International Journal of Lightweight Materials and Manufacture最新文献

{"title":"Fabrication of an isotropic Ti–3Al–8V–6Cr–4Mo–4Zr alloy with a combination of high strength and good ductility","authors":"Wensheng Li ,&nbsp;Yinxiang Chai ,&nbsp;Zhongliang Lin ,&nbsp;Yue Qi ,&nbsp;Jie Zheng ,&nbsp;Yan Liu ,&nbsp;Dunwen Zuo ,&nbsp;Wenbin Zheng ,&nbsp;Tong Liu ,&nbsp;Hongye Sun ,&nbsp;Xiaoling Zhang ,&nbsp;Shuo Zhao","doi":"10.1016/j.ijlmm.2025.08.005","DOIUrl":"10.1016/j.ijlmm.2025.08.005","url":null,"abstract":"<div><div>A method on fabricating the Ti-3.09Al-6.66V-5.62Cr-4.54Zr-4.93Mo (Ti-38644) fasteners with high strength and good ductility was reported in this study, whose tensile property evades the strength–ductility trade-off dilemma in Ti-38644 alloys. The microstructure in present Ti-38644 alloy is mainly composed of equiaxial β grains with tiny α particles embedded in them. The microstructure is homogeneous without obvious textures, leading to an isotropic mechanical property. The present method to process Ti-38644 fastener is both cost-effective and readily scalable. The process discovered here is readily scalable at a low cost and might be conducive to industrial production and to be applicable to other Ti alloys fasteners.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 1-5"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618687","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}

{"title":"Laser powder bed fusion of AlSi10Mg with increased layer thickness for higher building rate","authors":"Stanislav Chernyshikhin ,&nbsp;Leonid Fedorenko ,&nbsp;Vladimir Egorov ,&nbsp;Boris Zotov ,&nbsp;Veniamin Brykin ,&nbsp;Konstantin Korobov ,&nbsp;Anton Nalivaiko ,&nbsp;Dmitriy Zherebtsov ,&nbsp;Maria Lyange ,&nbsp;Ivan Pelevin","doi":"10.1016/j.ijlmm.2025.07.010","DOIUrl":"10.1016/j.ijlmm.2025.07.010","url":null,"abstract":"<div><div>Among existing metal additive manufacturing technologies, laser powder bed fusion (LPBF) has an outstanding resolution but, from the other side, inferior building rate. In this work, the LPBF process of AlSi10Mg with increased layer thickness was comprehensively studied to enhance productivity. The samples were manufactured at 30, 50, 70, and 90 μm layer thicknesses with an additional variation in laser power and scanning speed. To find a quasi-optimal process conditions for each layer thickness, the specimens were investigated in terms of relative density, defect generation, microstructure, mechanical properties, and surface roughness. A transition in the pores’ morphologies along the building direction was identified. Namely, small metallurgical pores at the bottom surface, and irregular pores in the rest of the volume were observed. Therefore, special attention should be provided to the downskins of parts. The surface roughness tends to increase with the layer thickness, but it has been shown that the deterioration of the top surface quality is insignificant, and Ra for the side surface can be minimized via optimization of process conditions. It was demonstrated that an increase of layer thickness up to 50 μm is possible with a minor decrease in relative density and almost complete preservation of mechanical properties.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 37-46"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618686","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}

{"title":"Analysis and optimisation of parent grain reconstruction for additively manufactured Ti–6Al–4V","authors":"Lu Yang ,&nbsp;Saranarayanan Ramachandran ,&nbsp;Axieh Bagasol ,&nbsp;Fan Wu ,&nbsp;Qiyu Guan ,&nbsp;David J. Browne ,&nbsp;Denis Dowling ,&nbsp;Wajira Mirihanage","doi":"10.1016/j.ijlmm.2025.07.009","DOIUrl":"10.1016/j.ijlmm.2025.07.009","url":null,"abstract":"<div><div>During solidification processing, most common titanium alloys solidify as high-temperature parent phase and it subsequently transforms into the room-temperature child phase. This parent to child transformation occurred as a solid-state transformation. Even though the parent phase is not observable at room temperature, it is considerably associated with solidification defects such as porosity. Parent grain reconstruction based on Burgers orientation relationship, which shows the crystallographic relationship between two phases, has been applied to examine the high temperature and transitional parent phases of titanium alloys and steels. This contribution presents the reconstructed high temperature parent phase and the sensitivity analysis related to a series of parameters for three crucial parent phase reconstruction steps for additively manufactured titanium alloy Ti–6Al–4V. The analysis examines the reconstruction, merging of very small and neighbouring grains together, and finally cleaning of inclusive noise, which referred as inclusions during the rendering process of the parent phase. The analysis offers an instruction for threshold selection that enables optimised parent phase reconstruction.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 91-102"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618690","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}

