Journal of Manufacturing and Materials Processing最新文献_第2页

Monitoring of the Weld Pool, Keyhole Morphology and Material Penetration State in Near-Infrared and Blue Composite Laser Welding of Magnesium Alloy 监测镁合金近红外和蓝色复合激光焊接中的焊池、锁孔形态和材料渗透状态

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-15 DOI: 10.3390/jmmp8040150

Wei Wei, Yang Liu, Haolin Deng, Zhilin Wei, Tingshuang Wang, Guangxian Li

{"title":"Monitoring of the Weld Pool, Keyhole Morphology and Material Penetration State in Near-Infrared and Blue Composite Laser Welding of Magnesium Alloy","authors":"Wei Wei, Yang Liu, Haolin Deng, Zhilin Wei, Tingshuang Wang, Guangxian Li","doi":"10.3390/jmmp8040150","DOIUrl":"https://doi.org/10.3390/jmmp8040150","url":null,"abstract":"The laser welding of magnesium alloys presents challenges attributed to their low laser-absorbing efficiency, resulting in instabilities during the welding process and substandard welding quality. Furthermore, the complexity of signals during laser welding processes makes it difficult to accurately monitor the molten state of magnesium alloys. In this study, magnesium alloys were welded using near-infrared and blue lasers. By varying the power of the near-infrared laser, the energy absorption pattern of magnesium alloys toward the composite laser was investigated. The U-Net model was employed for the segmentation of welding images to accurately extract the features of the melt pool and keyhole. Subsequently, the penetrating states were predicted using the convolutional neural network (CNN), and the novel approach employing Local Binary Pattern (LBP) features + a backpropagation (BP) neural network was applied for comparison. The extracted images achieved MPA and MIoU values of 89.54% and 81.81%, and the prediction accuracy of the model can reach up to 100%. The applicability of the two monitoring approaches in different scenarios was discussed, providing guidance for the quality of magnesium welding.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141646413","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

The Influence of the Process Conditions on the Thermo-Mechanical Fatigue Damage of the Rolls in the Twin-Roll Casting Process of Aluminum Alloys 铝合金双辊铸造过程中工艺条件对轧辊热机械疲劳损伤的影响

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-12 DOI: 10.3390/jmmp8040149

Ratibor Shevchenko, N. Zani, A. Mazzù

{"title":"The Influence of the Process Conditions on the Thermo-Mechanical Fatigue Damage of the Rolls in the Twin-Roll Casting Process of Aluminum Alloys","authors":"Ratibor Shevchenko, N. Zani, A. Mazzù","doi":"10.3390/jmmp8040149","DOIUrl":"https://doi.org/10.3390/jmmp8040149","url":null,"abstract":"Twin-roll casting is a technology for the production of thin strips directly from liquid metal by combining continuous casting with hot rolling in a single step. The thermo-mechanical cyclic interaction with the solidifying strip causes fatigue crack formation at the outer surface of the rolls. A 2D FEM model with Eulerian boundary conditions and the interference fit load on the rolls was defined. The influence of the roll–strip thermal contact, the inlet temperature of the liquid aluminum, the efficiency of the water cooling and the production rate on the fatigue damage of the rolls was analyzed with a parametric study. The maximum temperature of the rolls, the maximum contact pressure, the accumulated plastic strain and the equivalent strain computed (considering a multiaxial out-of-phase fatigue criterion) were considered to investigate the thermo-mechanical fatigue load on the rolls. The results showed that, in the considered range, the most influential parameters on the fatigue mechanism are the heat contact conductance coefficient, which dominates the thermo-mechanical load, and the tangential velocity of the rolls, which contributes to the thermal field and determines the roll–strip mechanical contact interaction.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141652623","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

A Workflow for the Compensation of Substrate Defects When Overprinting in Extrusion-Based Processes 在挤压工艺中进行叠印时补偿基底缺陷的工作流程

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-09 DOI: 10.3390/jmmp8040147

