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Sustainable assessment of diamond wire sawing for monocrystalline silicon wafers: Conventional and electrophoretic cooling strategies
IF 1.9
Manufacturing Letters Pub Date : 2025-01-05 DOI: 10.1016/j.mfglet.2024.12.004
Eyob Messele Sefene , Chao-Chang A. Chen , Jin-Wei Yang
{"title":"Sustainable assessment of diamond wire sawing for monocrystalline silicon wafers: Conventional and electrophoretic cooling strategies","authors":"Eyob Messele Sefene ,&nbsp;Chao-Chang A. Chen ,&nbsp;Jin-Wei Yang","doi":"10.1016/j.mfglet.2024.12.004","DOIUrl":"10.1016/j.mfglet.2024.12.004","url":null,"abstract":"<div><div>Pursuing sustainable advancement in diamond wire sawing (DWS) is crucial for reducing environmental impact and improving manufacturing efficiency in silicon wafer production. However, the existing sawing methods lack eco-friendly cooling strategies that lower energy consumption and carbon dioxide (CO<sub>2</sub>) emissions while maintaining wafer surface quality. This paper evaluates and improves sustainability by integrating machinability characteristics, such as energy consumption, CO<sub>2</sub> emissions, and surface roughness, while slicing monocrystalline silicon (mono-Si) wafers. Traditional DWS (T-DWS) and electrophoretic-assisted reactive (ER-DWS) cooling strategies were implemented to assess and enhance sustainability. Results demonstrate that ER-DWS achieves a 14.16 % reduction in specific cutting energy, a 9.22 % decrease in total CO<sub>2</sub> emissions, and an 8.78 % improvement in surface roughness (Ra) compared to T-DWS. This study addresses the gap by proposing a sustainable cooling strategy in the DWS process, providing insights into eco-friendly and efficient wafer manufacturing techniques.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 46-50"},"PeriodicalIF":1.9,"publicationDate":"2025-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157612","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 investigations on the ductility improvement due to stress relaxation in aluminium alloy 5083 under biaxial loading conditions
IF 1.9
Manufacturing Letters Pub Date : 2024-12-12 DOI: 10.1016/j.mfglet.2024.11.007
Vikram Balaji , Rubal Dongarwar , Hariharan Krishnaswamy , Sushil Mishra
{"title":"Experimental investigations on the ductility improvement due to stress relaxation in aluminium alloy 5083 under biaxial loading conditions","authors":"Vikram Balaji ,&nbsp;Rubal Dongarwar ,&nbsp;Hariharan Krishnaswamy ,&nbsp;Sushil Mishra","doi":"10.1016/j.mfglet.2024.11.007","DOIUrl":"10.1016/j.mfglet.2024.11.007","url":null,"abstract":"<div><div>The influence of stress relaxation on ductility improvement has been extensively studied for metallic materials, primarily through interrupted uniaxial tensile tests. However, components in typical press forming processes are subjected to multiaxial states of stresses. The applied load paths are expected to have a bearing on the failure strain post relaxation, which is infeasible to study under uniaxial loading. Therefore, single relaxation tests are carried out through interrupted planar biaxial tensile tests in cruciform samples of an aluminum alloy. The tests are performed at different load ratios to assess the load path dependency of stress relaxation, which is otherwise neglected.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 37-45"},"PeriodicalIF":1.9,"publicationDate":"2024-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157611","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
Simultaneous 4D printing and In-Situ foaming for tailoring shape memory behaviors in polylactic acid foams
IF 1.9
Manufacturing Letters Pub Date : 2024-12-06 DOI: 10.1016/j.mfglet.2024.11.005
Pedram Honari , Davood Rahmatabadi , Abbas Bayati , Erfan Rassi , Ismaeil Ghasemi , Majid Baniassadi , Mahdi Bodaghi , Mostafa Baghani
