Manufacturing Letters最新文献

{"title":"Nanotechnology-enhanced castability of wrought aluminum alloys 2024 and 6063","authors":"Guan-Cheng Chen ,&nbsp;Xiaochun Li","doi":"10.1016/j.mfglet.2024.09.033","DOIUrl":"10.1016/j.mfglet.2024.09.033","url":null,"abstract":"<div><div>In the realm of high-performance applications, wrought aluminum alloys are esteemed for their high mechanical properties and excellent strength-to-weight ratio. However, their limited castability poses challenges in economically producing intricate structures through casting processes. To address this issue, a small proportion of TiC nanoparticles is introduced into the melts of AA 2024 and AA 6063 for nano-treating. This nano-treatment imparts several beneficial effects, including the delayed release of latent heat, inhibition of grain growth, and improvement of wettability. These effects enhance the fluidity of the melt, eliminate hot cracking, and elevate the surface quality of the castings. The outcomes underscore the promising potential of emerging nano-treatment technology in rendering traditionally non-castable wrought aluminum alloys suitable for cost-effective casting processes, ultimately delivering high-performance products for a wide range of applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 281-286"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434281","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}

{"title":"Mechanical property improvements of LPBF-AlSi10Mg via forging to modify microstructure and defect characteristics","authors":"Austin Ngo ,&nbsp;Noah Kohlhorst ,&nbsp;Svitlana Fialkova ,&nbsp;Bradley Jared ,&nbsp;Tony Schmitz ,&nbsp;Glenn Daehn ,&nbsp;Jennifer L.W. Carter ,&nbsp;Jian Cao ,&nbsp;John J. Lewandowski","doi":"10.1016/j.mfglet.2024.09.072","DOIUrl":"10.1016/j.mfglet.2024.09.072","url":null,"abstract":"<div><div>Additive Manufacturing (AM) processes have versatile capabilities but are susceptible to the formation of as-cast non-equilibrium microstructures, process-induced defects, and porosity, which have deleterious effects on the mechanical performance. As part of our NSF-ERC-HAMMER program, isothermal forging was investigated as a novel post-processing technique for refining microstructure, reducing process defect severity, and thereby improving mechanical properties. Specimens of Laser Powderbed Fusion (LPBF) AlSi10Mg were fabricated over a range of process parameters and tensile tested as a baseline. Initial work focused on duplicate AM material that was then hot forged with 20 % strain to investigate the effects of isothermal forging at one temperature and strain rate on the microstructure, tensile, and fatigue properties of the as-deposited materials. The microstructures, process-induced defect populations, and tensile/fatigue properties of both as-deposited and forged materials were quantified and analysed by OM, EBSD, XCT, and SEM by various NSF-ERC-HAMMER team members. Isothermal hot forging was found to induce recrystallisation and modify process-induced defect geometry along with increasing tensile ductility. The effects of AM deposition parameters and forge post-processing conditions on LPBF AlSi10Mg will be discussed in terms of microstructure, mechanical properties, and fractography.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 568-574"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434285","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}

{"title":"Analytical temperature model for spindle speed selection in additive friction stir deposition","authors":"Tony Schmitz ,&nbsp;Elijah Charles ,&nbsp;Brett Compton","doi":"10.1016/j.mfglet.2024.09.090","DOIUrl":"10.1016/j.mfglet.2024.09.090","url":null,"abstract":"<div><div>This paper describes a physics-based, analytical model for additive friction stir deposition (AFSD) spindle speed selection to achieve a desired deposition temperature. In the model, power input to the feedstock, which enables plastic flow and deposition, is related to the material temperature rise and subsequent flow stress reduction using Fourier’s conduction rate equation. Power input is modeled as frictional heating at the deposit-surface interface and adiabatic heating due to plastic deformation. The flow stress is predicted using the strain, strain rate, and temperature-dependent Johnson-Cook constitutive model for the selected feedstock alloy. Model predictions are compared to AFSD numerical simulation results available in the literature and experiments for aluminum alloys.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 720-729"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434299","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}

