International Journal of Lightweight Materials and Manufacture最新文献

{"title":"Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100","authors":"Yudha Eko Widyantono ,&nbsp;Yoshihiko Uematsu ,&nbsp;Ilhamdi ,&nbsp;Sulardjaka ,&nbsp;Jos Istiyanto ,&nbsp;Muizuddin Azka ,&nbsp;Nurul Muhayat ,&nbsp;Triyono","doi":"10.1016/j.ijlmm.2025.05.002","DOIUrl":"10.1016/j.ijlmm.2025.05.002","url":null,"abstract":"<div><div>Aluminum's lightweight nature and corrosion resistance make it a preferred material across various industries, including marine, automotive, railway, and aerospace sectors. However, traditional fusion welding of aluminum often leads to significant defects such as porosity and distortion. Friction Stir Welding (FSW), a solid-state welding technique, addresses many of these challenges but has limitations when welding thick plates, which can be alleviated through the use of a bobbin tool. This study presents a comparative analysis of a novel one-step double-acting tool, which operates dual tools simultaneously on both surfaces of the workpiece, against the bobbin tool. Aluminum AA1100 sheets measuring 200 × 240 mm and 8 mm thick were welded using both methods under standardized parameters: a tool rotation speed of 1500 rpm, a plunge depth of 0.2 mm, a travel speed of 25 mm/min, and a tilt angle of 2°. By varying the offset of the one-step double-acting tool between 0 mm and 2 mm, the impact on bead appearance and mechanical properties was assessed. Results indicated that the bobbin tool produced rougher beads and tear defects due to its design, while the one-step double-acting tool, particularly at a 2 mm offset, yielded cleaner, more uniform welds with fewer defects and enhanced material control. Microstructural analysis showed that the stir zone exhibited uniform grain refinement, and the Heat-Affected Zone (HAZ) benefited from finer grain structures due to improved heat management. Hardness testing revealed a characteristic W-shaped distribution, and tensile strength evaluations demonstrated the superior joint quality of the 2 mm offset, outperforming the bobbin tool in tensile strength and defect reduction. Although the bobbin tool showed slightly higher average strength in bending tests, the one-step double-acting tool proved to be more consistent and reliable.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 577-594"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654017","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":"Evaluation of mechanical and thermal properties of UV-curable resin-SiC composites for enhanced performance in abrasive applications","authors":"Babak Houshmand,&nbsp;Seyed Mohsen Safavi,&nbsp;Mehdi Karevan","doi":"10.1016/j.ijlmm.2025.02.007","DOIUrl":"10.1016/j.ijlmm.2025.02.007","url":null,"abstract":"<div><div>This research investigates the mechanical and thermal properties of a novel composite material designed for applications in the finishing industry, particularly in abrasive tools such as grinding wheels. The composite comprises a UV-curable ABS-like resin, silicon carbide (SiC) grains with an average particle size of 150 μm, and fumed silica utilized as an anti-settling agent. The choice of ABS-like resin is motivated by its elasticity, which enhances impact resistance while minimizing thermal effects during usage. Fabrication of this composite material was achieved through stereolithography-based 3D printing technology, allowing for precise control over material properties and geometrical configurations.</div><div>Standard test specimens were produced and subjected to a comprehensive series of evaluations, including tensile strength, compression, Charpy impact, hardness, Differential Scanning Calorimetry (DSC), Heat Deflection Temperature (HDT), and wear tests, following ASTM standards. The results from these tests were analyzed to gain insight into the performance characteristics and applicability of this novel composite in demanding environments.</div><div>To further explore the capabilities of the discussed composite, two grinding tool samples were designed and manufactured. A comparison of grinding performance between the T100 tool, a structured tool, and the Simple Tool, a non-structured tool has been discussed. The analysis focuses on their efficiency when grinding Aluminum T6 and MO40 steel, examining critical performance parameters such as cutting forces, surface roughness, tool wear, force-damping behavior, and the impact of the elastic ABS-like resin used in these tools. This study provides valuable information for the implementation of such composites in the finishing industry, highlighting their potential advantages in abrasive applications.