{"title":"Simultaneous 4D printing and In-Situ foaming for tailoring shape memory behaviors in polylactic acid foams","authors":"Pedram Honari ,&nbsp;Davood Rahmatabadi ,&nbsp;Abbas Bayati ,&nbsp;Erfan Rassi ,&nbsp;Ismaeil Ghasemi ,&nbsp;Majid Baniassadi ,&nbsp;Mahdi Bodaghi ,&nbsp;Mostafa Baghani","doi":"10.1016/j.mfglet.2024.11.005","DOIUrl":"10.1016/j.mfglet.2024.11.005","url":null,"abstract":"<div><div>This study introduces an innovative 4D printing technique combined with in-situ foaming to enhance the shape memory properties of polylactic acid (PLA) foams. By melt mixing PLA with azodicarbonamide (AZO) below its decomposition temperature, followed by direct pellet printing, the research achieves uniform microporous structures and tailored shape memory behaviors. The findings demonstrate that higher AZO content improves shape fixity (∼96 %) but reduces shape recovery. Moreover, the programming temperature significantly influences performance, with hot programming enhancing shape fixity and cold programming boosting shape recovery. This novel approach offers potential applications in lightweight, thermally insulative, and shock-absorbing materials with programmable properties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 33-36"},"PeriodicalIF":1.9,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156523","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
Effects of wire feeding direction on the deposition characteristics of 316L stainless steel in laser-directed energy deposition
IF 1.9
Manufacturing Letters Pub Date : 2024-12-05 DOI: 10.1016/j.mfglet.2024.11.006
Y.N. Aditya , Josip Vincic , Michael J. Benoit
{"title":"Effects of wire feeding direction on the deposition characteristics of 316L stainless steel in laser-directed energy deposition","authors":"Y.N. Aditya ,&nbsp;Josip Vincic ,&nbsp;Michael J. Benoit","doi":"10.1016/j.mfglet.2024.11.006","DOIUrl":"10.1016/j.mfglet.2024.11.006","url":null,"abstract":"<div><div>This study investigates the effect of wire feeding direction on the microstructure of 316 stainless steel during the laser-directed energy deposition (L-DED) process. The process parameters were optimised by varying the scan speed, laser power, and wire feed rate to identify a common parameter set for all feed directions to give desired weld bead geometries. The identified process parameter window has shown that the conduction mode is preferred over the balling and keyhole modes. Comprehensive microstructural characterization using optical and electron microscopy has revealed that for the same parameters, the front wire feed had higher penetration, while the back wire feed had a wider bead with optimal penetration. The current findings are of significance for advancing wire-L-DED additive manufacturing for more complex component designs.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 27-32"},"PeriodicalIF":1.9,"publicationDate":"2024-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156512","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
The effect of adding ZrH2 particles on grain refinement and tensile strength during laser metal deposition of 7075 aluminum alloy
IF 1.9
Manufacturing Letters Pub Date : 2024-11-27 DOI: 10.1016/j.mfglet.2024.11.003
Yongjian Li , Junjie Tang , Xiaoting Liu , Xiwang Guan , Shiyun Dong , Xudong Ren
{"title":"The effect of adding ZrH2 particles on grain refinement and tensile strength during laser metal deposition of 7075 aluminum alloy","authors":"Yongjian Li ,&nbsp;Junjie Tang ,&nbsp;Xiaoting Liu ,&nbsp;Xiwang Guan ,&nbsp;Shiyun Dong ,&nbsp;Xudong Ren","doi":"10.1016/j.mfglet.2024.11.003","DOIUrl":"10.1016/j.mfglet.2024.11.003","url":null,"abstract":"<div><div>7075 aluminum alloy is a type of lightweight metal material with high mechanical properties. Due to the intricate solidification process that produces the coarse grains and cracks, it is challenging to produce 7075 aluminum alloy using additive manufacturing techniques like laser metal deposition (LMD). Due to its similar crystal structure to the 7075 aluminum alloy, ZrH<sub>2</sub> powders were used in this study as the nucleation particles during the laser metal deposition process. The results demonstrated that the addition of ZrH<sub>2</sub> particles allowed the grains to be clearly refined, and that maximum tensile strength was above 330 MPa, which represents promising performance among the reported LMD-fabricated Al alloys.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 1-5"},"PeriodicalIF":1.9,"publicationDate":"2024-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156513","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
