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Aging response of AA7075 + TiC fabricated by wire + laser directed energy deposition
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
Experimental study on surface roughness and residual stress development in loose-abrasive polishing of hardened tool steel
IF 1.9
Manufacturing Letters Pub Date : 2025-03-10 DOI: 10.1016/j.mfglet.2025.02.001
Holger Ruehl , Yuxuan Li , Thomas Guenther , Bernd Breidenstein , André Zimmermann
{"title":"Experimental study on surface roughness and residual stress development in loose-abrasive polishing of hardened tool steel","authors":"Holger Ruehl ,&nbsp;Yuxuan Li ,&nbsp;Thomas Guenther ,&nbsp;Bernd Breidenstein ,&nbsp;André Zimmermann","doi":"10.1016/j.mfglet.2025.02.001","DOIUrl":"10.1016/j.mfglet.2025.02.001","url":null,"abstract":"<div><div>The repeatability and control of the achievable surface integrity in manual loose-abrasive diamond polishing of workpieces is very limited. In this study, first effects of polishing on the surface roughness and on induced near-surface residual stress of hardened tool steel X37CrMoV5-1 using an automatic metallographic grinder polisher have been investigated. The results show different effects of polishing parameters such as grain size, platen speed and forces applied to the workpiece on roughness and residual stress. XRD measurements of the residual stress depth profile showed a reduction in compressive stress which could be explained by the material removal mechanism and direction.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 6-11"},"PeriodicalIF":1.9,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143642965","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
In-situ observation of plastic material flow and interfacial condition in friction stir-based processes via particle image velocimetry
IF 1.9
Manufacturing Letters Pub Date : 2025-03-01 DOI: 10.1016/j.mfglet.2025.01.004
Yuxuan Yao , Abdul Sayeed Khan , Yanfei Gao , Pingsha Dong , Wenda Tan
{"title":"In-situ observation of plastic material flow and interfacial condition in friction stir-based processes via particle image velocimetry","authors":"Yuxuan Yao ,&nbsp;Abdul Sayeed Khan ,&nbsp;Yanfei Gao ,&nbsp;Pingsha Dong ,&nbsp;Wenda Tan","doi":"10.1016/j.mfglet.2025.01.004","DOIUrl":"10.1016/j.mfglet.2025.01.004","url":null,"abstract":"<div><div>Friction stir processes exhibit unique advantages in avoiding solidification-related defects in welding and additive manufacturing applications. These processes involve complex plastic flow of materials, which are critical for the product microstructure and properties but have not been well understood. The lack of quantitative measurements further prevents the quantitative distinction between plasticity versus friction induced heating analysis. This work thus presents an experimental work to visualize and quantify the material flow and frictional behavior under a friction stir spot welding process. Optically transparent polymethyl methacrylate (PMMA) was used as the substrate, and tracer particles were placed at the tool-material interface to visualize the plastic flow. The particle image velocimetry (PIV) algorithm was used to quantify the flow velocity. The experiments, for the first time, directly revealed the stick- and slip-dominant zones on the tool-material interface and their transition along the tool radial direction. The results were compared with a physics-based analytical model to understand the effects of processing conditions on the material deformation mechanisms and plastic flow behavior in the process.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 79-83"},"PeriodicalIF":1.9,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520866","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
A Comparison of Multi-Layered Ultrasonic Joints Fabrication using Layer-Wise vs Stacked Approaches for Battery Interconnects
IF 1.9
Manufacturing Letters Pub Date : 2025-02-19 DOI: 10.1016/j.mfglet.2025.01.003
Vijay Sharma, Abhishek Das
{"title":"A Comparison of Multi-Layered Ultrasonic Joints Fabrication using Layer-Wise vs Stacked Approaches for Battery Interconnects","authors":"Vijay Sharma,&nbsp;Abhishek Das","doi":"10.1016/j.mfglet.2025.01.003","DOIUrl":"10.1016/j.mfglet.2025.01.003","url":null,"abstract":"<div><div>This paper investigates two different approaches, namely the ‘<em>Layer-wise Approach</em>’ and ‘<em>Stacked Approach</em>’, employed to create multi-layered joints using ultrasonic metal welding (USMW), especially useful for electric vehicle (EV) battery interconnects. One such requirement is for the pouch cell to create multiple tabs to busbar joints. Multi-layer dissimilar joints were made using copper (Cu) tabs and aluminum (Al) busbars of thickness 0.25 mm and 1 mm, respectively. The 5Cu tabs to 1Al busbar joint created by layer-wise techniques exhibited 3.78 and 2.47 times more mechanical strength (∼237 N) than 3Cu to 1Al busbar and 2Cu to 1Al busbar combinations (as more than 3 Cu tabs to busbar welding was not possible using stacked approach), respectively, while necessitating reduced heat generation and clamping pressure.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 75-78"},"PeriodicalIF":1.9,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143474379","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Additive manufacturing of high-resolution solid microneedles via continuously variable stacked extrusion (CVSE) of conductive thermoplastic using a fused filament fabrication (FFF) printer
