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Friction-stir, tailor-welded blanks made from primary and recycled 6082 aluminium alloys 摩擦搅拌，定制焊接坯料由原铝和回收6082铝合金制成
IF 1.9
Manufacturing Letters Pub Date : 2025-06-01 DOI: 10.1016/j.mfglet.2025.05.001
Yugesh Raajha MS , Xiaochao Liu , Jun Ma , Torgeir Welo , Øystein Grong
{"title":"Friction-stir, tailor-welded blanks made from primary and recycled 6082 aluminium alloys","authors":"Yugesh Raajha MS ,&nbsp;Xiaochao Liu ,&nbsp;Jun Ma ,&nbsp;Torgeir Welo ,&nbsp;Øystein Grong","doi":"10.1016/j.mfglet.2025.05.001","DOIUrl":"10.1016/j.mfglet.2025.05.001","url":null,"abstract":"<div><div>The use of aluminum is increasing in electric vehicles (EVs) owing to the high demand for weight reduction. Producing aluminum from recycled scrap requires 95 % less energy than primary metal production, which provides the potential to accelerate the transition to a carbon–neutral economy. In this research, we use Tailor-Welded Recycled Aluminum (TWRA) made of recycled and primary aluminum, aiming to understand the weldability with recycled materials and their potential use as automotive components. AA6082 produced by extrusion from primary and recycled materials, respectively, were welded by conventional Friction Stir Welding (FSW). The welding process was performed both in T4 and T6 temper conditions. Despite the undermatched characteristics relative to the base metal, the primary–recycled joints showed higher joint strength when welded in T4 condition and higher ductility when welded in T6 condition. SEM and EDS analysis revealed precipitate evolution, and intermetallic phases played a strong role in determining the mechanical behavior of these welded joints.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 52-56"},"PeriodicalIF":1.9,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204839","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
Influence of convection heat transfer coefficient on the predicted macroscopic temperature field in direct laser deposition of large-scale parts 对流换热系数对激光直接沉积大型零件宏观温度场预测的影响
IF 1.9
Manufacturing Letters Pub Date : 2025-05-28 DOI: 10.1016/j.mfglet.2025.05.002
Sergei Ivanov, Artur Vildanov, Konstantin Babkin, Evgeniy Zemlyakov
{"title":"Influence of convection heat transfer coefficient on the predicted macroscopic temperature field in direct laser deposition of large-scale parts","authors":"Sergei Ivanov,&nbsp;Artur Vildanov,&nbsp;Konstantin Babkin,&nbsp;Evgeniy Zemlyakov","doi":"10.1016/j.mfglet.2025.05.002","DOIUrl":"10.1016/j.mfglet.2025.05.002","url":null,"abstract":"<div><div>In this work the influence of the heat transfer coefficient on the accuracy of the numerical prediction of the macroscopic temperature field in direct laser deposition of large-scale thin-walled structures is investigated in detail. It is shown that a temperature-independent constant heat transfer coefficient results in a considerable discrepancy in the prediction of the interpass temperature and the temperature distribution in the whole buildup. The numerical simulation revealed that the macroscopic temperature field in the buildup exhibits a pronounced sensitivity to the temperature dependence of the heat transfer coefficient. The film coefficient of the bottom surface of the substrate, which contacts the massive turntable of the direct laser deposition machine, has a negligible effect on the interpass temperature and mainly influences the temperature distribution near the substrate.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 1-7"},"PeriodicalIF":1.9,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212459","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
Advancing cold roll bonding efficiency by preceding XHV-adequate laser deoxidation 通过先前的xhv -充足的激光脱氧，提高冷轧粘合效率
IF 1.9
Manufacturing Letters Pub Date : 2025-05-12 DOI: 10.1016/j.mfglet.2025.03.002
Khemais Barienti , Finn-Lennard Janthur , Henri Heimers , Sarah Seffer , Jörg Hermsdorf , Sebastian Herbst , Ludger Overmeyer , Hans Jürgen Maier , Florian Nürnberger