{"title":"Clinical-relevant sized tubular capillary mimicries by sacrificial core-sheath electrospinning","authors":"Yan Chen,&nbsp;Yingge Zhou","doi":"10.1016/j.mfglet.2024.09.056","DOIUrl":"10.1016/j.mfglet.2024.09.056","url":null,"abstract":"<div><div>Electrospinning is a versatile technique that is often used to fabricate ultra-fine fibers. With the help of a coaxial spinneret, microtubes can be fabricated as potential biomimetic capillary vessels. However, the sizes of electrospun microtubes in recent research were around 5 μm which is smaller to native capillary vessels (5–10 μm). The electrospun microtube diameter can be determined by various electrospinning parameters such as spinning materials, solvent, spinning distance, solution pump rate, applied voltage, etc. In this research, we explored the effects of spinning distance and core/sheath pump rate ratio on microtube diameter and wall thickness. Viscosity, wettability, and tensile tests were also conducted for microtube characterization. The results indicated that the microtube diameters range from 5 μm to 12 μm, which provides a promising direction for the fabrication of biomimetic capillary vessels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 462-468"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434208","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}

{"title":"Effect of drying temperature on binder/current collector interfacial adhesion in electrode manufacturing of Li-ion batteries","authors":"Xiaowei Yu ,&nbsp;Mengyuan Chen ,&nbsp;Ming Wang ,&nbsp;Jennifer Bracey ,&nbsp;Bradley Frieberg ,&nbsp;Roland Koestner ,&nbsp;Wai Ping Gloria Tam ,&nbsp;David Titmuss ,&nbsp;Nicholas Ware","doi":"10.1016/j.mfglet.2024.09.036","DOIUrl":"10.1016/j.mfglet.2024.09.036","url":null,"abstract":"<div><div>Li-ion battery manufacturing process parameters are critical to the electrode properties and the final cell electrochemical performance. During the electrode drying process, the drying temperature plays a critical role on the binder migration, which affects the interfacial adhesion between the electrode and the current collector. However, the influence of the temperature on the properties of the binder material and the binder/current collector interface is yet unknown. In this work, we studied the effect of drying temperature on the interfacial adhesion between the binder and the current collector by direct coating of polyvinylidene fluoride (PVDF) solution on Al foil and then drying at various temperatures. The interfacial adhesion strength between the PVDF and the Al foil was significantly increased, from 9.72 N/m (dried at room temperature) to &gt; 665.80 N/m (dried at 200 ℃) with increased temperature. DSC and XRD analyses showed the changes in the crystalline forms of PVDF under different drying temperature. This work revealed that the drying temperature during electrode manufacturing should be considered from the aspects of both binder migration in mid-stage and PVDF crystalline properties in late-stage solvent drying.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 304-309"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434239","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}

{"title":"Investigations on ironing parameters in screw extrusion additive manufacturing (SEAM)","authors":"Yash Gopal Mittal ,&nbsp;Gopal Gote ,&nbsp;Yogesh Patil ,&nbsp;Avinash Kumar Mehta ,&nbsp;Pushkar Kamble ,&nbsp;K.P. Karunakaran","doi":"10.1016/j.mfglet.2024.09.102","DOIUrl":"10.1016/j.mfglet.2024.09.102","url":null,"abstract":"<div><div><em>Additive Manufacturing</em> (AM) is a novel manufacturing process that enables the physical realization of a given 3D model via layered deposition. <em>Material extrusion</em> (MEX) is one of the most widely used forms of the various AM techniques, in which the <em>screw extrusion</em>-based AM (SEAM) processing offers the most versatile characteristics, in terms of material handling and flow rate capacities. It involves continuous extrusion of the semi-solid material via an extruder screw. Ironing is a common practice in MEX techniques, to maintain <em>z</em>-height and improve the surface morphologies while deposition. Most commercially used nozzles for MEX are thin-walled, such that the ratio of the nozzle width to the diameter (<em>w/d</em>) is close to 1. In this research, investigations on the ironing effect during screw extrusion-based material deposition are explored using a set of wider nozzles (<em>w/d</em> as high as 40). Special emphasis is laid on the deposited surface finish, interlayer strength, and geometrical conformance of the extrusion. The nozzle diameter and the <em>stand-off distance</em> (SOD) are also independently varied. It is found that the best dimensional stability is achieved when the SOD is set between 75 % and 100 % of the nozzle diameter. Ironing improved the surface finish and the interlayer strength in all instances, with an average improvement of 50 % and 200 %, respectively.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 822-831"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434294","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}

