at electrode/sheet interfaces. A preliminary synthetic database was generated, including 10 stack-ups and about 1500 data. This study can help provide labeled data for machine/deep learning algorithm training and for interpreting the physical process of RSW.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 709-724"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143577754","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":"Temperature-sensitivity points selection for positioning error modeling of CNC machine tools based on analytic hierarchy process","authors":"Yang Li ,&nbsp;Jiaqi Wang ,&nbsp;Yue Yang ,&nbsp;Xu Zhao ,&nbsp;Hexuan Shi ,&nbsp;Fusheng Liang","doi":"10.1016/j.jmapro.2025.03.011","DOIUrl":"10.1016/j.jmapro.2025.03.011","url":null,"abstract":"<div><div>Selecting the appropriate temperature-sensitivity points (TSPS) is the key to robustly predict the thermal error, which is an important part of the thermal error data-driven model (DDM). At present, grouping search is a comprehensive and scientific method to select the TSPS. However, the temperature measurement points with relatively low correlation to thermal error will be selected as the TSPS by this method, which can affect the performance and the stability of the error model's long-term prediction. Therefore, analytic hierarchy process (AHP) is introduced to alleviate this problem. In this paper, AHP is firstly applied to reassign the weights of the TSPS, and then the TSPS are reselected again according to the result. To prove the effectiveness of AHP, extreme learning machine with AHP (ELM-AHP) and other three classic models are taken as examples to construct the thermal error model. The results show that ELM-AHP model has high predictive accuracy and strong robustness. It is proved that AHP can solve the problem of TSPS with low correlation to a certain extent, which can reduce the number of TSPS, and simplify the error model.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 667-678"},"PeriodicalIF":6.1,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578257","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":"Weldability study of alloys 625 and 718 fabricated by laser-based additive manufacturing","authors":"Jhoan Guzman ,&nbsp;Kaue C. Riffel ,&nbsp;William Evans ,&nbsp;Eric Brizes ,&nbsp;Nicholas Avedissian ,&nbsp;Francisco Werley Cipriano Farias ,&nbsp;Antonio J. Ramirez","doi":"10.1016/j.jmapro.2025.02.051","DOIUrl":"10.1016/j.jmapro.2025.02.051","url":null,"abstract":"<div><div>Nickel-based alloys, Alloys 625 and 718, are widely used in the aerospace industry due to their excellent corrosion resistance and high strength at elevated temperatures. Recently, these alloys have been utilized to manufacture rocket engine components using additive manufacturing (AM) technologies such as laser powder bed fusion (LPBF) and powder-blown laser-based directed energy deposition (DED). These technologies offer faster and more cost-effective production while enabling the fabrication of near-net-shape parts that are subsequently joined by welding. However, solidification cracking susceptibility varies significantly between AM and conventionally processed materials, and limited weldability characterization has been conducted on AM-fabricated materials. This study assesses the weld solidification cracking susceptibility of Alloys 625 and 718 produced by wrought (mill-rolled), LPBF, and DED using transverse varestraint testing, Scheil-Gulliver simulations, the Crack Susceptibility Index (CSI), and the Flow Resistance Index (FRI). Transverse varestraint testing revealed that AM parts exhibited higher susceptibility due to the presence of larger and elongated grains in the fusion zone, affecting the weld solidification cracking response. In Alloy 625, the LPBF condition exhibited the highest maximum crack distance (MCD) of 2.35 ± 0.16 mm, compared to 1.56 ± 0.06 mm for wrought and 1.72 ± 0.10 mm for DED. Similarly, in Alloy 718, the DED condition showed the highest MCD of 2.93 ± 0.41 mm, while the wrought condition had an MCD of 2.01 ± 0.12 mm, and the LPBF condition reached 3.01 ± 0.33 mm at 5 % strain, without a clearly defined saturation strain. Although wrought materials demonstrated greater resistance to solidification cracking, solidification simulations did not correlate with the experimental testing, as they do not account for microstructural and mechanical factors, relying solely on chemistry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"141 ","pages":"Pages 556-569"},"PeriodicalIF":6.1,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143578251","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}