{"title":"Microstructures evolution and properties of titanium vacuum sintering on metal injection molding 316 stainless steel via dip coating process","authors":"Cheng Liang , Bo-Cheng Shen , Shih-Hsien Chang , Muhtadin Muhtadin , Jung-Ting Tsai","doi":"10.1016/j.jmapro.2024.09.082","DOIUrl":"10.1016/j.jmapro.2024.09.082","url":null,"abstract":"<div><div>Enhancing the surface coating of 316 L stainless steel, fabricated via metal injection molding, is crucial for its application in cost-effective, mass-produced components. This study investigated the titanium coating on 316 L stainless steel to address its limitations in mechanical performance. Titanium was coated on the 316 L stainless steel via a dip coating process, followed by vacuum sintering at temperatures of 1100 °C, 1150 °C, and 1200 °C. The optimal mechanical properties were achieved with a 100 μm thick coating sintered at 1200 °C, which exhibited uniformity and good bonding strength. The microstructure results demonstrated an average yield strength of 342.63 MPa and a polarization impedance of 968.48 Ω·cm<sup>2</sup>. Electron probe microanalysis confirmed the uniform diffusion of titanium into the stainless steel substrate, forming intermetallic phases such as Fe<sub>2</sub>Ti and NiTi. In addition, this study conducted a heat treatment process for the as-coated specimens. It was found that annealing at 750 °C for 4 h oil quenched and a 550 °C three-hour aging treatment the polarization impedance increases to 1243.3 Ω·cm<sup>2</sup> without compromising the yield strength. These findings indicate that the titanizing process enhances the mechanical properties of 316 L stainless steel, making it more suitable for demanding applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1073-1085"},"PeriodicalIF":6.1,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359666","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":"Multiphysics modeling of flow characteristics and particulate migration behavior of titanium matrix composites by laser directed energy deposition","authors":"Jiahao Zhang , Leilei Wang , Kai Zhao , Yunbo Hao , Feiyue Lyu , Zhuanni Gao , Yiqing Zhao , Xiaohong Zhan","doi":"10.1016/j.jmapro.2024.09.062","DOIUrl":"10.1016/j.jmapro.2024.09.062","url":null,"abstract":"<div><div>Incorporating ceramic particles into titanium alloys during the laser directed energy deposition (DED) process has been shown to significantly enhance the mechanical properties. However, particulate migration behavior within the melt pool and the influence of ceramic particles on the flow characteristics remain unclear. Here, we developed a model for multiphysics simulations to investigate the interaction mechanisms between molten pool and unmelted ceramic particles of TiC/Ti6Al4V titanium matrix composites. This model employs a coupling of computational fluid dynamics and the discrete element method (CFD–DEM). The effectiveness of our model was verified by comparing the transverse sections and high-speed photographs of the molten pool by conducting DED experiments. The simulation findings suggest that the concentration of TiC reinforcing particles greatly influences both the temperature distributions and velocity fields. Increasing the content of TiC resulted in faster absorption of laser energy, ultimately leading to an increase in peak temperature. Additionally, the augmentation of TiC content resulted in elevated molten viscosity, which impeded Marangoni flow. Meanwhile, the migration of TiC particles is mainly influenced by Marangoni convection. TiC ceramic particles were predominantly distributed within the upper and lower regions of the deposition layer, and the particle distribution is closely related to the position of particles entering the molten pool. These findings offer valuable insights into the multiphase dynamics of metal matrix composites during the additive manufacturing process employing DED technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1014-1029"},"PeriodicalIF":6.1,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142326601","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}
Tingyang Chen , Shujuan Dong , Zhenhua Cai , Chunming Deng , Xueqiang Cao
{"title":"Study on robot trajectory planning and coating thickness prediction for plasma spraying on complex surface","authors":"Tingyang Chen , Shujuan Dong , Zhenhua Cai , Chunming Deng , Xueqiang Cao","doi":"10.1016/j.jmapro.2024.09.081","DOIUrl":"10.1016/j.jmapro.2024.09.081","url":null,"abstract":"<div><div>Plasma spraying techniques are commonly employed for the deposition of thermal barrier coatings (TBCs) due to their efficiency and cost-effectiveness. However, ensuring uniform coating thickness and quality on complex free-form surfaces poses significant challenges. This paper investigates the influence of spraying trajectory and related parameters (spraying distance, angle, velocity) on coating thickness distribution, addressing the need for simplified analysis among numerous variables affecting coating quality. Different from the predominantly existing research focusing on flat or rotationally symmetric substrates, this study delves into the planning of spray