Fynn Atzler, Simon Hümbert, Heinz Voggenreiter

{"title":"A Workflow for the Compensation of Substrate Defects When Overprinting in Extrusion-Based Processes","authors":"Fynn Atzler, Simon Hümbert, Heinz Voggenreiter","doi":"10.3390/jmmp8040147","DOIUrl":"https://doi.org/10.3390/jmmp8040147","url":null,"abstract":"Fused granular fabrication (FGF) is used in industrial applications to manufacture complex parts in a short time frame and with reduced costs. Recently, the overprinting of continuous fibre-reinforced laminates has been discussed to produce high-performance, functional structures. A hybrid process combining FGF with Automated Fibre Placement (AFP) was developed to implement this approach, where an additively manufactured structure is bonded in situ onto a thermoplastic laminate. However, this combination places great demands on process control, especially in the first printing layer. When 3D printing onto a laminate, the height of the first printed layer is decisive to the shear strength of the bonding. Manufacturing-induced surface defects of a laminate, like thermal warpage, gaps, and tape overlaps, can result in deviations from the ideal geometry and thus impair the bonding strength when left uncompensated. This study, therefore, proposes a novel process flow that uses a 3D scan of a laminate to adjust the geometry of the additively manufactured structure to achieve a constant layer height in the 3D print and, thus, constant mechanical properties. For the above-listed surface defects, only thermal warpage was found to have a significant effect on the bonding strength.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141664779","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effects of Layer Thickness and Compaction Thickness on Green Part Density in Binder Jetting Additive Manufacturing of Silicon Carbide: Designed Experiments 层厚和压实厚度对碳化硅粘合剂喷射增材制造中绿色部件密度的影响：设计实验

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-09 DOI: 10.3390/jmmp8040148

Mostafa Meraj Pasha, Md Shakil Arman, Fahim Khan, Zhijian Pei, Stephen Kachur

引用次数: 0

Selective Sheet Extrusion: A Novel Manufacturing Process for Large-Format Material Extrusion 选择性片材挤压：用于大型材料挤压的新型制造工艺

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-05 DOI: 10.3390/jmmp8040145

Brian Parrott, Angelica Coronado Preciado, Eric Feron

{"title":"Selective Sheet Extrusion: A Novel Manufacturing Process for Large-Format Material Extrusion","authors":"Brian Parrott, Angelica Coronado Preciado, Eric Feron","doi":"10.3390/jmmp8040145","DOIUrl":"https://doi.org/10.3390/jmmp8040145","url":null,"abstract":"The trade-off between resolution and speed represents a significant challenge when extrusion-based additive manufacturing (AM) is used for large-format additive manufacturing (LFAM). This paper presents an analysis of a new material extrusion process, named selective sheet extrusion (SSE), that aims to decouple these parameters. Unlike traditional single-nozzle material extrusion processes, SSE utilizes a single, very wide nozzle through which extrusion is controlled by an array of dynamically actuated teeth at the nozzle outlet. This allows the system to deposit a selectively structured sheet of material with each pass, potentially enabling the deposition of an entire layer of a part in a single pass. An analysis of the theoretical performance of the SSE technology, in terms of speed and material efficiency in comparison with single-nozzle extrusion systems, predicted speed increases of 2–3 times for the geometries that were explored. The analysis was then validated through experimental work that indicated a normalized improvement in print speed of between 2.3 and 2.5 times using a proof-of-concept SSE prototype. The SSE concept expands the opportunity frontier of LFAM technologies by enabling enhanced print speeds, while maintaining higher resolutions at scale. This enhancement in speed and/or resolution could have significant benefits, especially in large-scale prints that benefit from enhanced internal resolution.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141675954","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effect of Scanning Strategy on the Microstructure and Load-Bearing Characteristics of Additive Manufactured Parts 扫描策略对快速成型零件微观结构和承重特性的影响

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-05 DOI: 10.3390/jmmp8040146

