Smart Materials in Manufacturing最新文献

Machine learning prediction of surface roughness in sustainable machining of AISI H11 tool steel

Smart Materials in Manufacturing

Pub Date : 2025-01-01 DOI: 10.1016/j.smmf.2025.100075

Balasuadhakar A. , Thirumalai Kumaran S. , Uthayakumar M.

Surface roughness prediction ensures high product quality, boosts manufacturing efficiency, and aids in effective tool life management. In this study, surface roughness optimization and prediction in the end milling of AISI H11 die steel were examined under three cooling conditions: dry milling, Minimum Quantity Lubrication (MQL), and Nano Fluid Minimum Quantity Lubrication (NMQL). The experiments were designed using a Taguchi L27 orthogonal array, with cutting speed, feed, and cooling environments as the variables. Surface roughness, the performance output parameter, was analyzed through Taguchi Signal-to-Noise (S/N) analysis. The dataset's diversity and robustness were further enhanced using the Gaussian Data Augmentation (GDA) technique, ensuring improved predictive accuracy of the Machine Learning (ML) models. Advanced machine ML models, including Decision Tree(DT), XGBoost (XGB), Support Vector Regression (SVR), CATBoost, AdaBoost Regression (ABR), and Random Forest Regression (RFR), were developed, with hyperparameters optimized using Grid Search Cross Validation. The ideal cutting parameters were identified as a cutting speed of 40 m/min, a feed rate of 0.01 mm/rev, and utilization of the NMQL cooling environment. The ML models, including DT, ABR, RFR, and CATBoost, demonstrate exceptional performance by achieving accuracy rates above 90 % and determinant coefficient (R²) greater than 0.9. Remarkably, the CATBoost model exhibited heightened precision, boasting 90.8 % accuracy, a R² of 0.94, a mean absolute error (MAE) of 0.05, a mean squared error (MSE) of 0.005, a root mean squared error (RMSE) of 0.07, and a mean absolute percentage error (MAPE) of 9.17.

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引用次数: 0

Development and evaluation of urea formaldehyde resin-modified poly(vinyl alcohol)-based biocomposites reinforced with Corchorus olitorius cellulose microfiber

Smart Materials in Manufacturing

Pub Date : 2025-01-01 DOI: 10.1016/j.smmf.2025.100074

Shahin Sultana , Zahidul Islam , Md Khabir Uddin Sarker , Shamima Akther Eti , Swapan Kumer Ray , Mohammad Majedul Haque , Samia Tabassum

This study aimed to investigate the effects of thermosetting urea formaldehyde (UF) resin on thermoplastic poly (vinyl alcohol) (PVA) biocomposites. Cellulose microfiber (CMF) was prepared from the extracted cellulose of jute fibers (Corchorus olitorius) using a mechanical ball milling technique, and the resulting material was used as a reinforcing ingredient to produce biocomposites. CMF was characterized by attenuated total reflection-Fourier transform infrared (ATR-FTIR), particle size measurement, and scanning electron microscopy (SEM). Biodegradable PVA-based sustainable green biocomposites were prepared with different CMF loadings (0%–10 % in weight) by the solution casting technique. UF resins with seven different wt% (ranging from 0.5 % to 10 %) were added to thermoplastic PVA to enhance the interpenetrating polymer networks (IPNs) of UF-PVA sheets via the casting technique. Furthermore, seven different wt% of CMF and UF (ranging from 0.5 % to 10 %) were mixed with PVA to produce CMF-UF-PVA biocomposites. Thermogravimetric analysis (TGA), SEM, ATR-FTIR, and tensile property investigations were conducted to characterize the products. The effectiveness of UF in the biocomposites was evaluated through the comparative characterization of neat PVA and UF-PVA, CMF-PVA, and CMF-UF-PVA biocomposites. The results indicate that the tensile strength of the biocomposites produced from 1 wt% UF, 1 wt% CMF, and 98 wt% PVA significantly improved by 118 % compared to the neat PVA matrix and all other biocomposites. Additionally, the biodegradability test results indicate that the CMF-UF-PVA biocomposite is more biodegradable than neat PVA. Therefore, compared to neat PVA, the CMF-UF-PVA biocomposite is more environmentally beneficial and sustainable.

