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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
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
Experimental study on surface roughness and residual stress development in loose-abrasive polishing of hardened tool steel 淬硬工具钢松散磨料抛光表面粗糙度及残余应力发展的实验研究
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 基于颗粒图像测速的摩擦搅拌过程中塑性材料流动和界面状态的原位观察
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 采用分层与堆叠方法制造电池互连多层超声接头的比较
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
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