International Journal of Lightweight Materials and Manufacture最新文献

{"title":"Enhancing the performance of laser powder bed fusion through hybridization with bending","authors":"Valentino A.M. Cristino ,&nbsp;Rui FV. Sampaio ,&nbsp;João P.M. Pragana ,&nbsp;Ivo M.F. Bragança ,&nbsp;Carlos M.A. Silva ,&nbsp;Paulo A.F. Martins","doi":"10.1016/j.ijlmm.2024.12.003","DOIUrl":"10.1016/j.ijlmm.2024.12.003","url":null,"abstract":"<div><div>This paper is focused on the hybridization of metal additive manufacturing with bending to shape thin-walled deposited materials into fully three-dimensional custom parts with specific angles. The presentation covers material deposition by laser powder bed fusion, material and formability characterization using tension and three-point bending tests, and proof-of-concept validation through bending a flat, cross-shaped, deposited plate into a slender three-dimensional double U-shaped part. The use of digital image correlation and finite element analysis supports the presentation as well as the design and creation of the part. Results underscore the significance of hybridizing metal additive manufacturing with bending due to the gains obtained in material usage and fabrication time of 87.9 % and 85.7 %, respectively. The overall methodology integrating material deposition, formability analysis, and combined experimental and finite element simulation of bending proves effective for designing hybrid metal additive-manufactured parts, providing a comprehensive framework for future research and development in this area.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 301-309"},"PeriodicalIF":0.0,"publicationDate":"2024-12-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791536","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 burnishing strategies on surface integrity, microstructure and corrosion performance of wire arc additively manufactured AZ31 Mg alloy","authors":"Shambhu Kumar Manjhi ,&nbsp;Oyyaravelu R ,&nbsp;Srikanth Bontha ,&nbsp;A.S.S. Balan","doi":"10.1016/j.ijlmm.2024.12.001","DOIUrl":"10.1016/j.ijlmm.2024.12.001","url":null,"abstract":"<div><div>AZ31 Mg alloy is an emerging material that has received considerable attention in aerospace, automotive, and temporary biodegradable implant applications owing to its attractive properties, such as low density, high specific strength, and biodegradability. Nevertheless, some shortcomings in Mg alloys are their low ductility, which is associated with challenging its manufacturing, and poor corrosion resistance associated with unreliable components. Therefore, a cold metal transfer wire arc additive manufacturing (CMT-WAAM) process is used to manufacture AZ31 Mg alloy and achieved 29.4 % ductility by controlling the gas porosity, keyhole porosity, and internal cracks. Further, severe plastic deformation is induced on the surface of deposited parts by low plasticity burnishing (LPB) with parallel and cross-pattern burnishing to modulate their surface to slow down the kinetics of the corrosion damage. The average surface roughness (S_a) of the cross-burnishing pattern is 0.235 μm, which is 123.6 % lower than the parallel burnished and 261.7 % lower than the milled specimens. The residual stress (RS) of WAAM is 40 MPa with a tensile nature; however, it is drastically reduced and develops compressive RS of 45 MPa under a parallel burnishing pattern and 62 MPa under a cross-burnishing pattern. Moreover, LPB with cross pattern deformed ∼395 μm depth of WAAMed AZ31 workpiece, which is ∼45 % higher than deformed depth (∼272 μm) by parallel pattern burnishing. The electrochemical corrosion rate of the WAAM specimen is 9.71 mm/year^, and it is reduced to 1.82 mm/year under LPB caused by compressive residual stress and grain refinement.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 355-373"},"PeriodicalIF":0.0,"publicationDate":"2024-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800355","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":"Friction stir extrusion: Parametrical optimization for improved Al–Si aluminum tube production","authors":"Mostafa Akbari ,&nbsp;Parviz Asadi ,&nbsp;Fevzi Bedir ,&nbsp;Naghdali Choupani","doi":"10.1016/j.ijlmm.2024.11.003","DOIUrl":"10.1016/j.ijlmm.2024.11.003","url":null,"abstract":"<div><div>Friction Stir Extrusion (FSE) was employed to convert cylindrical LM13 ingots into pipes, utilizing three distinct designs of rotating tool heads. This study examined the influence of process variables, consisting of tool rotational speed and plunging speed, on key properties of the resulting products. The properties investigated encompassed the size of Si precipitates, microhardness, wear resistance, and ultimate compressive strength (UCS). To effectively establish the relationships between the process input variables and the resulting mechanical and microstructural characteristics of the produced pipes, an artificial neural network (ANN) was used. This established correlation was integrated into a hybrid multi-objective optimization framework to identify the optimal process parameters. The investigation determined the ideal configuration: a plunging rate of 31 mm/min, a rotational rate of 653 rpm, and tool design number 3.