Journal of Manufacturing Processes最新文献

{"title":"Predicting and preventing layer-wise surface defects: Towards proactive quality control in laser powder bed fusion","authors":"Chenguang Ma ,&nbsp;Aoming Zhang ,&nbsp;Zhangdong Chen ,&nbsp;Xiaojun Peng ,&nbsp;Jiao Gao ,&nbsp;Yingjie Zhang","doi":"10.1016/j.jmapro.2025.04.080","DOIUrl":"10.1016/j.jmapro.2025.04.080","url":null,"abstract":"<div><div>The quality of as-built parts in laser powder bed fusion (LPBF) is significantly affected by the condition of each manufactured layer. This study introduces a proactive quality control approach that integrates predictive modeling and dynamic process control to improve layer-wise surface quality. Specifically, an encoder-convolutional long short-term memory (ConvLSTM)-decoder model is developed to predict the surface morphology of subsequent layers using sequential post-recoating images. These predictions enable a control strategy that dynamically adjusts laser power to maintain consistent surface quality. Experimental results demonstrate that this approach facilitates early detection of potential surface defects, allowing for timely process parameter adjustments and preventing defect progression. Parts manufactured with this proactive strategy exhibit significantly improved surface quality compared to those produced without such adjustments. This integration of predictive modeling and proactive control offers a promising solution to maintain high surface quality and enhance overall part quality in LPBF processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 630-641"},"PeriodicalIF":6.1,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143898438","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":"Impact of process parameters on mechanical and microstructure properties of aluminum alloys and aluminum matrix composites processed by powder-based additive manufacturing","authors":"Zummurd Al Mahmoud ,&nbsp;Babak Safaei ,&nbsp;Mohammed Asmael ,&nbsp;Mohammad Saleh Kenevisi ,&nbsp;Saeid Sahmani ,&nbsp;Sina Karimzadeh ,&nbsp;Tien-Chien Jen ,&nbsp;David Hui","doi":"10.1016/j.jmapro.2025.04.059","DOIUrl":"10.1016/j.jmapro.2025.04.059","url":null,"abstract":"<div><div>This review provides a critical synthesis of aluminum (Al) alloys and aluminum matrix composites (AMCs) fabricated utilizing powder-based additive manufacturing (AM) techniques, with a focus on Powder Bed Fusion (PBF) and Direct Energy Deposition (DED). The work systematically examines how key process parameters such as laser power, scan speed, and energy density—influence microstructural topographies like porosity, grain morphology, and reinforcement distribution, which in turn govern mechanical performance. AlSi10Mg is identified as a widely used AM alloy due to its favorable mechanical and thermal properties. The addition of ceramic reinforcements such as TiB₂, SiC, and Ta nanoparticles enhances strength and grain refinement, although challenges remain in achieving uniform dispersion and minimizing interfacial defects. Powder characteristics, including particle size distribution and morphology, are shown to significantly affect packing density, melt pool behavior, and final part quality. Post-processing methods, including heat treatment and hot isostatic pressing (HIP), are reviewed for their roles in improving ductility and relieving residual stress. However, their effectiveness varies between PBF and DED due to differences in thermal profiles and solidification rates. Hybrid AM approaches and AI-driven process optimization are highlighted as emerging solutions for achieving more consistent microstructural control and defect mitigation. Despite advancements, gaps persist in understanding fatigue behavior, creep resistance, impact strength, and vibration tolerance in AMCs. This review addresses these limitations and introduces a structured framework linking process parameters to final properties, supporting the development of reproducible, high-performance aluminum-based AM components for industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 79-158"},"PeriodicalIF":6.1,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899610","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":"Ultrasonic-driven grain refinement in high-frequency pulsed welding of Inconel 690 alloy: Interplay between ultrasonic and molten pool dynamic","authors":"Yunhao Xia ,&nbsp;Bolun Dong ,&nbsp;Xiaoyu Cai ,&nbsp;Qihao Chen ,&nbsp;Yangyang Fan ,&nbsp;Sanbao Lin","doi":"10.1016/j.jmapro.2025.04.092","DOIUrl":"10.1016/j.jmapro.2025.04.092","url":null,"abstract":"<div><div>This study investigates the influence of pulse frequency on high-frequency pulsed gas tungsten arc welding (HFP-GTAW) of Inconel 690 alloy. The results reveal that increasing pulse frequency significantly modifies arc morphology through electromagnetic constriction and thermal delay effects, leading to concentrated heat input. At 20 kHz, pronounced grain refinement occurs, marked by reduced columnar grain proportion to 66.15 % and improved grain misorientation uniformity, driven by ultrasonic cavitation and acoustic streaming effects. However, as the pulse frequency exceeds 20 kHz, ultrasonic effects weaken and heat source concentration dominates, resulting in coarser grain structures and reduced orientation