{"title":"Evaluation and quantification of diffusion wear between cutting chip and workpiece using forging press","authors":"Junichi Nakagawa ,&nbsp;Yusuke Yoshimi ,&nbsp;Katsumasa Chiba ,&nbsp;Ryutaro Tanaka","doi":"10.1016/j.mfglet.2024.09.075","DOIUrl":"10.1016/j.mfglet.2024.09.075","url":null,"abstract":"<div><div>The state of the interface between the workpiece and the cutting tool affects the cutting temperature and pressure on the tool surface during the cutting process. In particular, while cutting difficult-to-cut materials such as Ni-based alloy 718, the workpiece exhibits a high affinity for cutting tool materials and could easily adhere to them. Adhesion can, at times, adversely affect productivity. The diffusion between the cutting tool and the workpiece is a factor considered to contribute to the adhesion phenomenon during cutting. Addressing this issue involves choosing tool materials and coated materials with high resistance to diffusion and optimizing cutting conditions, particularly the cutting speed, which significantly impacts cutting temperature. However, because cutting tool wear comprises various forms, clarifying the effect of diffusion on tool wear remains open. In this study, to reproduce the diffusion phenomenon between cutting tool and workpiece, two pairs of test specimens were prepared: (1) cemented carbide-AISI 1045 and (2) cemented carbide-Alloy718, which could be held at high temperature under vacuum conditions by a forging press. The degree of diffusion phenomena was evaluated at each tool-work material interface, and the quantification of diffusion amount was performed by diffused element in each work material. Additionally, the theoretical analysis of the diffusion phenomenon using the thermodynamic and phase diagram calculation software Thermo-Calc was also performed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 588-594"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434406","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}

{"title":"Effect of laser beam incident angle on welding of Ti6Al4V with fiber lasers","authors":"Jigar Krushna Pathak,&nbsp;N. Ramesh Babu,&nbsp;D.S. Srinivasu","doi":"10.1016/j.mfglet.2024.09.057","DOIUrl":"10.1016/j.mfglet.2024.09.057","url":null,"abstract":"<div><div>Laser beam welding (LBW) is widely used for welding Ti6Al4V alloys in aerospace applications. LBW has localized high-energy fluence with low-energy input compared to other fusion welding processes, resulting in narrower heat-affected zones. On the other hand, most metals are highly reflective when the laser beam impinges perpendicular to the surface, making the process inefficient. Hence, this work proposes to employ shallow angle incidence to reduce the reflectivity during the welding of Ti6Al4V material. To explore the potential of this idea, the current study focuses on studying the effect of laser incident angle (15°-90°), power (300 W-1500 W), and feed rate (10 mm/s-25 mm/s) on autogenous weld bead geometry. For this purpose, bead-on plate (BOP) LBW is conducted on mill-annealed Ti6Al4V material of dimensions 25 mm × 25 mm × 3 mm by employing a fiber laser source with a maximum power of 3 kW and a wavelength of 1080 nm. It is observed from the results that at a normal incident angle and low laser power (&lt; 600 W), the penetration depth is too low to generate a weld bead. Analyzing the cross-section of the weld bead, obtained from SEM, perpendicular to the weld direction reveals that the increase in laser incident angle up to an optimal angle resulted in increased bead dimensions (width and height), and beyond that, the dimensions decreased. However, the optimal incident angle changed when the laser power was changed. The major finding of this study is that at 600 W and a normal incident angle, the laser could not penetrate and generate a weld bead due to low absorptivity, while at an incident angle of 30⁰, 45⁰, and 60⁰, weld beads are generated because of increased absorptivity. Similarly, the increase in weld dimensions with the increase in laser power is observed. At higher laser power, underfill and oxide formation are observed. The feed rate is less predominant than the incident angle and the power.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 469-474"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434150","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}