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 182-193"},"PeriodicalIF":0.0,"publicationDate":"2024-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429653","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":"Sustainable transformation of waste Aluminium into high-performance composites: A review","authors":"Abdullah Al Mahmood ,&nbsp;Md. Abdul Kader ,&nbsp;M. Bodiul Islam ,&nbsp;Rumana Hossain","doi":"10.1016/j.ijlmm.2024.11.002","DOIUrl":"10.1016/j.ijlmm.2024.11.002","url":null,"abstract":"<div><div>In the modern age, metal matrix composites (MMC) are offering numerous advantages over the pure metal and their enhanced physical and mechanical properties have diversified the range of applications of the MMC. Aluminum is one of the most useful metals in the world and highly requires energy intensive process to produce from the ores. Recycling is the only option to save the resources, and it can be done by the minimum level of energy consumption and emission. However, it is very crucial to follow the proper procedure to eliminate any remaining impurities in the waste metal. Secondary Aluminum can be used for unlimited times in every field of applications where primary Aluminum is suitable. However, for the advanced applications of Aluminum including automobiles, aircrafts, defence, and biomedical instruments that require unique sets of properties, alloying or making composites is inevitable. Particulate reinforcement to the Aluminum matrix is an excellent way of modifying the physical, mechanical, and micro-structural properties of Aluminum. Silicon carbide is a very good reinforcing agent used for manufacturing Aluminum matrix composites (AMC). SiC reinforced AMC can offer strong resistance to fracture and high wear resistivity with excellent surface hardness. Recycling aluminum to manufacture AMC is a sustainable solution to meet the current demand for advanced materials. Synthesizing of reinforcing materials from waste materials can also help to build sustainable, affordable and light weight AMC. The aim of this work is to review the present methods of recycling Aluminum and sustainable transformation of the recycled Aluminum to high-performance particulate reinforced AMC.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 194-204"},"PeriodicalIF":0.0,"publicationDate":"2024-11-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429567","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":"Advanced machine learning and experimental studies of polypropylene based polyesters tribological composite systems for sustainable recycling automation and digitalization","authors":"Abrar Hussain ,&nbsp;Jakob Kübarsepp ,&nbsp;Fjodor Sergejev ,&nbsp;Dmitri Goljandin ,&nbsp;Irina Hussainova ,&nbsp;Vitali Podgursky ,&nbsp;Kristo Karjust ,&nbsp;Himanshu S. Maurya ,&nbsp;Ramin Rahmani ,&nbsp;Maris Sinka ,&nbsp;Diāna Bajāre ,&nbsp;Anatolijs Borodiņecs","doi":"10.1016/j.ijlmm.2024.11.001","DOIUrl":"10.1016/j.ijlmm.2024.11.001","url":null,"abstract":"<div><div>Digitalization and automation are emerging solutions to the complex problems of recycling. In this research work, the experimental and Python based Archard deep learning wear rate models are introduced regarding recycling automation and composite tribological systems optimization. The optimum polyester fibers (PESF) of length of 3–3.5 mm were used for fabrication of polypropylene (PP)-PESF composite systems. The deformation, high texture, asperities, and micro-cracks were observed during scanning electron microscope and machine-learning studies. The lowest experimental value of abrasive wear of 3.0 × 10⁻⁶ mm³/Nm was observed for PP. Comparatively, higher experimental values of abrasive wear of the PP-PESF composites are found in the range of 4.35 × 10⁻⁶ to 4.7 × 10⁻⁶ mm³/Nm due to presence micro-defects on the surface of composites. The experimental values of Coefficient of friction (COF) of PP and PP-PESF are found in the range of 0.70–0.8 and 1.1–1.3, respectively. The experimental values of abrasive wear and COF are found compatible with literature. Similarly, the simulated values of abrasive wear of PP and PP-PESF composites are predicted in the range of 4.8 × 10⁻⁷ to 3.75 × 10⁻⁷ mm³/Nm, respectively. The predicted values of PP and PP-PESF composite show better resistance towards abrasive wear. The proposed experimental and simulated (in terms of Python coding, machine learning, image processing, artificial intelligence, and deep learning studies) research work can be introduced industrially for automation as well as digitalization of grinding of PES waste, processing, tribological testing, and SEM characterization evaluations.