uniformity. The theoretical analysis explores molten pool resonance further highlights the interplay relationship between frequency-selective of arc-induced ultrasonic and molten pool dynamics (thermal gradient) on grain growth. This study provides novel insights into the ultrasonic effect in HFP-GTAW, offering a foundation for optimizing welding processes to achieve superior microstructure in nickel-based alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 172-190"},"PeriodicalIF":6.1,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899612","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":"Variable amplitude drilling strategy for CFRP delamination suppression based on ultrasonic effects: Finite element simulation and experimental validation","authors":"Yiqing Shi,&nbsp;Chen Zhang,&nbsp;Xin Hu,&nbsp;Zhenan Dong,&nbsp;Yujie Shang","doi":"10.1016/j.jmapro.2025.04.057","DOIUrl":"10.1016/j.jmapro.2025.04.057","url":null,"abstract":"<div><div>Carbon fiber-reinforced plastic (CFRP) composites are extensively applied in aerospace industry for their excellent mechanical properties such as high specific strength and high specific modulus. During the drilling of CFRP components, delamination is one of the most significant defects affecting their mechanical performance. Ultrasonic vibration-assisted drilling can effectively suppress delamination. However, there hasn't been sufficient exploration on how the ultrasonic vibration effect can improve the drilled hole quality considering the CFRP delamination mechanism. In this paper, a three-dimensional finite element model for CFRP laminates is established and validated. Subsequently, the delamination mechanisms at the entrance and exit of CFRP laminates are analyzed separately, and the influence of processing parameters on ultrasonic vibration effects are analyzed. In light of the mechanisms, a variable amplitude machining strategy for CFRP drilling delamination suppression is proposed based on ultrasonic vibration effects. Finally, experiments were conducted for conventional drilling (CD), ultrasonic vibration-assisted drilling (UAD), and varying amplitude ultrasonic vibration-assisted drilling (VAUAD). The VAUAD group exhibited a reduction of 63.8 % and 17.3 % in the mean square deviation of entrance delamination factors compared to the CD and UAD groups, and the mean square deviation of exit delamination factors decreased by 54.9 % and 23.9 % for the VAUAD group compared to the CD and UAD groups. These results validate the effectiveness of this strategy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 616-629"},"PeriodicalIF":6.1,"publicationDate":"2025-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143896127","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":"Predictive modeling of deformation induced by residual stress for thin-walled parts in double-sided alternating precision turning","authors":"Shutao Qi ,&nbsp;Shuyang Yan ,&nbsp;Jinting Xu ,&nbsp;Yuwen Sun","doi":"10.1016/j.jmapro.2025.04.085","DOIUrl":"10.1016/j.jmapro.2025.04.085","url":null,"abstract":"<div><div>Thin-walled parts are susceptible to distortion because of residual stress release after machining, resulting in out-of-tolerance size. Hence, it's highly desirable to accurately predict the machining deformation to ensure the machining precision. However, modeling deformation for thin-walled parts in double-sided alternating precision turning, where the stress state undergoes continuous release and transfer throughout whole machining process, has not been thoroughly investigated. To address this issue, considering the effects of initial residual stress (IRS) and machining-induced residual stress (MIRS), a finite element model to predict machining deformation based on the iterative strategy of residual stress field is proposed in this paper. Among the model, a mapping strategy based on the bilinear interpolation is built to establish the cutting velocity (CV)-dependent MIRS field of the workpiece. The IRS field is obtained by the reconstruction strategy and the stress release and transfer of the workpiece is realized through continuous iterative modeling. A typical pure copper thin-wall planar part with a large diameter-to-thickness ratio is given as an example and simulations and experiments are then conducted to verify the model. The results show that compared with the model not considering stress release and transfer, the amplitude and distribution of the prediction deformation result by the proposed model are both in better agreement with the experiments, which alignments strongly attests to the efficacy of the proposed modeling approach.