Journal of Manufacturing Processes最新文献

High-efficiency laser wire deposition process by programmed laser scanning on cage-arrayed quad wires 采用程控激光扫描技术对笼型阵列四线进行高效率激光线沉积

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.013

Weixing Sheng , Jun Xiao , Xin Xu , Zhifei Xu , Shengnan Gai , Shujun Chen

Laser wire deposition (LWD) is gaining significant attention for its application in additive manufacturing. However, its development is constrained by the inherently low laser absorptivity of materials, which severely limits the achievable deposition rate. This study proposes a novel oscillating-laser quad-wire deposition (OLQD) process. In this setup, four wires are arranged in a symmetrical cage-like configuration around the laser beam. The process utilizes laser oscillation patterns, including three widely used standard types (linear, circling, and infinite shape) and three self-defined patterns, to alternately melt the wires and the substrate. A comprehensive experimental investigation was conducted to evaluate the influence of oscillating-laser patterns and parameters on the deposited bead morphology and deposition rate. Results demonstrate that the cage-arrayed wires effectively capture more direct and reflected laser energy during laser oscillation, particularly under circular oscillation, leading to a considerable increase in the deposition rate. A laser-scan path planning system was developed to enable the three self-defined oscillation patterns, which are characterized by a controlled laser spot travel distance on the wires and thus regulated energy distribution. The results show that a maximum deposition rate of 85.44 g/min for aluminum wire can be achieved, while maintaining low porosity and a smooth surface morphology. The proposed OLQD process achieves a deposition rate comparable to that of wire arc additive manufacturing, while retaining the capability for precise heat input control.

激光丝沉积技术在增材制造中的应用越来越受到人们的关注。然而，它的发展受到材料固有的低激光吸收率的限制，这严重限制了可实现的沉积速率。本研究提出一种新的振荡激光四线沉积（OLQD）工艺。在这种设置中，四根导线在激光束周围以对称的笼状结构排列。该工艺利用激光振荡模式，包括三种广泛使用的标准类型（线性，圆形和无限形状）和三种自定义模式，交替熔化电线和衬底。通过综合实验研究了振荡激光模式和参数对沉积珠层形貌和沉积速率的影响。结果表明，在激光振荡过程中，特别是在圆振荡过程中，笼状阵列线能有效地捕获更多的直接和反射激光能量，从而显著提高沉积速率。开发了一种激光扫描路径规划系统，实现了三种自定义振荡模式，其特征是控制激光光斑在导线上的传播距离，从而调节能量分布。结果表明，在保持低孔隙率和表面光滑形貌的前提下，铝丝的最大沉积速率可达85.44 g/min。所提出的OLQD工艺实现了与丝弧增材制造相当的沉积速率，同时保留了精确热输入控制的能力。

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引用次数: 0

Effect of cooling time and residual layer of Al-Si coating on nugget growth and weldability in resistance spot welding of 1.5-GPa-grade 22MnB5 press hardened steels 冷却时间和Al-Si涂层残余层对1.5 gpa级22MnB5压淬钢电阻点焊熔核生长和可焊性的影响

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.016

Gi Wook Song , Deepak Kumar , Wookjin Oh , Chang Wook Lee , Taeseon Lee

Al-Si-coated 22MnB5 press-hardened steel exhibits a strong tendency toward interfacial fracture (IF) in resistance spot welding (RSW) due to coating-derived interfacial seams. We evaluate a production-feasible three-pulse stepped waveform, tuning inter-pulse cooling time (CT = 1–3 cycles; 16.7–50.0 ms) against a pre-pulse benchmark under matched total energy. A coupled 2-D axisymmetric electro-thermal-mechanical model is used to interpret how dwell modulates heat partitioning and nugget growth, and predictions are corroborated by lap-shear tests, metallography/SEM, SEM–EDS, and hardness mapping. The stepped schedule with CT = 2 cycles delivers the best performance: peak load increased by 29% than the pre-pulsed schedule, nugget diameter increased by 15%, and a consistent shift from IF to button pull-out (BPF) without expulsion. Etched-SEM quantifies a markedly finer FZ packet/cell scale under stepped pulse (143.1 μm) than pre-pulse (238.3 μm). SEM–EDS shows the FZ interior at/below detection for Al and Si in both schedules, while the interfacial rim/notch is AlSi enriched but becomes thinner/fragmented with the stepped pulsed cycles. Zone-wise Vickers profiles for optimized conditions are nearly coincident, indicating that the failure-mode transition is governed by waveform-controlled interfacial geometry/coalescence rather than bulk hardening. Overall, short, staged cooling expands the weldability window of coated PHS, enabling BPF at larger load and nugget size without peak-current escalation.