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引用次数: 0

Unveiling the structure-property relationships of multilayered Helmholtz resonance-based acoustic metamaterials

Smart Materials in Manufacturing

Pub Date : 2025-01-01 DOI: 10.1016/j.smmf.2025.100073

Jun Wei Chua , David Kar Wei Poh , Shuwei Ding , Haoran Pei , Xinwei Li

The principle of Helmholtz resonance has been widely employed in the design of sound-absorbing metamaterials. However, the relationship between various acoustic parameters and sound absorption performance remains insufficiently understood. This work investigates the effect of various structural parameters of multi-layered Helmholtz resonators (MLHRs) on sound absorption properties from a statistical point of view. The Taguchi method was used in the study with the pore diameter, pore thickness, and cavity depth of a layer of Helmholtz resonator as control variables and the number of layers of resonators as the noise variable. Results revealed a clear hierarchy of importance for maximizing sound absorption: increasing the number of layers, reducing pore diameter, enhancing pore thickness, and expanding cavity depth. Additionally, it is also found that the influence of the number of layers on said relationships was greatest with smaller pore diameters larger pore thicknesses, and cavity depths. All three control variables showed significant effects on the sound absorption properties of MLHRs when the number of layers was more than two, while the cavity width showed limited influence on sound absorption coefficients for a two-layer MLHR. This work provides a foundational understanding of the structural-property relationships in MLHRs, paving the way for optimized designs to achieve optimal sound absorption performance.

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引用次数: 0

Corrigendum for previously published articles

Smart Materials in Manufacturing

Pub Date : 2025-01-01 DOI: 10.1016/j.smmf.2025.100071

引用次数: 0

Mechanochemically modified graphene nanoplatelets for high-performance polycarbonate composites

Smart Materials in Manufacturing

Pub Date : 2025-01-01 DOI: 10.1016/j.smmf.2025.100072

Xiao Su , Seung Ho Lee , Yangzhe Hou , Nikki Stanford , Qingshi Meng , Hsu-Chiang Kuan , Xianhu Liu , Jun Ma

The exceptional mechanical, electrical and thermal properties of graphene and its derivative have established their vital role in developing novel polymer nanocomposites. However, it is a great challenge to achieve uniform dispersion of graphene and strong interfacial bonding within polymer matrices, especially by industry-compatible methods such as melt compounding. Different to traditional solvent-based modification methods, our mechanochemical approach involves the surface modification of graphene nanoplatelets (GNPs) with a long-chain surfactant – Jeffamine M2070. The process is scalable, environmentally friendly and solvent-free. GNPs, ball-milled GNPs (BMGNPs) and M2070-modified GNPs (MmGNPs) were respectively incorporated into a polycarbonate matrix using twin-screw extrusion, to produce three groups of nanocomposites. GNPs exhibited aggregation due to unideal compatibility with the matrix, whereas BMGNPs showed reduced aggregation owing to mechanical exfoliation. MmGNPs demonstrated the best compatibility with polycarbonate and thus exhibited the most uniform dispersion and significant improvements in mechanical performance, e.g., 16.9 % in tensile strength and 36.4 % in Young's modulus. Despite the defects caused by the mechanochemical modification, MmGNPs in the matrix resulted in an increment of 50 % in thermal conductivity, reaching 0.32 W m⁻¹ K⁻¹ in comparison with ∼0.18 W m⁻¹ K⁻¹ for polycarbonate. This study highlights the importance of surface modification by mechanochemical processing techniques in enhancing the exfoliation and dispersion of graphene and thus the properties of thermoplastics.

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引用次数: 0

Parametric optimisation for 3D printing β-tricalcium phosphate tissue engineering scaffolds using direct ink writing 利用直接墨水书写技术对 3D 打印β-磷酸三钙组织工程支架进行参数优化

Smart Materials in Manufacturing

Pub Date : 2024-11-11 DOI: 10.1016/j.smmf.2024.100070

D.L. Belgin Paul , Ayyappan Susila Praveen , Arun Arjunan

The quest for optimal bone tissue engineering materials has led to extensive research on tricalcium phosphate (TCP) ceramics, specifically the β-TCP phase, due to its superior biocompatibility and bioresorbability. Ensuring the structural fidelity and accuracy in creating porous architecture is very crucial for β-TCP scaffolds. In this regard, this study explores the critical role of 3D printing parameters such as pressure, nozzle diameter, print speed, and solid loading in determining the dimensional accuracy of β-tricalcium phosphate (β-TCP) scaffolds fabricated through direct ink writing (DIW). Experiments were conducted on a custom-built DIW system based on a four-factor, three-level L₉ Taguchi design. The influence of these parameters on dimensional accuracy was evaluated using Analysis of Variance (ANOVA). Optimal process conditions to print β-TCP were revealed as 3 bar pressure, 0.6 mm nozzle diameter, 5 mm/s print speed, and 55 vol% solid loading, yielding minimal dimensional error. ANOVA results highlighted nozzle diameter and pressure as significant factors, followed by solid loading and print speed. Validation experiments under these optimal conditions achieved a dimensional error of just 1.52 %. Additionally, the scaffold printed under optimal conditions demonstrated a compressive strength of 2.64 MPa.