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 19-29"},"PeriodicalIF":6.1,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143892319","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":"Improving fatigue property of linear friction welded cruciform joints of low carbon steel","authors":"Huilin Miao ,&nbsp;Takayuki Yamashita ,&nbsp;Kohsaku Ushioda ,&nbsp;Seiichiro Tsutsumi ,&nbsp;Yoshiaki Morisada ,&nbsp;Hidetoshi Fujii","doi":"10.1016/j.jmapro.2025.04.093","DOIUrl":"10.1016/j.jmapro.2025.04.093","url":null,"abstract":"<div><div>Improving the fatigue performance of welded structures is a critical engineering challenge. While previous studies have shown that modifying the weld toe geometry can enhance the fatigue properties of linear friction welded (LFWed) butt joints, industrial applications often require cruciform joints. In this study, we aimed to improve the fatigue properties by fabricating a cruciform joint using linear friction welding (LFW) and changing the welding conditions. LFWed cruciform joints were fabricated using short-side oscillation, in which the long side of the rib vibrated perpendicular to the oscillation direction, as established in our previous study. The results showed that all LFWed cruciform joints with flash exhibited superior fatigue performance, with fatigue cycles exceeding FAT63, the design curve for cruciform joints defined by the International Institute of Welding. Increasing the upset was found to enhance fatigue life more effectively than increasing post-oscillation pressure. When both the post-oscillation pressure and upset were increased, fracture occurred at the weld toe, regardless of fatigue stress level. Under a nominal stress range of 161 MPa, the longest fatigue life was observed, with the joint remaining unbroken even after 1 × 10⁷ cycles. The transition from welding interface fracture to weld toe fracture, which significantly improved fatigue life, was influenced by an increased welding interface area due to a larger upset and a corresponding reduction in local stress at the weld toe of the welding interface. These findings indicate that increasing the upset to expand the welding interface area is an effective approach to improve the fatigue properties of LFWed cruciform joints. To fabricate defect-free cruciform joints using LFW, short-side oscillation with a larger upset is recommended.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 55-64"},"PeriodicalIF":6.1,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143894988","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":"Effects of rotating speed on microstructure and mechanical properties of Al/Ti friction stir welding joints with trailing support","authors":"Yingying Zuo ,&nbsp;Yisong Gao ,&nbsp;Huijie Liu,&nbsp;Yongxian Huang","doi":"10.1016/j.jmapro.2025.04.090","DOIUrl":"10.1016/j.jmapro.2025.04.090","url":null,"abstract":"<div><div>The property differences between Al and Ti pose challenges in achieving a high-quality bonding interface during friction stir welding (FSW). Optimizing the bottom heat behavior in Al/Ti FSW is crucial for improving interface bonding. Trailing support FSW (TSFSW) technology replaced the traditional back support with a trailing support column, and prevented huge heat loss from the joint bottom. The temperature in the bottom weld was similar to or higher than that in the middle weld. The ranges of Al-SZ and Al-TMAZ at the bottom weld were both enlarged. Plasticized Al metal achieved a cycle flow depending on three flow routes, while Ti metal had two local and independent flow routes. The horizontal and vertical bonding interfaces of Al and Ti were generated because of unique material flow. The tearing zone, mixed zone, local IMCs block and continuous IMCs layer were gradually formed in the vertical interface as heat input increased. The mixed zone characterized as TiAl₃/Ti laminated pattern was the main interface structure, while the continuous IMCs layer including TiAl₃ and TiAl phases formed only at excessive heating (650 rpm). The joints obtained by 450 rpm and 650 rpm both fractured at the Al/Ti interface, leading to low tensile and interface strength. The maximum joint strength and interface strength of 223 MPa and 251 MPa were achieved at 500 rpm. These two strength values reached 73 % and 82 % of Al-BM strength, respectively.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 44-54"},"PeriodicalIF":6.1,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143894989","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":"Impact of interpass temperature on the microstructure and mechanical properties of super duplex stainless steel in CW-GMA additive manufacturing","authors":"P. Poulain ,&nbsp;J. Wang ,&nbsp;S. Bouvier ,&nbsp;S. Williams ,&nbsp;S. Budnyk ,&nbsp;A. Gavrilovic-Wohlmuther","doi":"10.1016/j.jmapro.2025.04.091","DOIUrl":"10.1016/j.jmapro.2025.04.091","url":null,"abstract":"<div><div>This study investigates the influence of interpass temperature (IPT) on microstructure evolution and mechanical properties of super duplex stainless steel (SDSS) manufactured by cold wire gas metal arc (CW-GMA) additive manufacturing. Thermal cycle analysis showed that cooling rates were not significantly affected by IPT under constant process parameters. However, higher IPTs resulted in higher thermal accumulation and extended exposure to elevated temperatures. Microstructural characterisation revealed the transformation of δ-ferrite grains into various austenitic phases and secondary chromium nitrides during cooling. Fine, needle-like secondary austenite formation was more pronounced at higher IPTs, driven by chromium nitride precipitation near layer transitions. Mechanical testing demonstrated consistent ultimate tensile strength around 810 MPa across IPTs, with ductility variations attributed to porosity. Hardness profiles were uniform, averaging approximately 300 Hv. These findings suggest