Journal of Manufacturing Processes最新文献

{"title":"A study on variable curvature trajectory planning method for robotic weld grinding based on line-structured light vision guidance","authors":"Dongliang Li ,&nbsp;Jimin Ge ,&nbsp;Zhaohui Deng ,&nbsp;Juchuan Dai ,&nbsp;Jigang Wu ,&nbsp;Lishu Lv ,&nbsp;Xian Wang ,&nbsp;Donggen Yang","doi":"10.1016/j.jmapro.2025.09.056","DOIUrl":"10.1016/j.jmapro.2025.09.056","url":null,"abstract":"<div><div>The service life and dynamic performance of structural welds are significantly influenced by the grinding precision and surface consistency. Currently, welding seam grinding is predominantly performed manually or through teaching methods, with the quality of grinding heavily reliant on the experience of the workers. Additionally, due to the complex shape and uneven curvature of weld seams, it is challenging to effectively track the weld seam contour, often resulting in workpiece scratches or inadequate weld seam removal during the grinding process. Based on the above problems, a trajectory planning method of robot weld grinding with variable curvature based on linear structured light vision guidance is proposed. Firstly, the effects of measurement angle (<span><math><mi>α</mi></math></span>) and forward-looking distance (<span><math><mi>l</mi></math></span>) on measurement error are analyzed based on the principle of pinhole imaging. This analysis yields the optimal measurement parameters (<span><math><mi>α</mi><mo>=</mo><msup><mn>90</mn><mo>°</mo></msup></math></span>, <span><math><mspace></mspace><mi>l</mi><mo>=</mo><mn>200</mn><mi>mm</mi></math></span>). Subsequently, the topological relationships between the weld point clouds are constructed, the three-dimensional topography is reconstructed, and the weld features (width, height, and centre position) are extracted. Next, the variable curvature-based grinding path planning method is described in detail. The proposed method can adaptively adjust the target points of discrete trajectories according to the threshold of curvature change, thereby enabling efficient and accurate tracking of the weld contour paths. To verify the effectiveness and superiority of this method, a comparative experiment on weld grinding was carried out with a curve weld of a pump truck as the experimental object. The experimental results show that the weld surface after grinding by this method is smooth, with no apparent ripples in the curvature transition zone, the minimum <em>Ra</em> value can reach 0.412 μm, and the average residual height is 0.151 mm.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 886-898"},"PeriodicalIF":6.8,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155035","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":"Fabrication of color tunable patterns using aerodynamically focused nanoparticle system","authors":"Minseok Kim,&nbsp;Jiseon Kim,&nbsp;Taehyeob Im,&nbsp;Sungjun Choi,&nbsp;Caroline Sunyong Lee","doi":"10.1016/j.jmapro.2025.09.048","DOIUrl":"10.1016/j.jmapro.2025.09.048","url":null,"abstract":"<div><div>Additive manufacturing-based patterning technologies have been actively explored for achieving simpler and more efficient fabrication and overcoming limitations of conventional patterning methods such as complex multistep processes and generation of toxic byproducts. To address this need, a novel solvent-free patterning system called aerodynamically focused nanoparticle (AFN) system was developed. This system utilizes aerodynamic control for precisely directing nanoparticle flow, thereby eliminating the need for solvents and post-processing. The AFN system demonstrated its ability to fabricate fine lines with a microsized width, narrower than the nozzle used, by adjusting air pressures for the two-step excitation and purging process.</div><div>In this study, the microsized patterns of tungsten trioxide were fabricated using an AFN system to fabricate a color-tunable (electrochromic) pattern. The pattern width and height were optimized by adjusting the scan times and jet pressure and analyzed using optical microscopy, a surface profiler, and scanning electron microscopy. Furthermore, the electrochromic performance evaluation confirmed the durability of AFN-patterned tungsten oxide lines, maintaining their stable operation without cracking or delamination for up to 500 coloration/bleaching cycles. The effective width of the pattern for color tuning was measured to be ∼91 μm, which is ∼14 % of the inner diameter (640 μm) of the nozzle, demonstrating that AFN can form patterns to be significantly narrower than that of the nozzle size via aerodynamically focusing process. This study highlights the contribution of the AFN system to advance electrochromic device technology by providing a highly precise and solvent-free method for electrochromic pattern formation.