IF 1.9
Manufacturing Letters Pub Date : 2025-02-19 DOI: 10.1016/j.mfglet.2025.01.005
Russell Kirk Pirlo, Carter McCrea, Lauren Carothers, Kyle Shrader, Evan Johnson, Trevor Tilly
{"title":"Additive manufacturing of high-resolution solid microneedles via continuously variable stacked extrusion (CVSE) of conductive thermoplastic using a fused filament fabrication (FFF) printer","authors":"Russell Kirk Pirlo,&nbsp;Carter McCrea,&nbsp;Lauren Carothers,&nbsp;Kyle Shrader,&nbsp;Evan Johnson,&nbsp;Trevor Tilly","doi":"10.1016/j.mfglet.2025.01.005","DOIUrl":"10.1016/j.mfglet.2025.01.005","url":null,"abstract":"<div><div>This study introduces Continuously Variable Stacked Extrusion (CVSE), a novel method for fabricating high-resolution microneedles using standard Fused Filament Fabrication (FFF) hardware. Unlike traditional FFF approaches requiring chemical etching, CVSE combines printing and drawing techniques through continuous vertical movement to create smooth, precise microneedles. Using conductive PLA filament, we demonstrated uniform arrays of microneedles with tip diameters under 25 μm and heights of 1185 ± 28 μm. The method showed excellent repeatability and enabled various needle profiles, including barbed and tissue-interlocking designs. This approach represents a significant advancement in microneedle fabrication using widely available FFF equipment.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 1-5"},"PeriodicalIF":1.9,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561887","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 interlayer TIG arc treatment on porosity of wire arc additive manufactured copper
IF 1.9
Manufacturing Letters Pub Date : 2025-01-25 DOI: 10.1016/j.mfglet.2025.01.002
Arun Kumar Singh, Shubham Sadhya, Sumit Chorma, Indrasen Singh, Yuvraj K Madhukar
{"title":"Effect of interlayer TIG arc treatment on porosity of wire arc additive manufactured copper","authors":"Arun Kumar Singh,&nbsp;Shubham Sadhya,&nbsp;Sumit Chorma,&nbsp;Indrasen Singh,&nbsp;Yuvraj K Madhukar","doi":"10.1016/j.mfglet.2025.01.002","DOIUrl":"10.1016/j.mfglet.2025.01.002","url":null,"abstract":"<div><div>The presented experimental research explores interlayer arc treatment in wire arc additive manufacturing using TIG (WAAM-TIG) to minimise the porosity which adversely affects the mechanical properties. Copper was chosen for this study due to its extensive utilisation in industries. WAAM-TIG deposition along with interlayer arc treatment was performed in continuous (ATC) and pulsed (ATP) mode, and the results were compared with as-fabricated (AF) samples. Both, arc treated samples showed significant reduction in porosity, however, the ATP mode performed relatively better decreasing from ∼ 16 % to ∼ 1 %. Further arc-treated samples were also exhibited an increase in hardness ensuring improvement in mechanical property.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 70-74"},"PeriodicalIF":1.9,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157617","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
Variations in temperature, residual stress, and distortion in collaborative robot-assisted patterned additive manufacturing
IF 1.9
Manufacturing Letters Pub Date : 2025-01-22 DOI: 10.1016/j.mfglet.2025.01.001
Mohammad Arjomandi, Rakshith Reddy Sanvelly, Tuhin Mukherjee
{"title":"Variations in temperature, residual stress, and distortion in collaborative robot-assisted patterned additive manufacturing","authors":"Mohammad Arjomandi,&nbsp;Rakshith Reddy Sanvelly,&nbsp;Tuhin Mukherjee","doi":"10.1016/j.mfglet.2025.01.001","DOIUrl":"10.1016/j.mfglet.2025.01.001","url":null,"abstract":"<div><div>Collaborative robots (COBOT) offer advantages over traditional robots by reducing the need for path programming, enhancing safety for human interaction, and improving user-friendliness and productivity, making them suitable for additive manufacturing of large and complex parts. COBOT simplifies path planning in patterned additive manufacturing by using teaching points where a complex deposition pattern can be represented by a few key coordinates. However, the selection of teaching points significantly affects the temperature fields, deposit geometry, residual stresses, and distortion, and these effects are not well understood. Here we use a combined experimental and computational approach to study the effects of four patterns with different teaching points (4, 5, 6, and 8) during wire arc-directed energy deposition (WA-DED) of stainless steel. Experiments are performed using an in-house COBOT-assisted WA-DED system. Finite element modeling is done to compute temperature fields, deposit geometry, residual stresses, and distortion. We concluded that the distribution of residual stress varies notably with different deposition patterns, even though the maximum stress values are not significantly different. Stress tends to accumulate at sharp corners where the arc heat source stays longer. In addition, thermal distortion is present in all parts due to variations in the temperature field, with the highest distortion occurring farthest from the molten pool. However, overall distortion remains comparable across parts due to a consistent total heat input.