al - si涂层22MnB5压硬化钢在电阻点焊（RSW）中表现出很强的界面断裂（IF）倾向。我们评估了一个生产可行的三脉冲阶跃波形，调整脉冲间冷却时间（CT = 1-3个周期；16.7-50.0 ms）与匹配总能量下的预脉冲基准。一个耦合的二维轴对称电-热-力学模型被用来解释居住如何调节热量分配和核块生长，并通过剪切试验、金相/扫描电镜、扫描电镜-能谱仪和硬度图证实了预测。CT = 2次循环的阶梯式计划提供了最佳性能：峰值负载比预脉冲计划增加了29%，金块直径增加了15%，并且从中频到按钮拔出（BPF）的一致转变没有排出。蚀刻扫描电镜量化了阶梯脉冲（143.1 μm）下比预脉冲（238.3 μm）下更精细的FZ包/细胞尺度。SEM-EDS显示，在两种时序下，FZ内部都存在Al和Si，而界面边缘/陷波是AlSi富集的，但随着脉冲周期的增加，界面边缘/陷波变得更薄/破碎。优化条件下的区向维氏剖面几乎一致，表明失效模式转变是由波形控制的界面几何形状/聚结而不是体硬化控制的。总体而言，短时间的分段冷却扩大了涂层小灵通的可焊性窗口，使BPF能够承受更大的负载和金块尺寸，而不会出现峰值电流上升。

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引用次数: 0

Multiscale modelling with data-calibrated material parameters for microstructure evolution in Ti5553 machining 基于数据校准材料参数的Ti5553加工微观结构演变多尺度建模

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-10 DOI: 10.1016/j.jmapro.2026.02.007

Shuyuan Chen , Liang Hou , Huaizhong Li , Xiubing Jing , Huikun Cai , Yun Chen

Precise prediction of microstructural evolution is essential for improving the machinability of high-strength titanium alloys. This study presents a multiscale modelling framework for Ti5553 machining by coupling FE, JMAK, and CA models. To ensure accuracy across macro–micro scales, key material parameters are calibrated using a hybrid strategy that integrates quasi-static, high strain rate, and high-temperature thermomechanical tests. TANH constitutive parameters are refined through inverse optimization based on cutting force data, while CA nucleation and dislocation parameters are identified using high-temperature SHPB tests. JMAK parameters are extracted from Gleeble-based deformation experiments. The model is validated under both orthogonal cutting and milling conditions. In orthogonal cutting, the maximum prediction error for cutting force is 3.5%, and grain size errors are within 15.8% (CA) and 8.7% (JMAK). In milling, the model captures the evolution of a work-hardened layer, with grain size predictions below 15% error. The dual-phase microstructure of Ti5553 leads to distinctive heterogeneous shear banding behaviors, which are clearly captured by the proposed multiscale model. The CA model effectively resolves grain size gradients in the subsurface, while JMAK provides a macro/meso view about average grain size distribution. This work offers a validated modelling tool for predicting machining-induced microstructure and provides guidance for process optimization.

准确预测高强钛合金的微观组织演变是提高高强钛合金可加工性的关键。本研究通过耦合FE、JMAK和CA模型，提出了Ti5553加工的多尺度建模框架。为了确保在宏观-微观尺度上的准确性，关键材料参数使用混合策略进行校准，该策略集成了准静态，高应变率和高温热机械测试。基于切削力数据通过逆向优化细化TANH本构参数，通过高温SHPB试验确定CA形核和位错参数。JMAK参数提取自基于gleeble的变形实验。在正交切削和铣削条件下对模型进行了验证。正交切削时，切削力的最大预测误差为3.5%，晶粒尺寸误差在15.8% （CA）和8.7% （JMAK）之间。在铣削过程中，该模型捕获了加工硬化层的演变，晶粒尺寸预测误差低于15%。Ti5553的双相微观结构导致了独特的非均质剪切带行为，这在多尺度模型中得到了清晰的体现。CA模型有效地解决了地下的粒度梯度，而JMAK模型提供了平均粒度分布的宏/中观视图。这项工作为预测加工诱导的微观结构提供了一个有效的建模工具，并为工艺优化提供了指导。

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引用次数: 0

An incremental learning method for resistance projection welding quality evaluation in complex multi-condition working environments 复杂多工况环境下电阻投影焊接质量评价的增量学习方法