{"title":"Effect of nanoclay additives on the salt water absorption and material characteristics of nylon additive manufactured polymers","authors":"Irine Chenwi,&nbsp;Julianna Martinez,&nbsp;Dillon Fontaine,&nbsp;Catherine DuBois,&nbsp;James LeBlanc","doi":"10.1016/j.ijlmm.2025.07.011","DOIUrl":"10.1016/j.ijlmm.2025.07.011","url":null,"abstract":"<div><div>An experimental investigation of the effectiveness of nanoclay material additives on the reduction of water absorption into a nylon AM polymer and the corresponding effects on the material and mechanical properties has been performed. The primary objectives of the study were to quantify the effectiveness of nanoclay material additives to mitigate the water absorption characteristics of extruded nylon, and quantify the changes in mechanical properties of the additive based material before and after salt water exposure. In the study three unique material configurations were evaluated: (1) Baseline Nylon, (2) Nylon with 2 % by weight nanoclay, and (3) Nylon with 5 % by weight nanoclay. The nanoclay powder that was used as an additive is Montmorillonite Clay (MMT) with surface modification. Water immersion was conducted with 3.5 % NaCl solution at room temperature for a time duration of 30 days. Each material configuration was being characterized mechanically in both dry and saturated conditions. The changes in mechanical properties were quantified through the controlled tensile testing. Additionally, thermogravimetric analysis (TGA) was conducted to quantify the changes in thermal decomposition. The thermal properties including glass transition temperature (T_g) and melting temperature (T_m) were evaluated by Differential Scanning Calorimetry (DSC). Finally, Dynamic Mechanical Analyzer (DMA) tests were conducted to understand the oscillation stress-strain behavior and thermal response of the neat nylon and the nanoclay modified material. The study's findings show that the use of nanoclay additives can reduce the amount of salt water absorbed by the respective materials, from 1.77 % to 1.63 %. However, there is a corresponding degrading effect on the mechanical properties of the materials themselves, even in the absence of salt water exposure. The incorporation of the nanoclay additives are shown to change the material behavior from highly ductile to highly brittle, with the failure strain being reduced from over 20 % to less than 2.5 %. Furthermore, The thermal properties of the baseline nylon were affected by the inclusion of the nanoclays by which the Glass Transition temperature was reduced from 45 °C to 43 °C and the melting temperature was increased from 200 °C to 204 °C.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 78-90"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618630","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}

{"title":"Feasibility of electrical discharge machining (EDM) of AZ31 lightweight magnesium alloy in dielectric fluids of hydrocarbon oil and deionized water","authors":"Saeed Asghari ,&nbsp;Mohammad Reza Shabgard ,&nbsp;Maghsoud Shalvandi ,&nbsp;S. Abolfazl Roudehchi ,&nbsp;Farzad Habibi","doi":"10.1016/j.ijlmm.2025.07.004","DOIUrl":"10.1016/j.ijlmm.2025.07.004","url":null,"abstract":"<div><div>In the current study, the effect of different types of dielectric fluids, including hydrocarbon oil and deionized water, on the material removal rate (MRR) and tool wear rate (TWR) of AZ31 magnesium alloy in the EDM process was investigated. X-ray diffraction (XRD) and FE-SEM coupled with energy dispersive spectroscope (EDS) were used to characterize the machined parts, while surface roughness and microhardness tests were used to evaluate the quality of the surface. The results revealed that the machining rate was significantly lower when using deionized water as the dielectric fluid. This was attributed to the formation of a 90 μm layer of magnesium oxide (MgO) on the machined surface, which was confirmed through EDS, XRD, and microhardness analyses. On the other hand, using oil as the dielectric fluid resulted in the formation of elemental carbon and Mg₂C₃ phase due to alloying with the workpiece. It was also observed that increasing the electric discharge current led to higher MRR and TWR values, with a smaller increase observed in specimens machined with deionized water. The surface roughness of the machined surfaces also increased significantly, from 10.12 to 19.2 μm for parts machined at 48 A/100 μs, indicating poor electrical discharge machinability of magnesium alloy in an aqueous environment.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 113-121"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145737661","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}