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 64-69"},"PeriodicalIF":1.9,"publicationDate":"2025-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157616","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 novel gap flushing insert for sink electrical discharge machining
IF 1.9
Manufacturing Letters Pub Date : 2025-01-10 DOI: 10.1016/j.mfglet.2024.12.001
Samuel Mander, Philip Koshy
{"title":"A novel gap flushing insert for sink electrical discharge machining","authors":"Samuel Mander,&nbsp;Philip Koshy","doi":"10.1016/j.mfglet.2024.12.001","DOIUrl":"10.1016/j.mfglet.2024.12.001","url":null,"abstract":"<div><div>Gap flushing in sink electrical discharge machining (EDM) is generally accomplished by forcing the dielectric fluid through a hole in the tool (through-tool flushing) or by periodically retracting the tool from the machining gap (jump EDM). Through-tool flushing is limited by the stump left on the workpiece from the flushing hole, and jump EDM by the reduced productivity from when the tool is not engaged in machining. In this context, this paper presents an innovation that involves a rotating flushing hole assembly incorporated within a prismatic tool, which can be self-propelled by the dielectric flow. The novel design is shown to essentially eliminate the formation of the said stump, and to correspond to removal rates surpassing jump EDM.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 55-59"},"PeriodicalIF":1.9,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157614","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Novel topological machine learning methodology for stream-of-quality modeling in smart manufacturing
IF 1.9
Manufacturing Letters Pub Date : 2025-01-10 DOI: 10.1016/j.mfglet.2024.12.002
Jay Lee , Dai-Yan Ji , Yuan-Ming Hsu
{"title":"Novel topological machine learning methodology for stream-of-quality modeling in smart manufacturing","authors":"Jay Lee ,&nbsp;Dai-Yan Ji ,&nbsp;Yuan-Ming Hsu","doi":"10.1016/j.mfglet.2024.12.002","DOIUrl":"10.1016/j.mfglet.2024.12.002","url":null,"abstract":"<div><div>This paper presents a topological analytics approach within the 5-level Cyber-Physical Systems (CPS) architecture for the Stream-of-Quality assessment in smart manufacturing. The proposed methodology not only enables real-time quality monitoring and predictive analytics but also discovers the hidden relationships between quality features and process parameters across different manufacturing processes. A case study in additive manufacturing was used to demonstrate the feasibility of the proposed methodology to maintain high product quality and adapt to product quality variations. This paper demonstrates how topological graph visualization can be effectively used for the real-time identification of new representative data through the Stream-of-Quality assessment.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 60-63"},"PeriodicalIF":1.9,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157615","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
Modeling the influence of fiber undulation in a filament-wound composite tube under radial crushing load
IF 1.9
Manufacturing Letters Pub Date : 2025-01-09 DOI: 10.1016/j.mfglet.2024.12.003
Ivan Komala , Julien van Campen , Daniël Peeters , Sebastian Heimbs
{"title":"Modeling the influence of fiber undulation in a filament-wound composite tube under radial crushing load","authors":"Ivan Komala ,&nbsp;Julien van Campen ,&nbsp;Daniël Peeters ,&nbsp;Sebastian Heimbs","doi":"10.1016/j.mfglet.2024.12.003","DOIUrl":"10.1016/j.mfglet.2024.12.003","url":null,"abstract":"<div><div>This study investigates a filament-wound tube model incorporating fiber undulation from the filament winding process. The model was analyzed using the finite element method in the linear regime, then compared with the shell model and radial crushing experiment. Results showed that the solid model predicts the radial compression stiffness with a higher level of accuracy than the shell model due to the inclusion of the fiber undulation feature. This model is a first step towards the development of a composite pressure vessel model where fiber undulation is more frequent, and also for predicting failure initiation and damage propagation.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 51-54"},"PeriodicalIF":1.9,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157613","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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