trajectories for free-form surfaces, which is crucial for industries dealing with complex components, such as turbine blades. Innovative optimization approaches are employed to refine spray trajectories and improve coating consistency. Through theoretical modeling, simulation and experimental validation, the impact of spray parameters on coating thickness was demonstrated. Both the mean and disperssion coefficient errors of the coating thickness, obtained by the theoretical prediction model and the spray experiments, are lower than 10 %. The normal spray trajectory makes the coatings more evenly distributed, and the coating uniformity is at least 50 % higher than that of the codirectional spraying. This research contributes to the optimization of plasma spraying processes, particularly on irregular surfaces, thereby facilitating the development of high-performance TBCs for industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1046-1060"},"PeriodicalIF":6.1,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359664","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":"MPS-GAN: A multi-conditional generative adversarial network for simulating input parameters' impact on manufacturing processes","authors":"Hasnaa Ouidadi, Shenghan Guo","doi":"10.1016/j.jmapro.2024.09.067","DOIUrl":"10.1016/j.jmapro.2024.09.067","url":null,"abstract":"<div><div>Identifying the right combination of process parameters is crucial to ensure a high quality of the manufactured products. Nevertheless, this task is not always straightforward, as it usually requires a lot of experimental trials and a deep understanding of the physical laws governing the process. This study presents an efficient way of dealing with this problem using a generative adversarial network (GAN) model. The proposed Multi-Parameter Simulation GAN (MPS-GAN) model can synthesize thermal and X-ray computed tomography (XCT) images conditioned on different combinations of build parameters. The study also proposes a model variant, named MPS-GAN-IR, that uses the content loss to generate large images with improved perceptual quality and resolution. The performance of the MPS-GAN and MPS-GAN-IR was tested on real datasets taken from two different manufacturing processes, mainly resistance spot welding and additive manufacturing. The image-generation capability of both models was also evaluated for various combinations of build parameters for each process. The “quality measure” for each process was considered to provide a quantitative evaluation of the models' performance. The visual and numerical results indicate that the MPS-GAN and MPS-GAN-IR models could be a viable alternative to experimental tests and physics-based simulations.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1030-1045"},"PeriodicalIF":6.1,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142327252","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}
Carlo A. Biffi , Paola Bassani , Jacopo Fiocchi , Mohammadjavad Abdollahzadeh , Saeedeh Vanaei , Mohammadreza Nematollahi , Mohammad Elahinia , Ausonio Tuissi
{"title":"Effect of laser emission mode on processability map, microstructure and martensitic transformation of Shape Memory NiTi alloy produced by laser powder bed fusion","authors":"Carlo A. Biffi , Paola Bassani , Jacopo Fiocchi , Mohammadjavad Abdollahzadeh , Saeedeh Vanaei , Mohammadreza Nematollahi , Mohammad Elahinia , Ausonio Tuissi","doi":"10.1016/j.jmapro.2024.09.066","DOIUrl":"10.1016/j.jmapro.2024.09.066","url":null,"abstract":"<div><div>In this work, the process-ability, microstructure, and martensitic transformation of NiTi shape memory alloy samples built through Laser Powder Bed Fusion (LPBF) were correlated to different thermal cycles induced using continuous wave (CW) and pulsed wave (PW) laser emission modes. The effect of the temporal and spatial profile of the laser on the microstructure and martensitic transformation is investigated. In detail, relative density versus laser volumetric energy density curves were obtained using the two laser emission modes; the corresponding optimal conditions were determined for two values of hatch distance (80 and120 μm). Microstructural investigation of the samples was carried out for analyzing the liquid pool shape and the texture orientation. The effect of the laser emission mode on the transformation temperatures of the built samples was analyzed by differential scanning calorimetry (DSC). Finally, thermal modeling of the LPBF process was considered for obtaining the temperature field associated with the investigated process conditions. It was found that the feasibility maps don't overlap when the laser emission mode changes. However, using CW mode led to a small shift when the laser volumetric energy density was high. In contrast, PW mode needed lower volumetric energy density values to get the most relative density. Moreover, the different temporal profiles of the laser power emission induce different sizes and shapes of the melt pools, and it was found that they also induce a different texture of the microstructure. The numerical results showed that the PW emission mode induced higher temperatures than the CW one, promoting faster cooling rates. Finally, the laser emission mode also affects the martensitic transformation of the NiTi parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1061-1072"},"PeriodicalIF":6.1,"publicationDate":"2024-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142359665","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}
