International Journal of Lightweight Materials and Manufacture最新文献

{"title":"Machine learning in additive manufacturing: A comprehensive insight","authors":"Md Asif Equbal ,&nbsp;Azhar Equbal ,&nbsp;Zahid A. Khan ,&nbsp;Irfan Anjum Badruddin","doi":"10.1016/j.ijlmm.2024.10.002","DOIUrl":"10.1016/j.ijlmm.2024.10.002","url":null,"abstract":"<div><div>Additive manufacturing (AM) is a technological advancement gaining colossal popularity due to its advantages and simplified fabrication. AM facilitates the manufacturing of complex, light, and strong products from digitized designs. With recent advancements, AM can bring digital flexibility and improved efficiency to industrial operations. Despite the various advantages, there is continuous variation in the qualities of AM products, which remains the main challenge in the wide application of AM. The performance of printed parts is directly influenced by processing parameters, and adjusting the parameters in the AM process can be quite challenging. The barrier can be minimized by proper monitoring of the AM process and precise measurement of AM materials and components, which is difficult to achieve through analytical and numerical models. Current research demonstrates machine learning (ML) and its techniques as a novel way to reduce costs. It also helps achieve optimal process design and part quality using the fundamentals of the AM process. ML is a subcategory of artificial intelligence (AI) that enables systems to learn and improve from measured data and past experiences. The present paper is focused on presenting a broad understanding of the current applications of ML in AM and thus provides a solid background for practitioners and researchers to apply ML in AM. Very few earlier reviews were presented before, but their studies mostly focus on artificial neural network technology and other irrelevant papers. In addition, most papers were published in 2021 and 2022 and were not discussed in earlier reviews. This state-of-the-art review is based on the latest database collected from Web of Science (WoS), Publons, Scopus, and Google Scholar using machine learning and additive manufacturing as the keywords. Extensive information collected on the possible applications of ML in AM shows that ML can be effectively applied to improve AM part quality and process reliability.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 264-284"},"PeriodicalIF":0.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143510543","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":"Experimental performance evaluation of a lightweight additively manufactured hydrodynamic thrust bearing","authors":"Collier Fais ,&nbsp;Isaiah Yasko ,&nbsp;Muhammad Ali ,&nbsp;Rick Walker ,&nbsp;Joe Walker","doi":"10.1016/j.ijlmm.2024.10.003","DOIUrl":"10.1016/j.ijlmm.2024.10.003","url":null,"abstract":"<div><div>In this paper, a lightweight additively manufactured (AM) fixed geometry hydrodynamic thrust bearing fabricated via laser powder bed fusion (LPBF) is experimentally compared to a traditionally manufactured cast aluminum alloy thrust bearing of similar design. The purpose of this study is to evaluate how weight-saving design features in the AM bearing affect active critical hydrodynamic performance parameters to better understand in-service viability. Under various static operating conditions, performance parameters such as hydrodynamic pressure distribution, minimum oil film thickness (MOFT), bearing temperature and increase in oil temperature are measured. Compared to the traditionally manufactured bearing, the AM bearing showed an average increase in minimum oil film thickness of 53 %, an average increase in trailing edge hydrodynamic pressure of 116 %, while exhibiting an average decrease in bearing temperature of 1 %. Experimental results are compared to numerical simulation showing reasonably good agreement.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 285-299"},"PeriodicalIF":0.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529322","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":"Hierarchical cubic lattice structures with bending- and stretching-dominated cellular designs for enhanced buckling resistance","authors":"A. Viswanath ,&nbsp;M. Khalil ,&nbsp;M.K.A. Khan ,&nbsp;W.J. Cantwell ,&nbsp;K.A. Khan","doi":"10.1016/j.ijlmm.2025.02.002","DOIUrl":"10.1016/j.ijlmm.2025.02.002","url":null,"abstract":"<div><div>Buckling is a common failure mode in low-density strut lattices, limiting their mechanical strength and stability. This work presents a novel methodology to design and manufacture lightweight, buckling-resistant strut-based lattice structures by reinforcing buckling-prone members with hierarchical lattice unit cells—either stretching- or