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 562-576"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654016","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":"Sustainability-driven additive manufacturing: Implementation and content optimization of fine powder recycled glass in polylactic acid for material extrusion 3D printing","authors":"Markos Petousis ,&nbsp;Nikolaos Michailidis ,&nbsp;Václav Kulas ,&nbsp;Vassilis Papadakis ,&nbsp;Mariza Spiridaki ,&nbsp;Nikolaos Mountakis ,&nbsp;Apostolos Argyros ,&nbsp;John Valsamos ,&nbsp;Nektarios K. Nasikas ,&nbsp;Nectarios Vidakis","doi":"10.1016/j.ijlmm.2025.02.008","DOIUrl":"10.1016/j.ijlmm.2025.02.008","url":null,"abstract":"<div><div>This work aimed to evaluate the capacity of recycled fine powder glass (RFPG) to reinforce the mechanical performance and characteristics of polylactic acid (PLA) for use in 3D printing (3DP) applications. Six composites with an RFPG filler quantity of 2.0 wt % −12.0 wt % (with a 2.0 step) were evaluated. The raw materials were turned into mixtures, which then fabricated respective filaments. The filaments were inspected and tested for their properties before being utilized to produce the specimens for testing with 3DP. The structures, morphologies, and mechanical properties of the specimens were examined by performing respective tests, scanning electron microscopy, and micro-computed tomography (μ-CT). Moreover, the samples were tested for their thermal properties through thermogravimetric and differential scanning calorimetry analyses, and for their rheological performance. Quality metrics were evaluated with μ-CT (porosity and dimensional accuracy). The findings indicated that RFPG as a filler reinforced the PLA matrix, in the case of 6.0 wt % (23.6 % and 28.7 % strength enhancement in the flexural and tensile tests respectively). The thermal properties were insignificantly changed with a small increase in the crystallization temperature, while the viscosity was significantly lowered with the increase of the powder content in the compounds. The quality metrics were enhanced as well, making this specific RFPG grade a promising filler for the PLA matrix in 3D printing.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 595-610"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654018","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":"Dynamics of microdischarges evolution during plasma electrolytic oxidation in alkaline and silicate-alkaline electrolytes","authors":"S.N. Grigoriev ,&nbsp;V.B. Ludin ,&nbsp;A.V. Apelfeld ,&nbsp;B.L. Krit ,&nbsp;I.V. Suminov ,&nbsp;S.V. Zhukov ,&nbsp;D.B. Chudinov ,&nbsp;A.V. Zakabunin ,&nbsp;A.V. Zheltuhin ,&nbsp;N.S. Popov","doi":"10.1016/j.ijlmm.2024.08.002","DOIUrl":"10.1016/j.ijlmm.2024.08.002","url":null,"abstract":"<div><div>The dynamics of microdischarges evolution during plasma electrolytic oxidation (PEO) of AMg6 aluminum alloy at anode-cathode mode in alkaline and silicate-alkaline electrolytes was investigated. Experimental studies were carried out using high-speed photography of surface being treated of the alloy synchronized with the registration of the electric current and voltage in the «alloy being treated ‒ electrolyte ‒ counter electrode » system. As a result, the ranges of electrical voltages at which surface being treated is affected by sporadic weak and plural weak, medium, as well as powerful anode microdischarges were identified. The conditions of sporadic cathode microdischarges displaying were determined. Differences in the dynamics of microdischarges evolution during PEO processes in alkaline and silicate-alkaline electrolytes were shown and determined their influence on the thickness, through porosity and microhardness of the formed coatings.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 648-657"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654015","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":"Investigation of the effects of ultrasonic assisted face turning with CO2 cooling on cutting forces, residual stress, and surface quality","authors":"Matin Mirzabagherian,&nbsp;Saeid Amini,&nbsp;Masuod Bayat","doi":"10.1016/j.ijlmm.2025.04.003","DOIUrl":"10.1016/j.ijlmm.2025.04.003","url":null,"abstract":"<div><div>Ultrasonic assisted turning (UAT) has emerged in recent years as an advanced machining technique, leveraging high-frequency harmonic vibrations at the tool edge to enhance cutting performance. In this study, ultrasonic assisted face turn (UAFT) was employed to machine steel 1.7225 under various cutting conditions. Experiments were conducted at three spindle speeds, three feed rates, and under two cooling states: dry and cooling using CO₂ gas. All tests were performed in the UAFT mode. Machining forces were recorded using a dynamometer, and surface integrity was assessed through high-resolution imaging using a video measuring machine (VMM). Additionally, the influence of UAFT on the tensile residual stresses was thoroughly investigated. Tensile residual stresses, which can significantly affect the mechanical performance and service life of components, were analyzed as a critical output parameter alongside cutting forces and surface quality. The integration of ultrasonic vibrations with CO₂ cooling demonstrated a notable enhancement in process performance. Results indicated a reduction in cutting force by approximately 28.3 % and a decrease in tensile residual stress by nearly 35 % when using UAFT + CO₂ compared to UAFT + dry conditions. Furthermore, improved surface morphology and more favorable chip formation were observed under UAFT + CO₂ conditions, highlighting the synergistic benefits of combining ultrasonic assistance with CO₂ cooling.