{"title":"Advancing cold roll bonding efficiency by preceding XHV-adequate laser deoxidation","authors":"Khemais Barienti ,&nbsp;Finn-Lennard Janthur ,&nbsp;Henri Heimers ,&nbsp;Sarah Seffer ,&nbsp;Jörg Hermsdorf ,&nbsp;Sebastian Herbst ,&nbsp;Ludger Overmeyer ,&nbsp;Hans Jürgen Maier ,&nbsp;Florian Nürnberger","doi":"10.1016/j.mfglet.2025.03.002","DOIUrl":"10.1016/j.mfglet.2025.03.002","url":null,"abstract":"<div><div>The influence of a preceding laser ablation surface treatment on cold roll bonding (CRB) efficiency under extreme high vacuum-adequate (XHV-adequate) conditions were examined. Experimental investigations were conducted in a controlled glovebox environment. The impact of varying laser parameters on the critical reduction required for bonding copper and aluminium sheets was analysed. The results demonstrate a significant reduction in critical deformation necessary for bond formation. Surfaces treated by laser ablation achieve bonding at plastic deformations as low as 0.5%. In comparison, brushed surfaces require a plastic strain of 19% in similar XHV-adequate conditions. Using confocal laser scanning microscopy, a correlation between laser parameters and resulting surface characteristics was established, revealing material-specific surface alterations. Scanning electron microscopy analysis of the bonded interfaces further shows enhanced interfacial deformation in laser-treated specimens, which is characterised by increased waviness and pronounced protrusions. The investigations demonstrate a synergistic effect between laser-induced surface modifications and oxide-free conditions in an XHV-adequate atmosphere, which leads to a significant optimisation of CRB efficiency.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 42-46"},"PeriodicalIF":1.9,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144069194","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
Local formability improvement of 6111-T6 aluminum alloy sheet through high-speed robotic friction stir processing 6111-T6铝合金板材高速机器人搅拌摩擦加工的局部成形性改善
IF 1.9
Manufacturing Letters Pub Date : 2025-05-10 DOI: 10.1016/j.mfglet.2025.03.006
Shivakant Shukla , Hrishikesh Das , Katherine E. Rader , Mayur Pole , Zehao Li , Mert Efe , Piyush Upadhyay
{"title":"Local formability improvement of 6111-T6 aluminum alloy sheet through high-speed robotic friction stir processing","authors":"Shivakant Shukla ,&nbsp;Hrishikesh Das ,&nbsp;Katherine E. Rader ,&nbsp;Mayur Pole ,&nbsp;Zehao Li ,&nbsp;Mert Efe ,&nbsp;Piyush Upadhyay","doi":"10.1016/j.mfglet.2025.03.006","DOIUrl":"10.1016/j.mfglet.2025.03.006","url":null,"abstract":"<div><div>This study examines the impact of friction stir processing (FSP) on the local formability of 6111-T6 aluminum alloy sheets, utilizing sub-scale tensile and VDA bend tests, along with electron microscopy for microstructural analysis. Results show that FSP notably increased uniform and total elongation by 100% and 50%, respectively, though it reduced yield and ultimate tensile strength. Electron backscatter diffraction revealed significant deformation within shear bands and varied fracture paths: intergranular for FSP due to increased grain boundary density and a mix for T6. FSP’s grain refinement facilitated plastic deformation at crack tip leading to blunting and enhanced fracture toughness thus improved bend properties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 47-51"},"PeriodicalIF":1.9,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144107813","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
Unit cell manufacture by blown powder directed energy deposition 用吹粉定向能沉积法制造单晶胞
IF 1.9
Manufacturing Letters Pub Date : 2025-05-08 DOI: 10.1016/j.mfglet.2025.04.001
Alan Burl , William Huggins , Rodrigo Zapata Martínez , Andrés Díaz Lantada , Jon Molina-Aldareguia , Christopher Saldaña , Kyle Saleeby
{"title":"Unit cell manufacture by blown powder directed energy deposition","authors":"Alan Burl ,&nbsp;William Huggins ,&nbsp;Rodrigo Zapata Martínez ,&nbsp;Andrés Díaz Lantada ,&nbsp;Jon Molina-Aldareguia ,&nbsp;Christopher Saldaña ,&nbsp;Kyle Saleeby","doi":"10.1016/j.mfglet.2025.04.001","DOIUrl":"10.1016/j.mfglet.2025.04.001","url":null,"abstract":"<div><div>Lattice structures manufactured by additive manufacturing show unique promise to alter existing components to improve the thermo-mechanical properties of the base structure. In the present study, the manufacture of a self-supporting lattice structure by blown powder directed energy deposition was explored. Converging struts were manufactured using multiple lean angles to facilitate the self-supporting structure and to avoid machine-part collisions. The struts showed near uniform straightness relative to a fitted line with a maximum deviation of 1mm at a lean angle of 10°. Micro–hardness and porosity evaluation results showed no significant variation along the struts.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 28-32"},"PeriodicalIF":1.9,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931760","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