bending-dominated—without changing the strut lattice's relative density. Four types of lattice unit cells were examined: plate, honeycomb, strut, and TPMS solids and sheets. These were tested on single-cell cubic lattice columns with square cross-sectional struts. The resulting hierarchical structures were additively manufactured and experimentally evaluated, demonstrating significantly enhanced buckling performance. Design for additive manufacturing principles were applied, and structures with stretching and bending-dominated unit cells achieved higher critical buckling loads, with the square honeycomb cell lattice showing the highest improvement at 179 % over the baseline. This approach broadens opportunities for enhancing low-density strut lattices and developing novel buckling-resistant designs.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 310-320"},"PeriodicalIF":0.0,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791537","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":"Enhancing the mechanical properties of 3D-Printed polylactic acid through pellet additive manufacturing: A grey relational analysis based on entropy weights","authors":"Radhika Mandala ,&nbsp;B. Anjaneya Prasad ,&nbsp;Suresh Akella","doi":"10.1016/j.ijlmm.2025.02.003","DOIUrl":"10.1016/j.ijlmm.2025.02.003","url":null,"abstract":"<div><div>The most prevalent and extensively employed additive manufacturing (AM) approach method is fused deposition modeling (FDM), which uses filament as feedstock. Pellet additive manufacturing (PAM) is an emerging technique within the field of FDM that utilizes thermoplastic pellets as the feedstock considering their greater ease of production compared to filaments. The PAM technique enables the production of intricate components with high dimensional precision and cost efficiency by eliminating the need to transform pellets into filaments. The discreet choice of printing parameters greatly influences the performance of 3D-printed objects. This work underscores the significance of printing parameters on mechanical performance measures, tensile, flexure, and hardness characteristics by utilizing a multi-objective optimization technique. It is a combination of the Taguchi, analysis of variance (ANOVA), and entropy-based grey relational analysis (EGRA). A Taguchi L9 orthogonal array is employed, with infill pattern, raster angle, and layer height as the control variables, while tensile and flexural strengths, and hardness serve as the output responses. The findings demonstrated that the optimum outcomes were achieved for the gyroid infill pattern at 45° orientation and 0.25 mm layer height. Enforcing EGRA in multi-objective optimization has resulted in an improvement of 3.3 % in the grey relational grade when compared to the initial parameter configurations. Hence, EGRA proves to be an effective potential tool for the optimization process in PAM.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 331-340"},"PeriodicalIF":0.0,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791543","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":"Bending-hydraulic forming stainless steel thin-walled tube fittings wall thickness distribution law research","authors":"Xinlong Zhang,&nbsp;Jiang Xiao,&nbsp;Xiaodong Xie,&nbsp;Zhaosong Jiang,&nbsp;Xueyan Liu","doi":"10.1016/j.ijlmm.2025.02.004","DOIUrl":"10.1016/j.ijlmm.2025.02.004","url":null,"abstract":"<div><div>A study was conducted to examine the distribution of wall thickness in stainless steel thin-walled tube fittings during the forming process. The research included simulation and experimental analyses of the bending and hydroforming processes of these fittings used in a passenger car. The goal was to analyze how process parameters affect the distribution of wall thickness. Auto Form software was utilized to simulate the bending process and investigate the impact of relative bending radius (Relative bending radius for the tube fittings bending neutral layer of the ratio of the radius and diameter of the tube) on the wall thickness distribution. Subsequently, hydroforming simulations were performed under varying internal pressure loading conditions. The findings revealed that as the relative bending radius increased, both the maximum thinning rate and maximum thickening rate of the tube fittings gradually decreased. Based on the simulation outcomes, the optimal bending process parameters were determined to be a 62 mm initial tube diameter and a 95 mm bending radius. Through finite element simulations of hydroforming, internal pressures of 30 MPa, 40 MPa, and 50 MPa were compared, with 40 MPa identified as the optimal pressure for forming. The thin-walled tube fittings were then manufactured based on the optimal parameters obtained from the simulation, which were validated through experimentation. The experimental results closely matched the simulation results, with a maximum error margin of 2.27 %. The final formed parts met all requirements without any failures.