由于具有优异的生物相容性和生物可吸收性，人们开始对磷酸三钙（TCP）陶瓷，特别是β-TCP相进行广泛研究，以寻求最佳的骨组织工程材料。确保多孔结构的保真度和准确性对 β-TCP 支架至关重要。为此，本研究探讨了三维打印参数（如压力、喷嘴直径、打印速度和固体负载）在决定通过直接墨水写入（DIW）技术制造的β-磷酸三钙（β-TCP）支架的尺寸精度方面的关键作用。实验是在定制的 DIW 系统上进行的，采用了四因素、三级 L9 Taguchi 设计。使用方差分析（ANOVA）评估了这些参数对尺寸精度的影响。结果表明，打印 β-TCP 的最佳工艺条件为：3 巴压力、0.6 毫米喷嘴直径、5 毫米/秒打印速度和 55 Vol% 固体负载，可产生最小的尺寸误差。方差分析结果表明，喷嘴直径和压力是重要因素，其次是固体负载和打印速度。在这些最佳条件下进行的验证实验，尺寸误差仅为 1.52%。此外，在最佳条件下打印的支架显示出 2.64 兆帕的抗压强度。

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引用次数: 0

A comprehensive study on the biodegradability, biocompatibility, and antibacterial properties of additively manufactured PLA-ZnO nanocomposites 关于添加型聚乳酸-氧化锌纳米复合材料的生物降解性、生物相容性和抗菌特性的综合研究

Smart Materials in Manufacturing

Pub Date : 2024-11-02 DOI: 10.1016/j.smmf.2024.100069

Wei Juene Chong , Paul Wright , Dejana Pejak Simunec , Srinivasan Jayashree , Winston Liew , Chad Heazlewood , Adrian Trinchi , Ilias (Louis) Kyratzis , Yuncang Li , Shirley Shen , Antonella Sola , Cuie Wen

The addition of zinc oxide (ZnO) nanofillers to 3D printable poly(lactic acid) (PLA) filaments for material extrusion (MEX) additive manufacturing (fused filament fabrication, FFF, a.k.a. fused deposition modelling, FDM) has the potential to enable the fabrication of biomedical devices with embedded antibacterial functionality. This work investigates the biological properties, mainly the biodegradability, antibacterial activity, and cytotoxicity of 3D printed PLA-ZnO nanocomposites containing between 1 wt% to 5 wt% of either untreated or silane-treated filler. This study demonstrated that the concentration and surface properties of the filler control the matrix degradation rate, which directly influences the release rate of ZnO and Zn²⁺, which in turn governs the antibacterial properties of the nanocomposites. All nanocomposites showed excellent antibacterial properties (> 99% reduction in bacteria) against both gram-positive (Staphylococcus aureus) and gram-negative (Escherichia coli) strains. Potential cytotoxic effects against human immune THP-1 cells were only evident at the highest filler loading (5 wt%), whereas nanocomposites with < 5 wt% filler loading were non-cytotoxic after 7 days of exposure. The 3D printed PLA-ZnO nanocomposites produced in this study show potential for use in clinical settings, with nanocomposites having filler loadings of < 2 wt% being the most appropriate candidates due to their excellent antibacterial properties while showing comparable biocompatibility to pristine PLA.

在三维打印聚乳酸（PLA）长丝中添加氧化锌（ZnO）纳米填料进行材料挤压（MEX）增材制造（熔融长丝制造，FFF，又称熔融沉积模型，FDM），有可能制造出具有嵌入式抗菌功能的生物医学设备。这项工作研究了三维打印聚乳酸-氧化锌纳米复合材料的生物特性，主要是生物可降解性、抗菌活性和细胞毒性，其中含有 1 wt% 至 5 wt% 的未处理或硅烷处理填料。该研究表明，填料的浓度和表面特性控制着基质降解率，而基质降解率直接影响着 ZnO 和 Zn2+ 的释放率，进而影响着纳米复合材料的抗菌性能。所有纳米复合材料对革兰氏阳性菌（金黄色葡萄球菌）和革兰氏阴性菌（大肠杆菌）均表现出优异的抗菌性能（细菌减少 99%）。对人体免疫THP-1细胞的潜在细胞毒性作用只有在填料含量最高（5 wt%）时才明显，而填料含量为< 5 wt%的纳米复合材料在暴露7天后无细胞毒性。本研究中制备的三维打印聚乳酸-氧化锌纳米复合材料具有临床应用潜力，其中填料负载量为 < 2 wt%的纳米复合材料是最合适的候选材料，因为它们具有优异的抗菌性能，同时显示出与原始聚乳酸相当的生物相容性。