Deposition stability and enhanced microhardness of laser shock peened of Ti6Al4V alloy manufactured by high layer thickness laser additive manufacturing 高层厚激光增材制造Ti6Al4V合金激光冲击强化的沉积稳定性及显微硬度的提高
IF 1.9
Manufacturing Letters Pub Date : 2025-05-07 DOI: 10.1016/j.mfglet.2025.03.004
Sapam Ningthemba Singh, Ashish B. Deoghare
{"title":"Deposition stability and enhanced microhardness of laser shock peened of Ti6Al4V alloy manufactured by high layer thickness laser additive manufacturing","authors":"Sapam Ningthemba Singh,&nbsp;Ashish B. Deoghare","doi":"10.1016/j.mfglet.2025.03.004","DOIUrl":"10.1016/j.mfglet.2025.03.004","url":null,"abstract":"<div><div>Thin layer thickness is one of the drawbacks of additive manufacturing (AM) leading to longer printing time. Higher layer thickness can address this with a higher tendency of improper deposition, and surface cracks. The current paper implements high-layer thickness laser-directed energy deposition (LDED) AM of Ti6Al4V alloy to investigate deposition stability, surface crack, and microhardness. Laser shock peening (LSP) is also employed to modify microstructures and enhance microhardness. This study provides the details of the surface cracks and effects of LSP on surface modification and hardness of the samples fabricated by the LDED process. Proper deposition with some spatters and surface cracks on as-printed samples were observed. Surface removal of about 0.5 mm eliminated most of the surface cracks. Elongated columnar β grains and Widmanstätten pattern were observed. Plastic deformation and grain refinement due to LSP resulted in enhanced microhardness. Highest increase of 48.12 % in microhardness was observed after LSP was applied to the fabricated samples.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 33-36"},"PeriodicalIF":1.9,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143935115","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
Precision measurement of distortions on a lengthy plates: A novel approach 长板变形的精确测量：一种新方法
IF 1.9
Manufacturing Letters Pub Date : 2025-05-07 DOI: 10.1016/j.mfglet.2025.03.007
Polamuri Sudheer Kumar, Adapa Mahanth Kumar, Degala Venkata Kiran
{"title":"Precision measurement of distortions on a lengthy plates: A novel approach","authors":"Polamuri Sudheer Kumar,&nbsp;Adapa Mahanth Kumar,&nbsp;Degala Venkata Kiran","doi":"10.1016/j.mfglet.2025.03.007","DOIUrl":"10.1016/j.mfglet.2025.03.007","url":null,"abstract":"<div><div>Measuring the distortion of a lengthy plates is often costly and tedious. This paper introduces a novel methodology for accurately measuring distortion in lengthy plates, which is crucial for various engineering and manufacturing applications. The methodology integrates a laser distance tracker, sophisticated data analysis algorithms, and a robust gantry setup to ensure the validity and repeatability of the measurements. By employing a laser distance tracker, the deflection of welded long plates in the Z-direction can be precisely measured. The gantry system allows for measuring the deflection at multiple locations along the plate. An advanced algorithm then processes this data to generate a contour plot of the distorted plate. This innovative approach not only enhances measurement accuracy but also streamlines the process, making it more efficient and cost-effective.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 23-27"},"PeriodicalIF":1.9,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143927425","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
Friction stir lap weld-brazing of AA7050 aluminium alloy to Ti6Al4V titanium alloy – Limitations in dissimilar metal joining AA7050铝合金与Ti6Al4V钛合金的搅拌摩擦搭接钎焊。异种金属连接的局限性
IF 1.9
Manufacturing Letters Pub Date : 2025-05-07 DOI: 10.1016/j.mfglet.2025.03.005
Felix Grassel , Benjamin Klusemann