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 402-414"},"PeriodicalIF":0.0,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800352","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":"Lightweight aluminum joint design: Enhancement of mechanical properties through novel inter-layer and powder additives in friction stir welding","authors":"Equbal Ahmed ,&nbsp;Muhammed Muaz ,&nbsp;Sajjad Arif ,&nbsp;Ravi Kant ,&nbsp;Syed Mohd Hamza ,&nbsp;Md Kashif Alim ,&nbsp;Musab Ahmad Khan ,&nbsp;Jaber Abu Qudeiri ,&nbsp;Sanan H. Khan","doi":"10.1016/j.ijlmm.2025.02.001","DOIUrl":"10.1016/j.ijlmm.2025.02.001","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B₄C), Titanium Dioxide (TiO₂), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 341-354"},"PeriodicalIF":0.0,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791544","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":"Thermo-mechanical and electrical properties of graphene nanoplatelets reinforced recycled polypropylene nanocomposites","authors":"Vimukthi Dananjaya ,&nbsp;Chamil Abeykoon","doi":"10.1016/j.ijlmm.2025.01.003","DOIUrl":"10.1016/j.ijlmm.2025.01.003","url":null,"abstract":"<div><div>This study investigates the thermo-mechanical properties of graphene nanoplatelet (GNP)-filled recycled polypropylene (rPP) nanocomposites to enhance their performance and sustainability. It examines the influence of GNP loading on mechanical, thermal, and electrical behaviour, focusing on tensile strength, Young’s modulus, impact strength, heat deflection temperature, thermal conductivity, and electrical resistivity. The GNP-PP composites are fabricated by functionalizing GNPs through mild acid treatment to enhance compatibility with the rPP matrix, followed by melt mixing in a twin-screw extruder at varying GNP loadings (0–20 Phr). The tensile strength, Young's modulus, and flexural strength of recycled polypropylene increased by 15.6 MPa, 3.7 MPa, and 2.41 MPa, respectively, as the GNP loading increased from 0 to 20 Phr. AddingAdding GNP up to 20 Phr into the rPP matrix also increased the crystallization, melting, onset, and maximum decomposition temperatures by 5, 4.7, 8.36, and 7.02 ˚C, respectively. Additionally, the thermal conductivity shows an increasing trend, with an improvement of 221 mW/mK. However, including fillers reduced electrical resistivity by 105 Ω cm and impact strength by 64.27 Jm⁻¹. The significance of this work lies in providing eco-friendly alternatives to conventional polymers, promoting the adoption of recycled materials, and contributing to sustainable product design. The outcomes offer valuable insights for industries promoting a circular economy with cleaner production while reducing the carbon footprint. Also, the recycling and reuse of synthetic polymers uncover a valuable prospect for tackling the escalating global polymeric waste problem.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800356","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":"Improving healing capability of the thermoplastic composites reinforced with carbon fibres in a Single Lap Joint (SLJ) using a co-cured method","authors":"Ferhat Kadioglu","doi":"10.1016/j.ijlmm.2025.01.001","DOIUrl":"10.1016/j.ijlmm.2025.01.001","url":null,"abstract":"<div><div>Thermoplastic composites as emerging materials for aerospace and automotive industries are suitable for mass-production and recycling. Healing is one of their inherent features when being damaged. This study aims to focus on the fusion bonding of a thermoplastic composite reinforced with carbon fibers. The material was fabricated in the Single Lap Joints (SLJs) configuration using a co-cured manufacturing method. First, the joints were subjected to quasi-static tensile tests to failure. The pristine joints with a 20 mm overlap length gave an average maximum load of about 5.5 kN. Then, the damaged joints were healed and subjected to the same test conditions to see their performance. It was observed that the thermoplastic adherends were able to be healed almost fully, giving a joint strength of about 5.2 kN, implying about 5 % of a decrement. Numerical works were also undertaken to see stress distributions in the joint and to predict the joint failure. Further investigations have shown the lap shear performance of such joints could be improved through different designs with no additional weight in the joint, which is feasible using the co-cured manufacturing methods.