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.018

Lei Zhou , Weiqiang Luo , Zhongdian Zhang

Due to limited model generalization ability and complex industrial environments, the failure of resistance welding quality evaluation models is often inevitable. Enabling models to iteratively update and evolve their cognition based on continuously changing external conditions, akin to human learning, is crucial for reliable quality monitoring in complex scenarios. However, this problem remains under-explored. Focusing on the nut resistance projection welding process, this study categorized experimental data into an initial dataset and six incremental learning datasets based on environmental variations. The initial dataset was employed to train a meta-model, and the incremental datasets are devoted to facilitating incremental learning. This paper proposed a progressive incremental learning framework for multi-condition scenarios. This framework employed dynamic time warping combined with principal component analysis to quantify the discrepancies between incremental and initial datasets, thereby optimizing the model's incremental learning path. A configurable LSTM-based quality evaluation model was designed, which preserves acquired knowledge by freezing the parameters of the LSTM-Attention backbone and incorporates new knowledge by updating adapter. Results demonstrate that, compared to model retraining, the meta-model-based incremental learning approach achieved higher evaluation accuracy across all incremental datasets. This confirmed the effective retention and transfer of historical knowledge, laying a solid foundation for the industrial application of resistance spot welding quality evaluation models.

由于模型泛化能力的限制和复杂的工业环境，电阻焊质量评价模型失效往往是不可避免的。使模型能够基于不断变化的外部条件迭代地更新和进化它们的认知，类似于人类学习，对于在复杂场景中可靠的质量监控至关重要。然而，这一问题仍未得到充分探讨。本研究以螺母电阻投影焊接工艺为研究对象，将实验数据分为一个初始数据集和六个基于环境变化的增量学习数据集。初始数据集用于训练元模型，增量数据集用于促进增量学习。本文提出了一种适用于多条件场景的渐进式增量学习框架。该框架采用动态时间翘曲结合主成分分析来量化增量数据集与初始数据集之间的差异，从而优化模型的增量学习路径。设计了一种基于可配置lstm的质量评价模型，该模型通过冻结LSTM-Attention主干的参数来保留已获取的知识，并通过更新适配器来吸收新知识。结果表明，与模型再训练相比，基于元模型的增量学习方法在所有增量数据集上获得了更高的评估准确性。这证实了历史知识的有效保留和传递，为电阻点焊质量评价模型的产业化应用奠定了坚实的基础。

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引用次数: 0

Development of damage energy based process signature for machined surface quality in CFRP cutting 基于损伤能量的CFRP切削加工表面质量过程特征研究进展

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.010

Zhitong Zhou , Hao Li , Zhengwei Bao , Shiguang Zhang , Shipeng Li , Xuda Qin , Guoyu Fu , Qing Zhao

A “Process Signature” is inherent to every cutting operation and serves as a crucial link between cutting parameters and the resulting component performance. It provides a potential pathway to directly correlate the energy or internal loads generated in the cutting zone with the resulting surface quality. Considering the anisotropic nature of carbon fiber reinforced plastics (CFRP), this study proposed a theoretical model of surface damage energy in CFRP cutting based on the law of energy conservation. Moreover, for the first time, an energy based process signature component (PSC) was established by examining the relationship between energy consumption and surface quality. Single-factor experiments were conducted using a specially designed pendulum cutting device to analyze cutting energy distribution. The total dissipated energy is divided into four components: friction energy on the rake and flank faces, surface damage energy, chip formation energy, and new surface energy. Among these, surface damage energy shows the highest linear correlation with surface quality indicators (S_q, S_a, H_v, H_t) (R² > 0.9). Furthermore, a three-level classification method based on surface damage energy is proposed to distinguish surface quality under different parameter combinations. These findings deepen the understanding of the process signature in CFRP cutting and provide a new, performance-oriented approach for process modeling in CFRP machining.

“工艺特征”是每个切割操作所固有的，是切割参数和最终部件性能之间的关键联系。它提供了一种潜在的途径，可以直接将切割区产生的能量或内部载荷与产生的表面质量联系起来。考虑到碳纤维增强塑料（CFRP）的各向异性，基于能量守恒定律，提出了CFRP切割过程中表面损伤能量的理论模型。此外，通过研究能耗与表面质量之间的关系，首次建立了基于能量的过程特征分量（PSC）。采用特殊设计的摆刀装置进行单因素实验，分析切削能量分布。总耗散能分为4个部分：前、翼面摩擦能、表面损伤能、切屑形成能和新表面能。其中，表面损伤能与表面质量指标Sq、Sa、Hv、Ht的线性相关性最高（R2 > 0.9）。在此基础上，提出了一种基于表面损伤能量的三级分类方法来区分不同参数组合下的表面质量。这些发现加深了对碳纤维布切割过程特征的理解，并为碳纤维布加工过程建模提供了一种新的、以性能为导向的方法。