Wire arc additive manufacturing of stainless steel/aluminum bi-metal using roll-bonded transition joint
IF 1.9
Manufacturing Letters Pub Date : 2024-11-27 DOI: 10.1016/j.mfglet.2024.11.004
Ashkaan Ozlati, Mojtaba Movahedi, Habibollah Ramezani
{"title":"Wire arc additive manufacturing of stainless steel/aluminum bi-metal using roll-bonded transition joint","authors":"Ashkaan Ozlati,&nbsp;Mojtaba Movahedi,&nbsp;Habibollah Ramezani","doi":"10.1016/j.mfglet.2024.11.004","DOIUrl":"10.1016/j.mfglet.2024.11.004","url":null,"abstract":"<div><div>Wire arc additive manufacturing was employed to produce an AISI316L stainless steel/AA5183 aluminum bi-metal wall using a bi-layer steel/aluminum transition joint fabricated by roll bonding. The transition joint was utilized to minimize the contact between molten aluminum and steel. The study explored the effect of three heat-input levels used for aluminum deposition on the microstructure and mechanical performance of the steel/aluminum interface in the wall. At the minimum heat-input, no defects or Al-Fe intermetallic compounds were observed at the interface, resulting in the highest bi-metal wall fracture strength (∼42 MPa) due to the absence of brittle intermetallic compounds.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 6-11"},"PeriodicalIF":1.9,"publicationDate":"2024-11-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156514","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
Analytical forming forces in two roller flow forming
IF 1.9
Manufacturing Letters Pub Date : 2024-11-26 DOI: 10.1016/j.mfglet.2024.11.001
Kyle Nelson , Alastair Conway , Kadir Paslioglu , Mykola Kulakov , David Milliken
{"title":"Analytical forming forces in two roller flow forming","authors":"Kyle Nelson ,&nbsp;Alastair Conway ,&nbsp;Kadir Paslioglu ,&nbsp;Mykola Kulakov ,&nbsp;David Milliken","doi":"10.1016/j.mfglet.2024.11.001","DOIUrl":"10.1016/j.mfglet.2024.11.001","url":null,"abstract":"<div><div>This paper presents a comprehensive model for calculating forming forces in two-roller flow forming using the upper-bound method. The model incorporates roller design parameters such as tip radius and attack angle, accurately defining the contact surface and including all relevant forming parameters. Experimental validation on a WF VUD 600 vertical former demonstrates the model’s predictive capability, with force measurements compared to theoretical values. Statistical analyses indicate strong correlations between predicted and actual forces, highlighting the model’s effectiveness.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 18-26"},"PeriodicalIF":1.9,"publicationDate":"2024-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156511","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
Inhibiting grain boundary cracking in laser additively-manufactured MoNbTaVTiCu refractory complex concentrated alloys by tuning the Cu/Ti content
IF 1.9
Manufacturing Letters Pub Date : 2024-11-22 DOI: 10.1016/j.mfglet.2024.10.008
Solomon-Oshioke Agbedor , Hong Wu , DongHui Yang , Ian Baker
{"title":"Inhibiting grain boundary cracking in laser additively-manufactured MoNbTaVTiCu refractory complex concentrated alloys by tuning the Cu/Ti content","authors":"Solomon-Oshioke Agbedor ,&nbsp;Hong Wu ,&nbsp;DongHui Yang ,&nbsp;Ian Baker","doi":"10.1016/j.mfglet.2024.10.008","DOIUrl":"10.1016/j.mfglet.2024.10.008","url":null,"abstract":"<div><div>Refractory complex concentrated alloys (RCCAs) have been proposed for extreme service applications due to their microstructural stability and excellent mechanical properties over a wide temperature range. However, printing MoNbTaV-based RCCAs by laser additive manufacturing can be challenging on account of the severe solidification cracking that occurs along grain boundaries (GBs), leading to poor mechanical strength. In this brief report, we describe a crack-free MoNbTaVTi<em><sub>x</sub></em>Cu<em><sub>y</sub></em> RCCA produced through compositional adjustment that leverages a Cu-Ti phase to suppress GB cracking. Printed and annealed specimen exhibited both good mechanical strengths and<!