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 860-867"},"PeriodicalIF":6.8,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155036","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":"An asymptotic approach for temperature field prediction in process equipment based on generative and graph neural network models","authors":"Wanda Zhang ,&nbsp;Yanchao Yin ,&nbsp;Raymond Chiong ,&nbsp;Bin Yi ,&nbsp;Chao Deng ,&nbsp;Jiagang Zhang","doi":"10.1016/j.jmapro.2025.08.032","DOIUrl":"10.1016/j.jmapro.2025.08.032","url":null,"abstract":"<div><div>Thermal processing is commonly used in process manufacturing, where temperature is a critical factor dictating material phase transformations and microstructural evolution. Accurate and real-time calculation of the temperature field is essential for guiding certain production decisions. However, traditional offline methods involving numerical analysis are limited in their ability to support real-time process monitoring due to the complexity of the production environment. Additionally, temperature field data in production are often characterized by small sample sizes, significant discrepancies between input and output data dimensions, and complex temperature distribution patterns. Under these conditions, existing surrogate models typically struggle to achieve satisfactory accuracy. To address these challenges, this paper proposes a novel generative model for generating temperature data samples based on an encoding-decoding framework, which effectively balances dimensional discrepancies and facilitates the expansion of temperature data. Building on this, an asymptotic temperature field graph data modeling approach is introduced, which focuses on addressing dimensional differences and capturing spatial relationships among temperature points. A graph neural network is utilized to perform directional aggregation and feature updates based on the spatial correlations of temperature points, leading to an asymptotic solution architecture that enables accurate resolution of the temperature field. Finally, to enhance the model's adaptability to new data, we introduce transfer learning strategies—including error tracing and migration techniques—which significantly improve model performance in dynamic production environments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 843-859"},"PeriodicalIF":6.8,"publicationDate":"2025-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118845","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":"In-situ oxygen-regulated heterogeneous FeCrNi MEA via laser cladding: enhancement of tribo-corrosion and corrosion resistance","authors":"Wei Cheng ,&nbsp;Xiu-Bo Liu ,&nbsp;Xin-Gong Li ,&nbsp;Hai-Bin Zhou ,&nbsp;Yuan Meng ,&nbsp;Zhi-Yuan Liu ,&nbsp;Zhi-Yong Wang ,&nbsp;Shi-Hong Zhang","doi":"10.1016/j.jmapro.2025.09.044","DOIUrl":"10.1016/j.jmapro.2025.09.044","url":null,"abstract":"<div><div>In this study, the FeCrNi-X (X = Ti, TiO₂) composite coating was prepared via laser cladding to investigate the regulatory mechanisms of micro‑oxygen alloying on microstructure, tribological properties and corrosion resistance, thereby advancing their application and development in manufacturing processes, contributing to increased production efficiency and improving component performance. The result show that partially dissolved oxygen atoms inhibited lattice migration through the solute drag effect, while in-situ formed oxides and residual TiO₂ acted as heterogeneous nucleation sites, leading to the pinning effect. The combined effects cause the multiphase heterogeneous structure formation, consisting of BCC and FCC phases and dispersed oxides, which effectively suppresses grain boundary migration and coarsening, while concurrently hindering dislocation propagation during deformation. As a result, the hardness increased to 466.14 HV_0.5, which is 1.56 times that of the FeCrNi alloy. The FeCrNi-TiO₂ coating benefits from the pre-oxidation effect, which promotes the preferential formation of a density oxide layer that effectively prevents further oxidation. The I_corr values in salt and acid solutions (2.93 × 10⁻⁵ and 1.65 × 10⁻⁵ A/cm²) are only 0.539 and 0.245 times those of the FeCrNi-TiO₂ alloy, respectively. Moreover, wear debris produced under tribo-corrosion coupling tends to oxidize, forming hard oxides that contribute to friction and increase interfacial shear resistance in acidic corrosion environments. In contrast, wear debris formed in salt corrosion