S. S. Sajin Jose, Santosh Kr. Mishra, Ram Krishna Upadhyay

{"title":"Effect of Scanning Strategy on the Microstructure and Load-Bearing Characteristics of Additive Manufactured Parts","authors":"S. S. Sajin Jose, Santosh Kr. Mishra, Ram Krishna Upadhyay","doi":"10.3390/jmmp8040146","DOIUrl":"https://doi.org/10.3390/jmmp8040146","url":null,"abstract":"Additive manufacturing has witnessed significant growth in recent years, revolutionizing the automotive and aerospace industries amongst others. Despite the use of additive manufacturing for creating complex geometries and reducing material consumption, there is a critical need to enhance the mechanical properties of manufactured parts to broaden their industrial applications. In this work, AISI 316L stainless steel is used to fabricate parts using three different strategies of the additively manufactured Laser Powder Bed Fusion (LPBF) technique, i.e., continuous, alternate, and island. This study aims to identify methods to optimize grain orientation and compaction support provided to the material under load, which influence the frictional and wear properties of the manufactured parts. The load-bearing capacity is evaluated by measuring the frictional and wear properties. The wear patch track is also examined to establish the physical mechanisms at the surface interface that lead to the smooth transition in response to the load. Grain orientation is compared across different strategies using Electron Backscatter Diffraction (EBSD) maps, and the influence of surface roughness on sliding behavior is also evaluated. The results demonstrate that the island scanning strategy yields the best performance for load-bearing applications, exhibiting superior grain orientation and hardness in the additively manufactured parts.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141674200","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Enhancing the Mechanical Properties of Transient-Liquid-Phase Bonded Inconel 617 to Stainless Steel 310 through Altering Process Parameters and Homogenisation 通过改变工艺参数和均质化提高瞬态液相结合铬镍铁合金 617 与不锈钢 310 的机械性能

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-04 DOI: 10.3390/jmmp8040143

Arash Dehghan, R. Emadi, Yunes Asghari, Hosein Emadi, S. Lotfian

{"title":"Enhancing the Mechanical Properties of Transient-Liquid-Phase Bonded Inconel 617 to Stainless Steel 310 through Altering Process Parameters and Homogenisation","authors":"Arash Dehghan, R. Emadi, Yunes Asghari, Hosein Emadi, S. Lotfian","doi":"10.3390/jmmp8040143","DOIUrl":"https://doi.org/10.3390/jmmp8040143","url":null,"abstract":"This study investigated the impact of temperature, time, and homogenisation on the transient liquid phase bonding of Inconel 617 to stainless steel 310, employing AWS BNI2 foil as an interlayer. Nine test series were conducted at temperatures of 1050 °C and 1100 °C, with bonding durations ranging from 10 to 60 min. The homogenisation process was carried out on specimens that underwent full isothermal solidification at a temperature of 1170 °C for 180 min. The microscopic analysis indicated that extending the time and raising the bonding temperature resulted in the extension of the isothermal solidified zone, accompanied by a reduction in the quantity of eutectic phases. Complete isothermal solidification was seen exclusively in samples bonded at temperatures of 1050 °C for 60 min and 1100 °C for a duration of 50 min. The size of the diffusion-affected zone expanded as the bonding temperature and duration rose, but the presence of brittle intermetallic phases diminished. The microstructure of the homogenised sample indicated that the diffusion-affected zone had been almost completely eliminated. Hardness variations indicated heightened hardness in the diffusion-affected zone (DAZ) and athermal solidified zone (ASZ). Shear strength is maximised in homogenised specimens with minimised ASZ.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141678920","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Cost Modelling for Powder Bed Fusion and Directed Energy Deposition Additive Manufacturing 粉末床熔融和定向能沉积增材制造的成本建模

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-04 DOI: 10.3390/jmmp8040142

Navneet Khanna, Harsh Salvi, Büşra Karaş, Ishrat Fairoz, A. Shokrani

{"title":"Cost Modelling for Powder Bed Fusion and Directed Energy Deposition Additive Manufacturing","authors":"Navneet Khanna, Harsh Salvi, Büşra Karaş, Ishrat Fairoz, A. Shokrani","doi":"10.3390/jmmp8040142","DOIUrl":"https://doi.org/10.3390/jmmp8040142","url":null,"abstract":"Additive manufacturing (AM) is increasingly used for fabricating parts directly from digital models, usually by depositing and bonding successive layers of various materials such as polymers, metals, ceramics, and composites. The design freedom and reduced material consumption for producing near-net-shaped components have made AM a popular choice across various industries, including the automotive and aerospace sectors. Despite its growing popularity, the accurate estimation of production time, productivity and cost remains a significant challenge due to the ambiguity surrounding the technology. Hence, reliable cost estimation models are necessary to guide decisions throughout product development activities. This paper provides a thorough analysis of the state of the art in cost models for AM with a specific focus on metal Directed Energy Deposition (DED) and Powder Bed Fusion (PBF) processes. An overview of DED and PBF processes is presented to enhance the understanding of how process parameters impact the overall cost. Consequently, suitable costing techniques and significant cost contributors in AM have been identified and examined in-depth. Existing cost modelling approaches in the field of AM are critically evaluated, leading to the suggestion of a comprehensive cost breakdown including often-overlooked aspects. This study aims to contribute to the development of accurate cost prediction models in supporting decision making in the implementation of AM.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141679608","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Digital Image Correlation for Elastic Strain Evaluation during Focused Ion Beam Ring-Core Milling 用于评估聚焦离子束环形铣削过程中弹性应变的数字图像相关性