{"title":"Heat partition evaluation during dry drilling of thick CFRP laminates with polycrystalline diamond drills","authors":"Fahim Shariar ,&nbsp;Umut Karagüzel ,&nbsp;Yiğit Karpat","doi":"10.1016/j.mfglet.2024.09.059","DOIUrl":"10.1016/j.mfglet.2024.09.059","url":null,"abstract":"<div><div>Since various material properties of carbon fiber-reinforced polymer (CFRP) are temperature dependent, dry drilling of CFRP is a delicate process. Thermal damage can be caused by a rise in temperature during drilling due to a large portion of heat being transferred into the material. Heat partition is used to quantify this, which represents the percentage of total heat being dissipated into the constituent objects during a machining operation. Drill margin and contact conditions at the tool-workpiece interface significantly affect the drilling of CFRP material. Drilling experiments were performed to measure thrust force, torque, and temperatures for five different sets of feed rates and rotational speeds. This study proposes a method for calculating heat partition values during CFRP drilling by developing a finite element-based thermal model. The FE model employs a Gaussian distributed ring-type heat flux that is a function of the equivalent contact length at the interface between the drill and the material surface and the geometry of the workpiece which operates as a moving heat source, emulating the progress of the drill through the CFRP laminate. The tool implements heat fluxes that use characteristic time-point-based step functions to represent the temperature on the drill as it advances through the workpiece during machining. The temperature profiles obtained from the FE analysis and the experiments for the workpiece and tool were subsequently matched iteratively to determine the corresponding heat partition value.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 483-493"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434152","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}

{"title":"3D melt blowing of Elastollan thermoplastic polyurethane for tissue engineering applications: A pilot study","authors":"Advay Pawar ,&nbsp;Bruce Anderson ,&nbsp;Behnam Pourdeyhimi ,&nbsp;Amy L. McNulty ,&nbsp;Matthew Fisher ,&nbsp;Rohan Shirwaiker","doi":"10.1016/j.mfglet.2024.09.043","DOIUrl":"10.1016/j.mfglet.2024.09.043","url":null,"abstract":"<div><div>Scaffolds, in addition to being biocompatible, should possess structural and mechanical properties similar to the natural tissues they intend to replace. Many tissue engineering applications require porous 3D scaffolds characterized by unique microfibrous organization and mechanical anisotropy. Manufacturing process principles and process parameter-biomaterial interactions ultimately govern the properties that can be achieved in the scaffold. In this study, we investigate a recently developed nonwoven scaffold fabrication process, 3D melt blowing (3DMB), for processing Elastollan®, a thermoplastic polyurethane with basic mechanical properties suitable for musculoskeletal tissue engineering. The range of feasible processing parameters was screened and the effects of two sets of critical process parameters (fiber deposition offset and surface velocity of the collector) that produced contrasting scaffold morphologies were assessed. Results showed that scaffolds of Group B that were fabricated at the higher fiber deposition offset (90 %) and higher surface velocity of the collector (6 × 10⁵ mm/min) possessed significantly smaller fiber diameter and higher porosity and degree of fiber alignment along the principal direction of collector rotation during 3DMB (all p &lt; 0.05) compared to Group A scaffolds (fabricated at 50 % offset and 1 × 10⁵ mm/min surface velocity). Although both groups possessed similar tensile stiffness, the elongation at failure was significantly different (p &lt; 0.0001). The higher elongation at failure of Group B correlated with the higher degree of fiber alignment in these scaffolds. In contrast, the more isotropic fibrous organization of Group A contributed to their higher compressive stiffness (p = 0.004). The introduction of NaOH treatment to improve hydrophilicity of the scaffolds resulted in a significant reduction of tensile stiffness of Group A (p &lt; 0.05) but not Group B. This treatment did not significantly affect the elongation at failure or compressive stiffness of both groups. With NaOH-treatment, both groups demonstrated good biocompatibility when seeded with fibroblast cells over 14 days. This study confirms the ability to fabricate via 3DMB, biocompatible, micro-fibrous, Elastollan scaffolds relevant for musculoskeletal tissue engineering.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 357-363"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434246","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}