{"title":"Development of magneto-rheological polishing process with NON-Newtonian fluid and uniform magnetic yoke for surface quality Ti–6Al–4V enhancement","authors":"Nguyen Minh Quang,&nbsp;Nguyen Tien Tung,&nbsp;Le Thi Phuong Thanh,&nbsp;Nguyen Duy Trinh","doi":"10.1016/j.ijlmm.2025.07.007","DOIUrl":"10.1016/j.ijlmm.2025.07.007","url":null,"abstract":"<div><div>Ti–6Al–4V is a widely used and crucial alloy in various industries, particularly in manufacturing. Aiming to achieve a flat and smooth Ti–6Al–4V surface, this study proposes a new magneto-rheological (MR) polishing process, enhanced by a non-Newtonian fluid (thickening fluids) and a uniformly distributed magnetic yoke. A new MR fluid formulation is presented and discussed in detail in this study to address issues of poor particle bonding and non-uniformity. The authors also analyse the magnetic field to evaluate the effectiveness and feasibility of using uniformly dispersed magnetic particles in the MR process. Through evaluations of magnetic field strength, magnetic flux distribution and field variations, the study concludes that this approach is suitable and can enhance polishing performance. A polishing process employing the novel MR suspension and uniformly distributed magnetic yoke was established. The underlying mechanisms and key characteristics of this method were examined and discussed. An experimental setup, based on the previous MR processes, was used to conduct a series of experiments to demonstrate the potential of this method. The experiments also investigated the influence of several key factors, including fluid thickness, magnetic disk speed, working gap and container speed, on surface quality improvement. After 100 min of polishing, the Ti–6Al–4V workpiece achieved a smooth and flat surface with a surface roughness of Ra = 17 nm, demonstrating the high polishing efficiency of the proposed method. This research offers a promising solution for the precision polishing of difficult-to-machine materials and contributes to the advancement of smart finishing technologies for next-generation manufacturing.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 6-19"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618688","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}

{"title":"Experimental investigation of degradation in the marine environment of FDM-based 3D printed specimens","authors":"Singaravel B ,&nbsp;Niranjan T ,&nbsp;Laxmireddy P ,&nbsp;Srinivasulu K ,&nbsp;Chakradhar B ,&nbsp;Poojitha G","doi":"10.1016/j.ijlmm.2025.08.002","DOIUrl":"10.1016/j.ijlmm.2025.08.002","url":null,"abstract":"<div><div>Additive manufacturing technology, commonly known as 3D printing, is used to create three-dimensional objects. In 3D printing, Fused Deposition Modeling (FDM) is a solid-based additive manufacturing technique. For FDM-printed parts used in environments with humidity or marine exposure, understanding polymer degradation is essential to ensure long-term performance. In this work, degradation was investigated in terms of tensile strength reduction using two different environments. The study also focused on how different raw materials and FDM process parameters influence the tensile strength of 3D-printed parts. Two different environments were considered: an artificial seawater environment (simulated) and a natural seawater environment (marine). The materials used in this study are Nylon, Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), and Polylactic Acid (PLA). The samples were stored for 30 days in both environments to examine changes in tensile strength. The experimental results revealed a decrease in tensile strength due to degradation, with reductions of 31–44 % in Nylon, 15–25 % in ABS, 17–28 % in PETG, and 26–35 % in PLA. It is understood that degradation resistance and mechanical retention are crucial for optimizing the performance and reliability of 3D-printed components in marine and offshore environments. The degradation of polymer molecules in artificial seawater is primarily influenced by hydrolytic reactions.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 103-112"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145685495","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}