Debasish Mishra , Krishna R. Pattipati , George M. Bollas
{"title":"Gaussian mixture model for tool condition monitoring","authors":"Debasish Mishra , Krishna R. Pattipati , George M. Bollas","doi":"10.1016/j.jmapro.2024.09.038","DOIUrl":"10.1016/j.jmapro.2024.09.038","url":null,"abstract":"<div><div>This article presents an unsupervised method for monitoring tool condition in precision machining processes. The method utilizes cutting force measurements to infer the tool condition. It computes the tool health indicators by analyzing force signals in the Fourier space. The method calculates signal energy, magnitude, and variance of regions surrounding the tooth passing frequency (TPF) of the force spectra as health indicators of tool wear. Then, a Gaussian Mixture Model (GMM), as an unsupervised machine learning (ML) algorithm, utilizes these indicators to estimate the tool condition. The method is validated using two sets of tool run-to-failure tests conducted on different machines with varying capabilities to develop a generic approach that is applicable across machines and cutting parameter settings. The developed approach is also validated using the IEEE PHM 2010 data. Results show that the derived indicators are highly informative of the tool condition, with a high Pearson correlation coefficient of 0.94 with tool wear measurements, regardless of differences in machine or cutting parameter settings. Results also reveal that tool conditions can be clustered into a mixture of Gaussian distributions by the same health indicators. Classification accuracy of 0.965 is achieved on the in-house machining data and 0.96 with the IEEE PHM 2010 data. Results also demonstrate that the GMM effectively predicts the evolution of tool life with the longest duration in the initial usage period, decreases during the uniform wear stage, and reaches a minimum during the accelerating wear stage towards the end of life. These tool life stage durations are measured with respect to the number of machining test runs. The study emphasizes the significance of indicators derived from the physics of the process and highlights the importance of an unsupervised and explainable monitoring system for assessing the tool condition.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 1001-1013"},"PeriodicalIF":6.1,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142326600","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}
Chao Zeng , Jiutian Xue , Yun Jia , Shaomin Luo , Fang Huang , Xiangyao Liu , Yulei Du
{"title":"A review of additive manufacturing of metallic materials assisted by electromagnetic field technology","authors":"Chao Zeng , Jiutian Xue , Yun Jia , Shaomin Luo , Fang Huang , Xiangyao Liu , Yulei Du","doi":"10.1016/j.jmapro.2024.09.078","DOIUrl":"10.1016/j.jmapro.2024.09.078","url":null,"abstract":"<div><div>Although additive manufacturing (AM) technology has been developed for many years, traditional metallurgical defects are inevitable most of the time by solely optimizing process parameters. To improve the manufacturing quality of as-built AMed parts, the electromagnetic (EM) field may show great potential for online use through the magnetohydrodynamics effect on the melt pool. This work aims to give a dedicated review of the application of EM fields state-of-art in metal AM processes. The working principle and metal solidification theory in the EM field are elucidated, followed by a review of typical EM fields that have been used and how they are arranged in AM processes. The effect of EM fields on melt temperature characteristics and the transient melt flow during the manufacturing process, the subsequent influence on macro and microstructure characteristics, and finally the mechanical properties of the AMed parts are discussed. This work is expected to be helpful for a critical understanding of the EM-field-assisted AM process of metallic materials and the mechanisms of EM effect in AM processes up to date.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 920-946"},"PeriodicalIF":6.1,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142326599","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}
Donghan Yang , Zhiqiang He , Mengya Zhang , Yi Liu , Ling Li