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 551-561"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654014","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 flame retardant and thermally stable acoustic green composites from waste hemp fibers reinforcement in fully biobased epoxy and benzoxazine hybrid thermosets","authors":"Abdul Qadeer Dayo ,&nbsp;Panuwat Luengrojanakul ,&nbsp;Nuttinan Boonnao ,&nbsp;Krittapas Charoensuk ,&nbsp;Hariharan Arumugam ,&nbsp;Cheol-Hee Ahn ,&nbsp;Sarawut Rimdusit","doi":"10.1016/j.ijlmm.2024.12.006","DOIUrl":"10.1016/j.ijlmm.2024.12.006","url":null,"abstract":"<div><div>This study presents an in-depth investigation of eco-friendly and renewable resources-based composites for lightweight structural applications by reinforcing waste hemp fibers (AWHF) in isosorbide (ISE) and neopentylglycol (NGDE) epoxy resins and epoxy/hydroquinone-furfurylamine (H-fa) benzoxazine hybrid matrix. The NGDE epoxy composite specimen produced the lowest results, and the sandwich-structured hybrid laminate specimen produced the best mechanical and thermal properties. The flexural strength and modulus values of sandwich structure hybrid laminate were recorded as 154.43 ± 7.14 MPa and 10.10 ± 0.35 GPa, respectively, while T₅, T_10, and Y_c values were recorded as 329 °C, 353 °C, and 23.78 %, respectively, and temperature tolerance (HRI) was estimated up to 178 °C. Moreover, the ISB/H-fa hybrid laminate showed self-extinguishing behaviour by crossing the LOI threshold value and got a V-0 rating for flame retardancy. The acoustic studies confirmed that the ISB-hybrid laminate had the highest sound absorption coefficient. The produced biobased sandwich structure composites with ISB/H-fa hybrid matrix showed better flame retardancy, sound absorption capacity, and mechanical strength are suitable for under-hood structural components in automobiles and other lightweight structural applications.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 658-668"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654022","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":"The effect of alumina nanoparticles on the properties of Al-based nanocomposites prepared by powder Metallurgy–Hot forging","authors":"Farah M. Abdul Razzaq,&nbsp;Adnan S. Jabur","doi":"10.1016/j.ijlmm.2024.12.005","DOIUrl":"10.1016/j.ijlmm.2024.12.005","url":null,"abstract":"<div><div>The development of the aluminum industry is intricately connected to its special characteristics that have made aluminum a highly desired material in engineering and structural applications. In the present work, the effect of alumina nanoparticle addition on the properties of Al-based nanocomposites was investigated. Al-based nanocomposite samples were fabricated by solid-state route using powder metallurgy and hot forging as a finishing process. The addition of alumina nanoparticles varied from 0 to 10 wt percentage. The structural, mechanical, tribological, and corrosion properties of the prepared Al- nanocomposites samples were studied. It was found that with an increase in the alumina nanoparticles addition up to 10 wt% to the Al-based nanocomposite samples, the hardness and yield strength increased while the reduction percentage, crystallite and grain size decreased. On the other hand, the wear rate decreased up to 5 wt% of addition and then increased again at 10 wt%, but the corrosion rate decreased up to 3 wt% of addition and then increased again up to 10 wt%.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 637-647"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654021","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":"Nondestructive test for quality control in laboratory-scale fabrication of laminated composites using programmable portable ultrasonic","authors":"Yusuf Giri Wijaya ,&nbsp;Suprijanto ,&nbsp;Damar Rastri Adhika ,&nbsp;Rhakamerta Hijazi ,&nbsp;Abian Nurrohmad","doi":"10.1016/j.ijlmm.2025.02.006","DOIUrl":"10.1016/j.ijlmm.2025.02.006","url":null,"abstract":"<div><div>Laminated composites are the most frequently used component materials in manufacturing unmanned aerial vehicles (UAVs) in research centers or start-up industries. On a laboratory scale, laminated composites are fabricated by relying on technicians' skills due to the involvement of manual processes. Nondestructive testing (NDT) is needed to guarantee the structural integrity of the final product of laminated composites. The work proposes a programmable portable ultrasonic for nondestructive testing (NDT) to detect a potential defect due to foreign object contamination of fabrication layers of laminate composite. The proposed programmable NDT system is built using open-board devices; therefore, it could be developed cost-effectively compared to a commercial NDT system. The proposed