{"title":"Removal notice to “Design, Analysis and Development of Prosthetic and Orthotic elements by Additive Manufacturing process” [Int. J. Lightweight Mater. Manuf. 8 (2025) 205–227]","authors":"Piyush Patel,&nbsp;Piyush Gohil","doi":"10.1016/j.ijlmm.2025.11.002","DOIUrl":"10.1016/j.ijlmm.2025.11.002","url":null,"abstract":"","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Page 122"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146022502","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}

{"title":"Rapid prototyping assisted optimization and experimental three point bending evaluation of spreader bar structure","authors":"Abian Nurrohmad ,&nbsp;Fajar Ari Wandono ,&nbsp;Awang Rahmadi Nuranto ,&nbsp;M Hafid ,&nbsp;Try Kusuma Wardana ,&nbsp;Kosim Abdurohman ,&nbsp;Ristiyanto Adiputra ,&nbsp;Agus Bayu Utama ,&nbsp;Didi Budhyarso ,&nbsp;Pramudita Satria Palar","doi":"10.1016/j.ijlmm.2025.08.004","DOIUrl":"10.1016/j.ijlmm.2025.08.004","url":null,"abstract":"<div><div>This paper investigates the advantages of optimization and rapid prototyping technology to aid in the improvement process of a spreader bar for an amphibious commuter aircraft, intended to withstand critical loads by combining topology and size optimization. The initial spreader bar, although lightweight, fails when subjected to a critical load. The geometrical parameters of the spreader bar's cross-section serve as the design variables for optimization. Topology optimization was performed first to minimize compliance under the fraction mass constraint, using a solid elliptical structure as a starting point. Following that, size optimization was conducted to reduce mass with the maximum stress constraint applied. The two-step topology and size optimization process resulted in a hollow ellipse cross-section with a spar in the middle as the optimized design. This optimized design turned the margin of safety from −0.37 to 0, which met the safety requirements. The initial and optimized designs were then scaled down and 3D printed using Polylactic Acid (PLA) material at a ratio of 1:5. Next, a three-point bending evaluation was carried out to compare the mechanical strength of the two designs. The experimental investigation revealed that the optimized design was considerably superior and more efficient than the initial design. The new parameter proposed in this research, maximum load efficiency, the optimized design was 7.16 N/g while the baseline design was about 1.94 N/g. The specific energy absorption of the spreader bar was improved from 6.32 J/g to 119 J/g. The findings of this study indicate that the combination of rapid prototyping and sequential topology–size optimization can be applied to real-world cases, taking into account design constraints from multiple aspects.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 47-59"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618740","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}

{"title":"Low-velocity impact response of novel hierarchical hexagonal multicell structures","authors":"M Hafid ,&nbsp;Abian Nurrohmad ,&nbsp;Dony Hidayat ,&nbsp;Riki Ardiansyah ,&nbsp;Aryandi Marta ,&nbsp;Citra Asti Rosalia ,&nbsp;Zaini Ahmad","doi":"10.1016/j.ijlmm.2025.07.008","DOIUrl":"10.1016/j.ijlmm.2025.07.008","url":null,"abstract":"<div><div>This study introduces two novel hierarchical hexagonal multicell (HHM) tube designs inspired by honeycomb and grass stem structures: full triangular hierarchical hexagonal multicell (FTHHM) and internal clone hierarchical hexagonal multicell (ICHHM). These tubes feature a triangular pattern and hierarchical arrangement with four orders (0^th-3^rd). The tubes, fabricated from PLA-ST using FDM 3D printing technology, were analyzed through finite element simulations of all hierarchical cross-sectional structures and validated against experimental results. Tubes with higher hierarchical orders consistently reduced total displacement and enhanced crashworthiness performance indices, particularly in crush force efficiency (CFE). Among the designs, the FTHHM-3 tube outperformed the ICHHM-3 tube. Furthermore, the effect of wall thickness on the FTHHM-3 tube was investigated by incrementally increasing the impactor mass until the densification phase was reached across the entire wall thickness. As a result, the FTHHM-3 model exhibited significant improvements in CFE by 24.77 % and in specific energy absorption (SEA) by 52.76 % compared to conventional hexagonal tubes. These findings indicate that 3D-printed FTHHM tubes, especially those with higher hierarchical orders, hold strong potential for application in future lightweight structural systems.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 1","pages":"Pages 20-36"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145618689","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}