{"title":"Molecular dynamics investigation of femtosecond laser ablation of Inconel 718 alloy","authors":"Donghan Yang , Zhiqiang He , Mengya Zhang , Yi Liu , Ling Li","doi":"10.1016/j.jmapro.2024.09.073","DOIUrl":"10.1016/j.jmapro.2024.09.073","url":null,"abstract":"<div><div>In this work, the expansion, spallation, pressure wave propagation, and structural evolution during femtosecond laser ablation of Inconel 718 alloy were investigated using molecular dynamics simulation. The results found that femtosecond laser ablation achieves deeper energy penetration than continuous laser, facilitating finer processing. Under the irradiation of femtosecond laser, the crystal structures of the target are gradually transformed from a long-range ordered structure to an amorphous structure, accompanied by the generation of stacking faults composed of BCC crystal structures. In addition, the effect of laser parameters is also examined. It is found that the expansion of the heat affected region with increasing laser fluences is one of the reasons for inducing compressive pressure generation. The transmission of the pressure wave is independent of the pulse durations, but the surface temperature rise of the target is closely related to the pulse durations. As pulse durations decrease, the surface ablation becomes more intense, which can be attributed to a higher temperature rise at the surface of the target rather than a greater tensile pressure. Thus, femtosecond laser ablation effect is caused by the combined impact of pressure wave and temperature. This work lays a theoretical foundation for exploring the dynamic thermodynamic mechanism phenomena and crystal structures evolution of high temperature alloy materials processed by femtosecond laser.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 984-1000"},"PeriodicalIF":6.1,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323319","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}
Boxiang Wang , Zhenhua Wang , Liyi Jiang , Weiwei Xu
{"title":"Investigation on the performance of spark plasma sintered ultrafine WC-Co cemented carbide end mills during high-speed precision milling of Ti-6Al-4V alloy","authors":"Boxiang Wang , Zhenhua Wang , Liyi Jiang , Weiwei Xu","doi":"10.1016/j.jmapro.2024.09.077","DOIUrl":"10.1016/j.jmapro.2024.09.077","url":null,"abstract":"<div><div>In this study, ultrafine WC-Co and WC-(Ti,W)C-Co cemented carbide end mills were fabricated via spark plasma sintering. The performance of those tools in the high-speed precision machining of Ti-6Al-4V alloy was investigated, focusing on the analysis of tool wear mechanisms, cutting performance, and machined surface roughness. The results reveal that adhesive wear emerges as the predominant wear mechanism influencing the performance of both tools. The addition of (Ti,W) C leads to high workpiece element enrichment on the flank face of the tool, increasing subsequently severe adhesive wear. WC-(Ti,W)C-Co displays a greater propensity for crack propagation and material chipping, culminating in premature tool failure with the formation of significant wear craters and cutting edge breakage. Conversely, WC-Co exhibits comparatively milder wear patterns and a reduced incidence of cutting edge chipping due to its inherent resistance to adhesive wear. Additionally, the comparison of the developed ultrafine cemented carbide tools with similar commercial tools demonstrates that WC-Co has superior cutting performance in terms of tool life, 1.5–1.8 times longer than the commercial tools. These findings provide guidance for optimizing machining strategies and developing advanced tool materials for high-speed milling titanium alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 973-983"},"PeriodicalIF":6.1,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323318","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}
Jun Uk Lee , Jeong Myung Yung , Kwangseuk Kyhm , Bo-Sung Shin , Patrick C. Lee
{"title":"Non-thermal inactivation effects of metal oxide nanoparticles–graphene composite films on foodborne pathogens to reduce proliferation","authors":"Jun Uk Lee , Jeong Myung Yung , Kwangseuk Kyhm , Bo-Sung Shin , Patrick C. Lee","doi":"10.1016/j.jmapro.2024.08.024","DOIUrl":"10.1016/j.jmapro.2024.08.024","url":null,"abstract":"<div><div>Emergence of antibiotic-resistant foodborne pathogens poses a significant threat to global public health. There is an urgent demand for next-generation antibacterial materials to effectively control the proliferation of pathogenic bacteria. This study fabricated graphene films with bactericidal properties via an approach that entailed the laser synthesis of high dense and uniform metal oxide nanoparticles, viz., titanium dioxide (TiO<sub>2</sub>), copper (II) oxide (CuO), and iron (II) oxide (Fe<sub>3</sub>O<sub>4</sub>) nanoparticles, directly onto ultraviolet laser-induced graphene (UV-LIG) surfaces. Bacterial treatment on UV-LIG decorated with dense and uniform TiO<sub>2</sub> nanospheres significantly reduced the counts of <em>Bacillus cereus</em>, <em>Salmonella enterica</em> serovar Typhimurium, <em>Escherichia coli</em> O157:H7, and <em>Staphylococcus aureus</em> to below the detection limit (log CFU/mL), achieving above 99.999 kill rate. TiO<sub>2</sub>/UV-LIG films limited cell proliferation rates of pathogens <em>B. cereus</em> to 1.3 % and <em>S. Typhimurium</em> to 2.1 % after 24-h. These results demonstrate that utilizing highly dense and uniform TiO<sub>2</sub> nanospheres on UV-LIG composite films is a promising strategy for combating foodborne pathogens.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"131 ","pages":"Pages 910-919"},"PeriodicalIF":6.1,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323315","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}