environments mainly comprises low-hardness chlorides, which serve as solid lubricants. This research aims to systematically investigate the enhancement mechanisms of micro‑oxygen on the wear and corrosion resistance of FeCrNi alloy, thereby advancing their application and development in manufacturing processes, contributing to increased production efficiency and improving component performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 827-842"},"PeriodicalIF":6.8,"publicationDate":"2025-09-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118846","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 new compliant polishing method using 3D-printed elastic polishing tool with TPMS structure","authors":"Cheng Fan ,&nbsp;Zhi Han ,&nbsp;Congyu Zha ,&nbsp;Gaopeng Sun ,&nbsp;Wenbin Wang ,&nbsp;Junfei Xu ,&nbsp;Feng Zhao ,&nbsp;Fusheng Liang ,&nbsp;Zhao Wang","doi":"10.1016/j.jmapro.2025.09.046","DOIUrl":"10.1016/j.jmapro.2025.09.046","url":null,"abstract":"<div><div>Leveraging the advantageous properties of Triply Periodic Minimal Surface (TPMS) structures, including tunable stiffness, lightweight design, superior heat transfer, and excellent energy absorption, this study utilizes 3D printing technology to develop a flexible polishing tool. The stiffness of the tool can be tuned by adjusting the type and relative density of the internal TPMS structures within the polishing head. Experimental and finite element analysis (FEA) were combined to simulate the compression behavior of TPMS lattice structures with different configurations and relative densities, revealing their tunable mechanical properties. Compression process simulations further revealed that an increase in relative density amplifies both the output pressure and its fluctuations, attributable to the distinctive structural properties of the architecture. Polishing experiments on K9 glass were conducted using the self-developed polishing tool on a robotic polishing platform, with processing performance evaluated through material removal rate, removal function, and surface roughness. Experimental results demonstrate the outstanding process stability and time-dependent controllability, achieving an average surface roughness Sa as low as 5.531 nm. The contact pressure critically influences the material removal rate, while pressure fluctuations from the internal TPMS structure affect surface roughness. The P-type structure, producing lower pressure, is ideal for fine finishing, whereas the higher-pressure D-type variant is better suited for coarse material removal. This novel tool provides a new pathway for ultra-precision machining applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 788-804"},"PeriodicalIF":6.8,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145109315","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":"Enhancement of surface quality and properties of NAK80 mold steel through hybrid laser polishing","authors":"Hang Zhang ,&nbsp;Xiaoyu Sun ,&nbsp;Xuebo Xu ,&nbsp;Jianglong Cai ,&nbsp;Dichen Li ,&nbsp;Xin Guo ,&nbsp;Feng Zhao ,&nbsp;Ziye He ,&nbsp;Binru Dong ,&nbsp;Lei Wang","doi":"10.1016/j.jmapro.2025.09.033","DOIUrl":"10.1016/j.jmapro.2025.09.033","url":null,"abstract":"<div><div>Laser polishing is an advanced surface processing technique. However, with the development of modern manufacturing, single laser polishing often fails to meet the stringent requirements for surface quality and performance in high-end manufacturing. This study aims to enhance the surface polishing quality as well as the mechanical and chemical properties of NAK80 mold steel by employing a hybrid laser polishing technique that combines continuous wave and pulsed lasers. The surface morphology, microstructure, microhardness, wear resistance, and corrosion resistance of unprocessed NAK80, single continuous wave laser polishing (CWP), and sequential continuous wave and pulsed laser hybrid polishing (CPP) samples were systematically investigated. The results revealed that the original surface roughness was 0.232 μm Ra, which decreased to 0.155 μm Ra and 0.094 μm Ra after CWP and CPP processing, respectively. Neither CWP nor CPP processing altered the phase composition of NAK80, which remained as α-Fe. Both processes resulted in the formation of a remelted layer that exhibited significant grain refinement, particularly in the CPP processed samples, where the smallest grain size (0.15–0.75 μm) was observed, along with a large number of low-angle grain boundaries (LAGBs, &lt;15°) enriched near the surface. Due to the grain refinement and increased presence of LAGBs, the hardness of CWP and CPP processed surfaces increased by 41.2 % and 