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 252-263"},"PeriodicalIF":0.0,"publicationDate":"2024-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429715","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":"Electro-discharge machining of microholes on 3d printed Hastelloy using the novel tool-feeding approach","authors":"Akash Korgal ,&nbsp;Arun Kumar Shettigar ,&nbsp;Navin Karanth P ,&nbsp;Nishanth Kumar ,&nbsp;Bindu Madhavi J","doi":"10.1016/j.ijlmm.2024.10.005","DOIUrl":"10.1016/j.ijlmm.2024.10.005","url":null,"abstract":"<div><div>Hastelloy, a nickel-based superalloy renowned for its exceptional resistance to corrosion at high temperatures, is widely used in sectors such as nuclear, aerospace, chemical processing, and pharmaceuticals. Microelectrical discharge machining (μ-EDM) is crucial for generating microholes and channels on Hastelloy. Since it effectively addresses difficulties like work hardening, high strength &amp; wear resistance, and low thermal conductivity in traditional machining. Microholes play a major role in many critical components for precise control of fluids in fuel injectors, managing heat in turbine blades, controlled gas exchange, etc. The current research investigates the drilling of 8:1 aspect ratio microholes machined by 400 μm diameter electrodes. This study investigated the influence of tool material (tungsten carbide, carbide drill bit, and brass) on μ-EDM performance. Compared to tungsten carbide and carbide drill bits, brass exhibited significantly lower electrode wear, leading to more precise microholes with reduced overcut and taper angle. However, brass also required a substantially longer machining time. Carbide drill bits offered a balance between wear resistance, machining time, and overcut/taper angle.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 157-164"},"PeriodicalIF":0.0,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429799","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":"Environmentally friendly chemical–magnetorheological finishing method for Ti–6Al–4V biological material based on Fe3O4@SiO2, oxaloacetate acid and H2O2","authors":"Le Anh Duc,&nbsp;Vu Minh Yen,&nbsp;Nguyen Duy Trinh","doi":"10.1016/j.ijlmm.2024.10.004","DOIUrl":"10.1016/j.ijlmm.2024.10.004","url":null,"abstract":"<div><div>Titanium alloy is extensively utilised in various advanced equipment across multiple industries, especially in biological implantable devices. The surface machining of such devices is required to provide a finished surface with high precision and gloss. This study presents an established ecofriendly slurry for a hybrid polishing process utilising a highly efficient chemical and magnetorheological fluid (C-MRF) to obtain ultraprecise surface quality. This slurry incorporated Fe₃O₄@SiO₂ abrasive particles, oxaloacetate acid (C₄H₆O₅), deionised water and hydrogen peroxide (H₂O₂) as an oxidiser. Ti–6Al–4V workpieces polished with C-MRF based on Fe₃O₄@SiO₂ abrasives and polishing performance were used to investigate the influence of the oxidising agent H₂O₂ and oxaloacetate acid (monitored with a pH indicator) on the surface finish of Ti–6Al–4V biomaterial. In contrast to the traditional mechanical and chemical polishing methods for titanium alloys that often include strong bases and acids along with chemicals that endanger the environment and humans, the proposed polishing process based on the newly developed ecofriendly magnetic composite leveraged the advantages of magnetorheological fluid with chemical reactions to create an ultra smooth surface. Experiments were performed to investigate the influence of different polishing durations and factors on the quality of polished surfaces, thereby optimising technological parameters, reducing time and improving surface quality. Various technological parameters were evaluated through single-factor and orthogonal experiments to assess their distinct effects on surface quality and material removal capability. This work proposed an environmentally friendly C-MRF method for finishing Ti–6Al–4V biomaterial with high efficiency and industrial applicability.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 228-240"},"PeriodicalIF":0.0,"publicationDate":"2024-10-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429569","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":"Data-driven approaches in incremental forming: Unravelling the path to enhanced manufacturing efficiency using data acquisition","authors":"S. Pratheesh Kumar,&nbsp;V. Joseph Stanley,&nbsp;S. Nimesha","doi":"10.1016/j.ijlmm.2024.10.001","DOIUrl":"10.1016/j.ijlmm.2024.10.001","url":null,"abstract":"<div><div>Incremental forming is a versatile and cost-effective sheet metal forming technique widely adopted in low-volume manufacturing and prototyping across various industries. Recent advancements in data-driven approaches, including machine vision, neural networks, and 3D reconstruction methods, have significantly enhanced the precision and efficiency of incremental forming processes. This study explores the integration of advanced data acquisition and processing techniques to improve the accuracy, automation, and