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 385-392"},"PeriodicalIF":0.0,"publicationDate":"2025-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800357","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":"Microstructural analysis and preliminary wear assessment of wire arc additive manufactured AA 5083 aluminum alloy for lightweight structures","authors":"Prasanna Nagasai Bellamkonda ,&nbsp;Maheshwar Dwivedy ,&nbsp;Kaushik N.Ch","doi":"10.1016/j.ijlmm.2024.09.003","DOIUrl":"10.1016/j.ijlmm.2024.09.003","url":null,"abstract":"<div><div>The proliferation of Wire Arc Additive Manufacturing (WAAM) has significantly enhanced the production capabilities for lightweight and structurally robust components. This study investigates the microstructural characteristics, tensile properties, and preliminary wear performance of AA 5083 aluminum alloy processed via WAAM, focusing on applications for lightweight structures. Using SEM and XRD, microstructural changes during the WAAM process are analyzed, and tensile testing evaluates the mechanical properties, including ultimate tensile strength (UTS) and elongation. The results reveal that the microstructure consists of α-Al and β-(Al₅Mg₈) phases, with the Al₅Mg₈ phase distributed along grain boundaries and within grains. Notably, the grain size in the Y-direction (building direction) is larger than in the X-direction (deposition direction) due to temperature variations during processing. Tensile testing shows that horizontal samples (X-direction) have a UTS of 295 ± 5 MPa and elongation of 20.08 ± 0.8 %, while vertical samples (Y-direction) have a UTS of 267 ± 10 MPa and elongation of 16.43 ± 2.1 %. This results in an anisotropy of 9.4 % in tensile strength, reflecting the differences in mechanical properties between the two directions. The WAAM AA 5083 aluminum part exhibits a maximum wear rate of 5.22 × 10⁻³ mm³/m and a coefficient of friction of 0.52 at a load of 3.5 kg and 450 rpm. Under these conditions, deep grooves, layer separation, and load-induced deformation are observed. The primary wear mechanisms include delamination, adhesion, and abrasion. Hardness levels are consistent in the X-direction and show minimal variance in the Y-direction, with an average hardness of 89.4 ± 5.14 HV0.5. The study demonstrates that WAAM-produced AA 5083 aluminum alloy, with an anisotropy below 10 %, is suitable for real-time lightweight structures, offering effective performance in engineering applications such as aerospace and automotive industries. Future research should focus on further quantifying wear behavior and optimizing processing conditions to enhance material performance for specific applications.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 1-13"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099457","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":"Microstructure and properties of the Al-0.5 wt.% Fe alloy wire, copper-clad by electrochemical deposition","authors":"A.E. Medvedev ,&nbsp;K.E. Kiryanova ,&nbsp;E.B. Medvedev ,&nbsp;M.V. Gorbatkov ,&nbsp;M.M. Motkov","doi":"10.1016/j.ijlmm.2024.08.001","DOIUrl":"10.1016/j.ijlmm.2024.08.001","url":null,"abstract":"<div><div>This study examines the microstructure, mechanical and electrical properties of the copper-clad wires with a core of Al-0.5Fe alloy, obtained by casting into an electromagnetic crystallizer (EMC). The outer copper layer with a thickness of 90 ± 10 μm was applied via electrochemical deposition. Copper cladding of the aluminum wire leads to (without loss of strength and electrical conductivity) a decrease in the ductility to the value less than 2% which is the minimal recommended level of the elongation to failure for the commercially used aluminium alloys. Such drop in ductility also results in the shift of the fracture type to a brittle one. The cause of brittle fracture is the presence of a transition nickel layer required by the technological process of the electrochemical deposition of copper onto aluminium alloy. Annealing at 300 °C for 1 h leads to recovery of the ductility to the original level (4.3% for the cold-drawn Al-0.5Fe alloy wires) with a slight decrease in the ultimate tensile strength to 184 MPa and an increase in the specific electrical conductivity of the bimetallic wire to 60.9%IACS, as well as a change in fracture behavior to ductile. This method is promising for creating the bimetallic aluminum wires with a thin copper layer of controlled thickness and chemical composition to produce conductive elements in which the skin effect could be realized.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 1","pages":"Pages 28-37"},"PeriodicalIF":0.0,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143099863","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}