51.9 %, respectively, compared to the original surface. Furthermore, both wear resistance and corrosion resistance were significantly improved. These enhancements in key performance indicators are expected to extend the service life of molds. This study underscores the significant potential of hybrid laser polishing technology, which is likely to find broader applications in the future, further advancing the manufacturing industry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 817-826"},"PeriodicalIF":6.8,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118848","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":"Real-time quality classification of robot self-piercing rivet processes in CFRP-steel joints using machine learning","authors":"Beomjin Kim ,&nbsp;Md. Saiful Islam ,&nbsp;Kihyun Kim ,&nbsp;Hyo-Young Kim","doi":"10.1016/j.jmapro.2025.08.056","DOIUrl":"10.1016/j.jmapro.2025.08.056","url":null,"abstract":"<div><div>This study presents a machine learning-based method for real-time quality classification of robotic self-piercing rivet (SPR) processes using pressing force as an input. Unlike previous studies focusing on general SPR processes, this study specifically targets automated robot SPR processes. Data for the study was acquired using a load cell, strain gauge, and accelerometer to develop a nondestructive quality evaluation system for real-time robotic SPR processes. This study introduced an effective and robust data preprocessing method to enhance quality classification by applying signal processing and data dimensionality reduction techniques to pressing force data. While recent advances in deep learning and machine learning have explored various complex networks to improve performance, research specifically addressing the quality of automated robot SPR processes remains limited. Although robotic SPR quality classification may appear similar to conventional SPR quality assessment, the data input differs significantly owing to the vibrations generated by industrial robots. These vibrations reduce the effectiveness of conventional classification methods, making accurate quality assessment more challenging. To address these challenges, six relatively simple yet effective machine learning algorithms were employed to demonstrate the advantages of the preprocessed features of the robotic SPR process, and the optimal algorithm was selected by comparing these algorithms. The proposed method was validated using real SPR data from two automotive production lines. By combining time-domain, processed, and dimensional reduced features from pressing force data, the machine learning model achieved 99.6 % accuracy in real-time SPR quality classification. This confirms its effectiveness and reliability for use in robotic manufacturing environments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 774-787"},"PeriodicalIF":6.8,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145109314","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":"Synergistic laser cladding and ion sulfurization strategy for in-situ FeS-WS2 solid lubrication film on CoCrFeNiW0.8 high-entropy alloy: Tribological system design and process-structure-property insight","authors":"Chunyang Hu ,&nbsp;Bin Han ,&nbsp;Gang Cui ,&nbsp;Meiyan Li ,&nbsp;Zubin Chen ,&nbsp;Jialin Wang ,&nbsp;Huiqiu Yuan ,&nbsp;Liqiang Wang ,&nbsp;Chunlong Liu","doi":"10.1016/j.jmapro.2025.09.050","DOIUrl":"10.1016/j.jmapro.2025.09.050","url":null,"abstract":"<div><div>This work employs ion sulfurization to fabricate a sulfide solid lubricating film on CoCrFeNiW_0.8 high-entropy alloy (HEA) coatings, aiming to enhance wear resistance and friction reduction. Systematic characterization reveals the HEA coating's multiphase composition (FCC, BCC, and α-phase) with an average hardness of 521 HV_0.2. A 3.8 μm thick porous feather-like FeS-WS₂ solid lubricating film was formed on the surface of the CoCrFeNiW_0.8 HEA coating, and the bonding force of this film to the HEA coating reached 43.9 N. Tribological tests revealed that the ion sulfurized HEA exhibited a 73.3 % reduction in friction coefficient (from 0.45 to 0.12) and a wear rate reduced to 52.4 % of the untreated HEA (from 4.2 mg to 2.2 mg) under a 3 N applied load. The lubricating film maintains stable low friction (0.11–0.15) across 1.5–4.5 N loads but loses its friction-reducing ability when the normal load reaches 5 N. Wear mechanism analysis identifies distinct transitions: untreated HEA progresses from abrasive to abrasive-fatigue wear, while the sulfurized coating exhibits mild abrasive wear through synergistic FeS-WS₂ lamellar lubrication and HEA substrate support. This