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引用次数: 0

Heat sources in wire arc additive manufacturing and their impact on macro-microstructural characteristics and mechanical properties – An overview 线弧快速成型制造中的热源及其对宏观微观结构特征和机械性能的影响 - 概述

Smart Materials in Manufacturing

Pub Date : 2024-10-17 DOI: 10.1016/j.smmf.2024.100059

Nabeel Ahmed Siddiqui , Muhammad Muzamil , Tariq Jamil , Ghulam Hussain

The layer-by-layer production idea known as Wire Arc Additive Manufacturing (WAAM) is suggested as a viable substitute for conventional subtractive methods because of its ability to produce massive metallic components with a moderate degree of geometric complexity. This technology has garnered attention recently because of its advantages over traditional Additive Manufacturing (AM) procedures, namely its low cost and high deposition rates. This review investigated various electric arc heat inputs and energy sources for the material depositing processes of gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), cold metal transfer (CMT), plasma arc welding (PAW)-based wire arc additive manufacturing systems. This is achieved through the application of a thorough methodology for comprehending the primary process factors and their impact on the final component qualities. In the present review, the macro-microstructure and mechanical behavior were examined with respect to various energy sources and electric arc heat inputs. This review also examines the input elements related to heat on the wire arc additive manufacturing process. It is necessary to describe the factors influencing these features in order to determine the best wire arc additive manufacturing technique in terms of heat input. The principal aim of the review is to investigate the correlation between heat input and the mechanical, microstructural, and macrostructural features of parts deposited using wire arc additive manufacturing technology. The heat input, which is thoroughly examined in this study, is crucial to the stability of the wire arc additive manufacturing process and affects the mechanical characteristics and microstructural development of the parts during the manufacturing process. The review addresses a wide range of materials, including aluminium alloys, copper alloys, steel alloys, nickel alloys, iron alloys, titanium alloys, magnesium alloys, and smart materials, with a focus on their microstructure, macrostructure, and mechanical properties, providing significant insights into their application across many industries.

线弧增材制造（WAAM）的逐层生产理念被认为是传统减材制造方法的可行替代品，因为它能够生产几何复杂程度适中的大型金属部件。与传统的增材制造（AM）工艺相比，该技术具有成本低、沉积率高等优势，因此最近备受关注。本综述研究了基于线弧增材制造系统的气体钨极氩弧焊 (GTAW)、气体金属弧焊 (GMAW)、冷金属转移 (CMT)、等离子弧焊 (PAW) 材料沉积过程中的各种电弧热输入和能源。要做到这一点，必须采用全面的方法来理解主要工艺因素及其对最终部件质量的影响。在本综述中，针对各种能源和电弧热输入，研究了宏观微观结构和机械行为。本综述还研究了线弧快速成型制造工艺中与热量有关的输入要素。为了确定热输入方面的最佳线弧快速成型技术，有必要描述影响这些特征的因素。本综述的主要目的是研究热输入与使用线弧快速成型技术沉积的零件的机械、微观结构和宏观结构特征之间的相关性。本研究深入探讨的热输入对线弧快速成型制造工艺的稳定性至关重要，并在制造过程中影响零件的机械特性和微观结构发展。综述涉及多种材料，包括铝合金、铜合金、钢合金、镍合金、铁合金、钛合金、镁合金和智能材料，重点关注其微观结构、宏观结构和机械性能，为其在多个行业的应用提供了重要见解。

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引用次数: 0

Corrosion resistance of in situ steam LDH coating on AZ31 and AM30 Alloys: Influence of NaOH and Al–Mn phase AZ31 和 AM30 合金原位蒸汽 LDH 涂层的耐腐蚀性：NaOH 和铝锰相的影响