defect detection capabilities in incremental forming. Key advancements such as robot-assisted forming, computer-controlled toolpath generation from CAD models, and real-time quality monitoring using machine vision are discussed. The potential of single- and multi-view 3D reconstruction methods for optimizing toolpath strategies and enhancing formability is also examined. The findings highlight opportunities for full automation in incremental forming, demonstrating its potential to revolutionize modern manufacturing by reducing costs, increasing customization, and improving product quality. These advancements could benefit industries such as aerospace, automotive, and medical device manufacturing, where precision and flexibility are critical.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 165-181"},"PeriodicalIF":0.0,"publicationDate":"2024-10-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429652","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":"Design, analysis and development of prosthetic and orthotic elements by additive manufacturing process","authors":"Piyush Patel,&nbsp;Piyush Gohil","doi":"10.1016/j.ijlmm.2024.09.004","DOIUrl":"10.1016/j.ijlmm.2024.09.004","url":null,"abstract":"<div><div>According to patient needs, unique Prosthetic and Orthotic (P&amp;O) elements are created using Additive Manufacturing (AM) without the need for part-dependent equipment. This paper presents the basic information about the element's materials, and techniques of P&amp;O. This paper discusses the detailed procedure for designing, analyzing, and developing various P&amp;O models. Through analysis, the result shows that the desirable values of natural frequency (3103.1 Hz), total deformation (0.00261 mm), and strain energy (0.07011 mJ) of the prosthetic foot model 1 is for carbon fiber material. Therefore, for the preparation of the foot, this material can be selected for the best performance of the prosthetic foot.</div><div>Traditionally, individual P&amp;O devices are manufactured using plaster molds, which require multiple patient visits and take a lot of effort and time to produce. Therefore, our main attention is the process of designing and developing lightweight P&amp;O elements quickly with a simplification of the manufacturing process. The AFO and flex foot prosthetic parts are printed using PLA material on FDM machines. The entire process takes less than 7 h, with an average hands-on time of only 10–15 min for AFO parts and about 10 h for Flex-Foot prostheses. In other words, using 3D printing to create a P&amp;O device for a patient is significantly less time-consuming than traditional methods. In the future, it is intended to compare altered effects obtained by using various types of materials for the improvement of the P&amp;O devices by the AM method.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 205-227"},"PeriodicalIF":0.0,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429568","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":"Design of a test rig for the characterization of friction and wear in hot-metal gas-forming of AA 5083 aluminium sheets","authors":"Federico Simone Gobber ,&nbsp;Alexandru Tancau ,&nbsp;Leonardo Daniele Scintilla ,&nbsp;Marco Fontana ,&nbsp;Marco Actis Grande","doi":"10.1016/j.ijlmm.2024.09.002","DOIUrl":"10.1016/j.ijlmm.2024.09.002","url":null,"abstract":"<div><div>Advanced aluminium sheet-forming processes such as the hot-metal gas-forming represent a challenging solution for producing small lots in the high-end car bodies industry, and the adoption of single cavity moulds made from low-cost, easily machinable materials such as cast iron reduces the overall sheet-forming costs. The tribological properties of the mould-sheet tribopair are of great interest for optimizing the sheet forming obtaining an acceptable esthetic surface finishing. This study presents the design and construction of a lab-scale experimental test rig for the tribological characterization at high temperatures of the mould-sheet tribopair. The proposed test method reproduces the sliding at the mould-sheet interface with contemporary sheet straining up to ε = 0.8 at strain rates in the 1.2∗10⁻³ to 2∗10⁻² s⁻¹ range. A series of experiments were carried out in dry and lubricated conditions for a ductile iron EN-GJS grade sliding against a AA 5083 aluminium alloy while straining. After comparing the experimental results with the literature data from other test rigs, comparable results were obtained as COF regards, ranging between 1.2 and 2.5 in dry sliding and between 0.05 and 0.2 in lubricated sliding. The morphological characterization of the sliding surfaces and cross-sections highlights the strong tendency to galling in dry sliding conditions expecially for low strain rates.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 241-251"},"PeriodicalIF":0.0,"publicationDate":"2024-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429570","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}