study develops a wear-resistant tribological system combining the CoCrFeNiW_0.8 HEA substrate and the in-situ FeS-WS₂ solid lubricant film with strong interfacial adhesion. The synergy between HEA design and ion sulfurization technology establishes a new strategy for high-performance anti-wear applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 805-816"},"PeriodicalIF":6.8,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145118847","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 tool design on synergistic improvement of tribological and mechanical properties of AA5083/CeO2 + hBN hybrid surface composites fabricated via friction stir processing (FSP)","authors":"Yinwei Wang ,&nbsp;Azlan Mohd Zain ,&nbsp;Sherzod Abdullaev ,&nbsp;T. Satish Kumar ,&nbsp;Xiao Liu ,&nbsp;Sadok Mehrez ,&nbsp;Moslem Paidar","doi":"10.1016/j.jmapro.2025.09.041","DOIUrl":"10.1016/j.jmapro.2025.09.041","url":null,"abstract":"<div><div>This paper assessed and compared the effect of shoulder shape on microstructural, mechanical and tribological characteristics of AA5083/CeO₂ + hBN hybrid surface composites fabricated via friction stir processing (FSP). For this purpose, a novel tool defined as double step shoulder (DSS) tool was designed. It was found that the dissemination of CeO₂ + hBN particles within the matrix is one of the main reasons for the increment of hardness and thereby the improvement of wear and shear resistance. Results also showed that using the DSS tool during FSP not only can improve surface quality but also increase the material's plastic flow ability, thereby diminishing the chance of the formation of defects in the stirred zone. Attained data also revealed that DSS tool can also lead to better plasticization and further dissemination of CeO₂ and hBN particles within the matrix. An increase in the flowability of materials via a DSS tool also resulted in an improvement in the shear strength of the AA5083/CeO₂ + hBN hybrid surface composite from 159 MPa to about 193 MPa. The combined effect of the DSS tool on reducing the reinforcing particles and grain size not only remarkably improved the friction coefficient of the composites from 0.42 to 0.36 but also enhanced the wear resistance of the composite by eradicating large agglomerations of particles in the matrix.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 748-756"},"PeriodicalIF":6.8,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145109457","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":"Additive manufacturing of wear–resistant CuCMnNiTi HEA coating through entropy reduction–phase separation technique","authors":"Yuling Lu ,&nbsp;Yuxing Peng ,&nbsp;Xiangdong Chang ,&nbsp;XuePing Wang ,&nbsp;Zhiyuan Shi","doi":"10.1016/j.jmapro.2025.09.031","DOIUrl":"10.1016/j.jmapro.2025.09.031","url":null,"abstract":"<div><div>Copper (Cu)–based alloys with superior corrosion resistance are widely applied in industry, but their poor hardness limits their wider application. There are many researches focusing on adjusting the composition of Cu–based alloys to improve their deficiency, but the traditional “one–pot” process is difficult to form nanocrystals, which is unable to improve their hardness at the atomic level. Here, an innovative entropy reduction phase separation (ERPS) process was first proposed, and the additive manufacturing of Cu–based alloy high–entropy alloy (HEA) coating was achieved by the entropy reduction phase separation (ERPS), which included three steps of rapid prototyping, phase precipitation and enhanced phase stabilization. The CuCNiTiMn HEA coating was deposited using laser cladding (LC), and laser remelting (LR) and tempering treatment (TT) were used to release entropy and induce the phase separation at the grain boundaries, where the Cu/Ni₃Ti nanocrystalline crystals were formed. During the additive manufacturing process, the C element effectively inhibited the formation of oxides, and the Mn stabilized the Cu/Ni₃Ti nanocrystals in the CuCNiTiMn HEA coating. The hardness (624 HV_0.2) of CuCNiTiMn HEA coating is increased by 208 % compared with the commercial Cu–Ni–Ti alloy (∼300 HV_0.2) by the ERPS process, and the corresponding wear resistance (10⁻⁷ mm³/N·m) is also increased by 1000 times compared with the commercial Cu–Ni–Ti alloy (10⁻⁵ mm³/N·m). This ERPS process breaks through the hardness limit of the existing Cu–based alloys, which opens up a new idea for the application of Cu–based alloy coatings.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 731-747"},"PeriodicalIF":6.8,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145109316","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}