NDT can measure and analyze a pattern of A-scan signal as a function of foreign object contamination material. Based on a C-scan image, the proposed NDT system could also be programmed to detect the size area of potential defects due to foreign object contamination. Two types of specimens, carbon fiber-reinforced polymer (CFRP) and glass fiber-reinforced polymer (GFRP), were tested to evaluate the performance of the developed NDT system. Testing aims to identify artificial defects intentionally placed within these specimens. The proposed portable ultrasonic NDT effectively detects CFRP and GFRP defects on A-mode and C-scan images. Therefore, the proposed portable ultrasonic NDT is an affordable system that can be developed in a laboratory workshop for quality control in laboratory-scale fabrication of laminated composites.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 623-636"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654020","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":"Failure mechanism of aluminium – carbon fibre reinforced polymer interlocking joints through punching","authors":"Núria Latorre ,&nbsp;Norbert Blanco ,&nbsp;Daniel Casellas ,&nbsp;Josep Costa","doi":"10.1016/j.ijlmm.2025.01.002","DOIUrl":"10.1016/j.ijlmm.2025.01.002","url":null,"abstract":"<div><div>Single-Step Punch Interlocking (SSPI) is a recently developed joining methodology between aluminium and Carbon Fibre Reinforced Polymer (CFRP) aiming to contribute to multi-material design of structural parts. This hybrid joint technology combines adhesive bonding with mechanical interlocking. Elucidating the failure mechanism of the developed joint is relevant to provide insights for future enhancements in performance, increase its lifespan and prevent premature failure. Therefore, the different subcritical failure events were identified through interrupted Single-Lap Shear (SLS) tests and subsequent non-destructive ultrasonic inspection, and the global failure mechanism was described. Results indicate that the addition of the SSPI joint delayed the onset and propagation of adhesive failure between both substrates, providing residual strength and increasing the ultimate load in a 65 % and the absorbed energy of the joint in a 156 %.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 611-622"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654019","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":"The experimental and numerical results of a spinning/whirling composite thick-beam of glass fibers reinforced with CNR based on SSDT and neutral axis with electric field","authors":"Fatemeh Bargozini,&nbsp;Mehdi Mohammadimehr","doi":"10.1016/j.ijlmm.2025.05.003","DOIUrl":"10.1016/j.ijlmm.2025.05.003","url":null,"abstract":"<div><div>This article examines a spinning/whirling vibration for a thick composite beam, including one hundred layers of glass fibers, epoxy resin, and carbon nanorods (CNRs). The CNR used in the present investigation was synthesized using recycled materials (potato peel) and hydrothermal methods. The impact of CNR on the vibrations is analyzed using numerical and experimental evidence. Experimental results show that by adding 0.32 % CNRs, the natural frequency increases by 46.6 %. The equations are formulated based on the sinusoidal shear deformation beam theory and the neutral axis. Then, the equations are solved using the Ritz method. The study examines the impact of different parameters, including rotational speeds, axial force, Young's modulus of the resin epoxy and glass fibers, aspect ratio, temperature change, volume fraction of CNR, and thickness on Campbell diagrams for the composite beam with and without CNR as reinforcement. Gyroscopic effects of the composite beam caused by the rotation of this beam around the y and x-axis are investigated. The Campbell diagrams, which are based on the rotational speed of the thick structure, reveal that higher temperatures lead to a decrease in natural frequency. Conversely, raising Young's modulus increases the natural frequency because increasing the stiffness of composite beam. By enhancing volume fraction of CNR, the damped and undamped natural frequency increases. Augmenting the velocity of the structure diminishes the natural frequency. The angular velocity along the y-axis exerts a more significant impact. The traction force significantly enhances the natural frequency of the rotating structure. The findings indicate that CNR is an economical and eco-friendly substitute for nanotubes. This amplifier is used in several sectors, including aviation, terrestrial, and maritime transportation, as well as in rotating turbines, rotating structures, and rotary drilling machinery. Also, the comparison of different theories shows that the effect of SSDT on the natural frequency is lower than that of the other theories.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 5","pages":"Pages 669-680"},"PeriodicalIF":0.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144654023","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}