--> <!--> thermal conductivities.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 12-17"},"PeriodicalIF":1.9,"publicationDate":"2024-11-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156522","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
Applicability of circularity protocols to extend the lifetime of a thermoplastic pultrusion line: A case study 延长热塑性拉挤生产线使用寿命的循环性协议的适用性：案例研究
IF 1.9
Manufacturing Letters Pub Date : 2024-11-01 DOI: 10.1016/j.mfglet.2024.10.002
Anurag Pisupati , Axel Boivin , Alexandre Beigbeder , Roi Méndez-Rial , Ronan Le Goff
{"title":"Applicability of circularity protocols to extend the lifetime of a thermoplastic pultrusion line: A case study","authors":"Anurag Pisupati ,&nbsp;Axel Boivin ,&nbsp;Alexandre Beigbeder ,&nbsp;Roi Méndez-Rial ,&nbsp;Ronan Le Goff","doi":"10.1016/j.mfglet.2024.10.002","DOIUrl":"10.1016/j.mfglet.2024.10.002","url":null,"abstract":"<div><div>This study explores the applicability of circular economy protocols (CEP) to refurbish an old pultrusion machine in line with Industry 4.0 standards, aiming to optimize resource use, reduce waste, and extend equipment life at large scale. Incorporation of CEP seeks to revolutionize the conventional refurbishment model in manufacturing industries, creating a sustainable technological advanced framework that promotes economic viability and environmental responsibility. These protocols assure a significant reduction of investments costs (−62%) and ensure real-time monitoring and adaptive control systems to enhance operational efficiency of the machine. A significant improvement in overall equipment effectiveness by 74% and reduction in waste by 23%. Lastly, various steps of integration of CEP in the modernization of old machinery, contributing significantly to their operability and functionality in a real industrial scenario are discussed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 56-60"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655676","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
Scalable and efficient fabrication of surface microstructures using a small wheeled robot with a vibration-cutting tool 利用带振动切割工具的小型轮式机器人，可扩展且高效地制造表面微结构
IF 1.9
Manufacturing Letters Pub Date : 2024-11-01 DOI: 10.1016/j.mfglet.2024.10.004
Peiyuan Ding , Jianfu Zhang , Pingfa Feng , Xiangyu Zhang , Jianjian Wang
{"title":"Scalable and efficient fabrication of surface microstructures using a small wheeled robot with a vibration-cutting tool","authors":"Peiyuan Ding ,&nbsp;Jianfu Zhang ,&nbsp;Pingfa Feng ,&nbsp;Xiangyu Zhang ,&nbsp;Jianjian Wang","doi":"10.1016/j.mfglet.2024.10.004","DOIUrl":"10.1016/j.mfglet.2024.10.004","url":null,"abstract":"<div><div>Bioinspired microstructure emerges as a powerful technique to enhance the surface functionalities and properties in a seizes of breakthrough areas. However, its application is limited by the scalability of fabrication methods. This study introduces a scalable fabrication technique utilizing a small wheeled robot designed to operate on a workpiece surface. Due to its unique three-point-support design, the robot maintains a stable cutting depth and exhibits high adaptability to large-scale workpieces. Motion stability is calibrated using a laser displacement sensor, achieving a maximum velocity of approximately 3.7 mm/s. Finally, the robot successfully produces microstructures with a height of 8 μm on aluminum workpieces, demonstrating its promising capacity.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 46-51"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655678","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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