that while IPT influences thermal accumulation and microstructural details, its effect on ferrite-to-austenite ratio and mechanical properties is minimal. Optimising IPT remains essential for increasing the productivity of SDSS in CW-GMA additive manufacturing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"146 ","pages":"Pages 30-43"},"PeriodicalIF":6.1,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143894417","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 heat treatment and hot isostatic pressing on the structure and mechanical properties of Inconel 939 manufactured via casting and LPBF","authors":"Josef Sedlak ,&nbsp;Jan Zouhar ,&nbsp;Zdenek Pokorny ,&nbsp;Jan Robl ,&nbsp;Stepan Kolomy ,&nbsp;Marek Pagac ,&nbsp;Karel Kouril","doi":"10.1016/j.jmapro.2025.04.082","DOIUrl":"10.1016/j.jmapro.2025.04.082","url":null,"abstract":"<div><div>The powder bed fusion method is one of the metal additive technologies, which can be used for the fabrication of difficult-to-process materials, such as cobalt and nickel superalloys. Inconel 939 is an example of a nickel superalloy widely used in constructions subjected to high temperatures such as industrial gas turbines. The current paper studies the effect of heat treatment and Hot Isostatic Pressing (HIP) on the structure and mechanical properties of additively manufactured (AM) Inconel 939. Mechanical properties i.e., tensile yield strength, ultimate tensile strength, and creep resistance were observed after the heat treatment (comprised of annealing and subsequent aging), HIP, and compared to the conventionally casted material. HIP post-process caused an increase of 5.73 % and 3.81 % in ultimate tensile strength at the room temperature as well as at the elevated temperature. A detailed analysis of the microstructure of AM and casting samples via light and electron microscopy was performed. The maximum grain sizes in AM samples were similar (122.9 μm and 127.2 μm in the axis and periphery, respectively), while the grain size in casting samples exhibited a mean equivalent circle diameter of 440 μm in the axial region and 398 μm in the vicinity of the peripheral region.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 556-570"},"PeriodicalIF":6.1,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143887818","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":"Deposition strategy correlation with texture development, geometric homogeneity, and mechanical anisotropy in robotic WAAM-fabricated aluminum alloy thick walls","authors":"Deepak Kumar,&nbsp;Sunil Jha","doi":"10.1016/j.jmapro.2025.03.121","DOIUrl":"10.1016/j.jmapro.2025.03.121","url":null,"abstract":"<div><div>This research comprehensively examines the impact of deposition strategies on the microstructural evolution, geometric homogeneity, and mechanical properties of AA4043 aluminum alloy thick walls fabricated via robotic Wire Arc Additive Manufacturing (WAAM) using Cold Metal Transfer Gas Metal Arc Welding (CMT-GMAW). Utilizing unidirectional and bidirectional deposition techniques with a triangular weaving pattern, the study explores the influence of thermal gradients and solidification dynamics on grain morphology, texture development, porosity formation, silicon segregation, and mechanical anisotropy. Advanced characterization methods, including Field Emission Scanning Electron Microscopy (FESEM), X-ray Diffraction (XRD), and Energy Dispersive X-ray Spectroscopy (EDS), were employed to correlate the microstructural features with mechanical response characterized through uniaxial tensile tests and Vickers microhardness across different orientations. Fractography of fractured specimens elucidated failure mechanisms. Results indicated that unidirectional deposition promotes finer, relatively less elongated grains due to higher thermal gradients and rapid cooling rates, enhancing nucleation rates and leading to comparatively isotropic mechanical properties. In contrast, bidirectional deposition resulted in elongated grains aligned along the build direction, increased porosity, and pronounced silicon segregation at grain boundaries, culminating in anisotropic mechanical behavior. While unidirectional deposition promoted isotropic mechanical properties due to faster cooling rates and refined grain structure, bidirectional deposition offered superior geometric homogeneity and consistency, effectively minimizing the humping phenomenon. This improved geometric consistency leads to enhanced material-saving and sustainable manufacturing practices, as dimensional accuracy is critical in WAAM-fabricated structures. The scientific rationale behind these findings is supported by detailed microstructural analysis and mechanical testing, including hardness measurements and tensile testing. These results underscore the significance of deposition strategy in tailoring both the microstructure and geometric characteristics of WAAM components, contributing to the optimization of additive manufacturing processes for producing high-performance metallic components with minimal material wastage.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"145 ","pages":"Pages 545-555"},"PeriodicalIF":6.1,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143887819","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}