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-04 DOI: 10.3390/jmmp8040144

F. Uzun, Alexander M. Korsunsky

{"title":"Digital Image Correlation for Elastic Strain Evaluation during Focused Ion Beam Ring-Core Milling","authors":"F. Uzun, Alexander M. Korsunsky","doi":"10.3390/jmmp8040144","DOIUrl":"https://doi.org/10.3390/jmmp8040144","url":null,"abstract":"The utilization of the focused ion beam digital image correlation (FIB-DIC) technique for measuring in-plane displacements and the employment of the height digital image correlation (hDIC) technique as two-step DIC for determining both in-plane and out-of-plane displacements within the region of interest are detailed in this paper. Consideration is given to the microscopy data’s measurement scale and resolution to confirming the capability of both techniques to conduct micro-scale correlations with nano-scale sensitivity, thereby making it suitable for investigating the residual elastic strains formed due to processing. The sequential correlation procedure of the FIB-DIC technique has been optimized to achieve a balance between accuracy and performance for correlating sequential scanning electron microscope images. Conversely, the hDIC technique prioritizes the accurate correlation of SEM images directly with the reference state without a sequential procedure and offers optimal computational performance through advanced parallel computing tools, particularly suited for correlating profilometry data related to large-scale displacements. In this study, the algorithm of the hDIC technique is applied as two-step DIC to evaluate the elastic strain relaxation on the surface of a ring-core drilled using focused ion beam. Both techniques are utilized to correlate the same scanning electron microscope images collected during the monitoring of the ring drilling process. A comparison of the correlation results of both techniques is undertaken regarding the quantification of the near-surface residual elastic strains, with the analysis conducted to discern the superior accuracy of the hDIC algorithm. Furthermore, the distinctions between the two techniques are delineated and discussed.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141677397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Lagrangian Finite Element Model Formulation and Experimental Validation of the Laser Impact Weld Process for Ti/Brass Joining 钛/黄铜激光冲击焊接工艺的拉格朗日有限元模型计算与实验验证

IF 3.3

Journal of Manufacturing and Materials Processing Pub Date : 2024-07-02 DOI: 10.3390/jmmp8040141

S. Caruso, M. Sanguedolce, G. Serratore, Carmine De Bartolo, L. Filice, D. Umbrello

{"title":"Lagrangian Finite Element Model Formulation and Experimental Validation of the Laser Impact Weld Process for Ti/Brass Joining","authors":"S. Caruso, M. Sanguedolce, G. Serratore, Carmine De Bartolo, L. Filice, D. Umbrello","doi":"10.3390/jmmp8040141","DOIUrl":"https://doi.org/10.3390/jmmp8040141","url":null,"abstract":"Information on the flyer deformation during laser impact welding (LIW) is an important aspect to consider when high reliability of the welded components is required. For this reason, accurate numerical models simulating thermal and mechanical aspects are needed. In the present work, the cross-section morphology during LIW of Ti/Brass joints at varying laser pulse energies is modeled by a 2D finite element (FE) model. A hydrodynamic plasma pressure model able to describe the evolution of the pressure load step by step, taking into account the progressive deformation of the flyer, was implemented. Hence, this paper proposes an alternative method to the conventional node concentrated forces or predefined velocity as flyer boundary conditions. The levels of the equivalent plastic strain (PEEQ), shear stress, and critical flyer velocity at the collision point were used as reference parameters to predict the success of the welding bond, distinguishing the welded area from the unwelded area. The model was validated by comparison with the experimental data, which showed the effectiveness of the proposed FE code in predicting the cross-section morphology of the welded materials. Moreover, practical industrial information such as variation in the flyer impact velocity, collision angle, and process temperatures was predicted by varying the process laser pulse energy according to the basic principle of the process.","PeriodicalId":16319,"journal":{"name":"Journal of Manufacturing and Materials Processing","volume":null,"pages":null},"PeriodicalIF":3.3,"publicationDate":"2024-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141687001","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0