{"title":"Friction stir lap weld-brazing of AA7050 aluminium alloy to Ti6Al4V titanium alloy – Limitations in dissimilar metal joining","authors":"Felix Grassel ,&nbsp;Benjamin Klusemann","doi":"10.1016/j.mfglet.2025.03.005","DOIUrl":"10.1016/j.mfglet.2025.03.005","url":null,"abstract":"<div><div>Joining of high-strength aluminium and titanium alloys gives new opportunities for cost- and energy-efficient designs especially in the transportation industry. In the present study, friction stir lap joining of AA7050 and Ti6Al4V was conducted, investigating the thermal cycle in the interface via variation of energy input by the spindle rotation rate. Temperature measurements reveal that the interface temperature exceeds the solidus temperature of the aluminium alloy and reached up to 570 °C, so that the process should be classified as semi-solid-state. Additionally, no indication for intermetallic compounds was found. Lap-shear strength of the joint is found to be limited by low diffusion kinetics at low temperatures and liquation cracking at high temperatures, revealing clear indications for the limitations of this specific material combination for the first time.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 37-41"},"PeriodicalIF":1.9,"publicationDate":"2025-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144069193","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
Atomically precise yet rapid micromachining via projection-based femtosecond laser ablation 通过基于投影的飞秒激光烧蚀进行原子精确而快速的微加工
IF 1.9
Manufacturing Letters Pub Date : 2025-05-04 DOI: 10.1016/j.mfglet.2025.03.003
Rugile Zilenaite, Harnjoo Kim, Sourabh K. Saha
{"title":"Atomically precise yet rapid micromachining via projection-based femtosecond laser ablation","authors":"Rugile Zilenaite,&nbsp;Harnjoo Kim,&nbsp;Sourabh K. Saha","doi":"10.1016/j.mfglet.2025.03.003","DOIUrl":"10.1016/j.mfglet.2025.03.003","url":null,"abstract":"<div><div>It is extremely challenging to achieve atomic scale depth resolutions with top-down micromachining techniques while simultaneously achieving high processing rates. Here, we have overcome this challenge by projecting patterned light sheets of spatio-temporally focused femtosecond laser. It has enabled ablation-based micromachining of thin gold films with depths of cut between 7–14 nm, depth resolvability of 1–3 atoms, and linewidths smaller than 500 nm. Furthermore, we have achieved a processing rate of 9 mm<sup>2</sup>/s, which is 10–10<sup>5</sup> times faster than the state-of-art. Thus, our process enables rapid and atomically precise machining of metal thin films.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 18-22"},"PeriodicalIF":1.9,"publicationDate":"2025-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143922128","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
Aging response of AA7075 + TiC fabricated by wire + laser directed energy deposition 线+激光定向能沉积制备AA7075 + TiC的时效响应
IF 1.9
Manufacturing Letters Pub Date : 2025-03-20 DOI: 10.1016/j.mfglet.2025.03.001
Taha Waqar , Emma Pugsley , Haiou Jin , Amir Horr , Mark A. Easton , Michael J. Benoit
{"title":"Aging response of AA7075 + TiC fabricated by wire + laser directed energy deposition","authors":"Taha Waqar ,&nbsp;Emma Pugsley ,&nbsp;Haiou Jin ,&nbsp;Amir Horr ,&nbsp;Mark A. Easton ,&nbsp;Michael J. Benoit","doi":"10.1016/j.mfglet.2025.03.001","DOIUrl":"10.1016/j.mfglet.2025.03.001","url":null,"abstract":"<div><div>The objective of this study is to evaluate laser directed energy deposition of AA7075 wire with TiC nanoparticles to promote grain refinement and eliminate cracking. Microstructure analysis showed the presence of a nonuniform distribution of TiC clusters and the formation of a mix of equiaxed and columnar grains. The effect of direct and traditional T6 aging heat treatments was studied, and it was shown that the direct aged sample heated for 5 hrs at 120 °C was of comparable hardness to the T6 heat-treated sample (115 HV0.5). However, no age hardening conditions matched the hardness of wrought AA7075, due to evaporation of Zn and Mg during printing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 12-17"},"PeriodicalIF":1.9,"publicationDate":"2025-03-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143697311","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
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