Smart Materials in Manufacturing

Pub Date : 2024-01-01 DOI: 10.1016/j.smmf.2024.100045

Yan-Jie Zhao, Fen Zhang, Lan-Yue Cui, Shuo-Qi Li, Cheng-Bao Liu, Rong-Chang Zeng

In situ formation mechanism of steam Mg–Al layered double hydroxide (Mg–Al–CO₃-LDH) coatings on AZ31 and AM30 alloys was compared in presence of NaOH aqueous solution. The microstructure and elemental composition of the obtained coatings were analyzed using SEM, EDS, XRD and FTIR. The corrosion resistance of the coated samples was evaluated using potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), and salt spray test. The results indicated that the addition of NaOH significantly influenced the morphology as well as the thickness of the prepared LDH coating. The effect of different Al–Mn phase contents of AZ31 and AM30 alloy on the growth mechanism of the LDH coatings was discussed. The addition of 0.01 M NaOH promoted the growth of the LDH coating on AZ31 and AM30 alloys. The AM30-NaOH-0.01 sample possessed the most compact and uniform surfaces as well as the maximum thickness. The corrosion current density of the samples was reduced by three orders of magnitude compared to their substrates. It was revealed that the addition of a moderate amount of NaOH in the steam would raise the pH level, which would benefit the dissolution of the aluminum phase and promote the growth of LDH coating.

在 NaOH 水溶液存在下，比较了 AZ31 和 AM30 合金上蒸汽镁铝层状双氢氧化物（Mg-Al-CO3-LDH）涂层的原位形成机制。使用 SEM、EDS、XRD 和 FTIR 分析了所得涂层的微观结构和元素组成。使用电位极化、电化学阻抗谱（EIS）和盐雾试验评估了涂层样品的耐腐蚀性。结果表明，NaOH 的加入对制备的 LDH 涂层的形貌和厚度有显著影响。讨论了 AZ31 和 AM30 合金中不同的铝锰相含量对 LDH 涂层生长机制的影响。添加 0.01 M NaOH 促进了 AZ31 和 AM30 合金上 LDH 涂层的生长。AM30-NaOH-0.01样品的表面最紧密、均匀，厚度也最大。与基底相比，样品的腐蚀电流密度降低了三个数量级。研究表明，在蒸汽中加入适量的 NaOH 会提高 pH 值，从而有利于铝相的溶解并促进 LDH 涂层的生长。

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引用次数: 0

Gradient microstructures and mechanical properties of Ti–6Al–4V alloy induced by laser surface quenching 激光表面淬火诱导的 Ti-6Al-4V 合金梯度微结构和力学性能

Smart Materials in Manufacturing

Pub Date : 2024-01-01 DOI: 10.1016/j.smmf.2024.100056

Enqing Wang , Jinpeng Tuo , Fengqi Hou , Dongjie Li , Yuanhang Li , Lvhao Zheng , Kai Zhang , Longlong Dong , Yi Yang , Hao Wang , Aijun Huang , Lai-Chang Zhang

Laser surface quenching (LSQ) was employed to fabricate gradient microstructures in a Ti–6Al–4V alloy. The influence of the LSQ parameters on the surface morphology, the depth of the LSQ layer, gradient microstructure, and microhardness were investigated. The results showed that as the laser energy density increases, the surface roughness and thickness of the heat-affected zone (HAZ) increase. From the internal matrix to the surface, the microstructure in the HAZ changes from the equiaxed structure to the mixt structure, martensitic structure, Widmanstätten structure, and then the oxide layer. The size of the β grains gradually decreases as the distance from the surface increases. The different microstructures and elemental distributions in the HAZ result in different microhardness values, which gradually decrease from the surface to the matrix. The laser energy density of 8.0 J/mm² is recommended to obtain a HAZ with a thickness of 1200 μm and a peak microhardness of 393 ± 7.3 H V without surface remelting. The LSQ process may help to increase the longevity of Ti–6Al–4V alloy implants by hardening the surface.

采用激光表面淬火（LSQ）技术在 Ti-6Al-4V 合金中制造梯度微结构。研究了 LSQ 参数对表面形态、LSQ 层深度、梯度微观结构和显微硬度的影响。结果表明，随着激光能量密度的增加，表面粗糙度和热影响区（HAZ）厚度也随之增加。从内部基体到表面，热影响区的微观结构从等轴结构变为混杂结构、马氏体结构、维德曼斯泰滕结构，然后是氧化层。随着与表面距离的增加，β 晶粒的尺寸逐渐减小。热影响区中不同的微观结构和元素分布导致了不同的显微硬度值，这些值从表面到基体逐渐降低。建议使用 8.0 J/mm2 的激光能量密度，以获得厚度为 1200 μm 的 HAZ 和 393 ± 7.3 H V 的峰值显微硬度，而无需进行表面重熔。LSQ 工艺可通过硬化表面来延长 Ti-6Al-4V 合金植入体的使用寿命。

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引用次数: 0