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引用次数: 0

Microstructure and micro-mechanical property evaluation of high-aspect-ratio micro-ribs constructed via elliptical vibration chiseling 椭圆振动凿凿高纵横比微肋的微观结构及微力学性能评价

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-13 DOI: 10.1016/j.jmapro.2026.02.006

Zhiwei Li , Hansong Ji , Pingfa Feng , Jianfu Zhang , Dingwen Yu , Qilin Li , Chaojiang Li , Jianjian Wang

Elliptical vibration chiseling (EV-chiseling) is a novel superior process to create micro-ribs on metallic surfaces. However, the formation mechanism and mechanical properties of micro-ribs are still unclear, which hinders its deterministic fabrication. This study concentrates on the formation mechanism clarification and mechanical property characterization of the as-constructed micro-ribs. A mechanistic cutting force model was developed and validated experimentally, revealing that the strain rate in EV-chiseling can reach up to 10³ s⁻¹. Crystallographic analysis on the microstructural evolution inside the micro-ribs exhibited that high strain rate deformation induced significant grain refinement, up to 41 times finer than the material matrix. Dislocation analysis further revealed high-density dislocation accumulation and extensive twin formation, contributing to microstructural refinement. As compared to the material matrix, in-situ micro-mechanical testing confirmed substantial improvements in mechanical properties, with hardness and reduced modulus increased by up to 27.4% and 24.2%, respectively. These enhancements were correlated with grain size reduction through the Hall-Petch relationship. The findings bring valuable insights into the interplay between high strain rate deformation, microstructural evolution, and mechanical property enhancement in the EV-chiseling process, and highlight the potential of constructed metallic micro-ribs for improved durability. Furthermore, higher frequency in EV-chiseling process is believed to introduce higher deformation strain rates, more significant grain refinement and more micro-mechanical property improvement.

椭圆振动凿削（ev -凿削）是一种在金属表面上制造微肋的新型优越工艺。然而，微肋的形成机制和力学性能仍不清楚，这阻碍了其确定性的制造。本文主要研究了预制微肋的形成机理及力学性能表征。建立了机械切削力模型，并进行了实验验证，结果表明，电火花切割的应变速率可达103 s−1。对微肋内部微观组织演变的晶体学分析表明，高应变速率变形引起了显著的晶粒细化，晶粒细化程度是材料基体的41倍。位错分析进一步揭示了高密度的位错积累和广泛的孪晶形成，有助于微观组织的细化。与材料基体相比，原位微力学测试证实其力学性能有明显改善，硬度和降低模量分别提高了27.4%和24.2%。这些增强通过Hall-Petch关系与晶粒尺寸减小相关。这些发现为ev -凿削过程中高应变率变形、微观组织演变和力学性能增强之间的相互作用提供了有价值的见解，并强调了构建金属微肋提高耐久性的潜力。此外，越高的电火花凿凿频率可以带来更高的变形应变率、更显著的晶粒细化和更大的微观力学性能改善。

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引用次数: 0

Integrating microstructural defect mapping into geometric refinement of LPBF lattices for enhanced mechanical performance 将微结构缺陷映射集成到LPBF晶格的几何细化中以提高力学性能

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.015

Shahid Ghafoor, Minyang Wang, Xinzhi Li, Xuefang Guo, Xuewei Fang, Muhammad Jawad Ahmad, Ke Huang

Additive manufacturing of Ti-6Al-4V lattices via laser powder bed fusion (LPBF) is often limited by unquantified geometric deviations and process-induced porosity that degrade mechanical reliability and design predictability. This work introduces a metrologically calibrated, Micro-CT driven framework that quantitatively links measured defect morphology and dimensional uncertainty to geometric refinement, while integrating finite-element and digital image correlation (DIC) validation to ensure experimental correlation of stress distribution and strain localization. A custom calibration phantom with engineered strut variations and controlled porosity zones (2–8%) was fabricated to calibrate Micro-CT accuracy and establish regional uncertainty maps, ensuring traceable dimensional fidelity across the lattice geometry. Guided by these data, defect-prone junctions and overhangs were re-engineered to improve local heat dissipation and geometric continuity, thereby mitigating melt-pool instability, stress distribution and suppress premature fracture. The optimized configuration (OC) lattice achieved 47.5% higher compressive strength, 47.1% greater energy absorption, and improved strain-rate insensitivity relative to the initial configuration (IC) at identical relative density (0.29). CT-derived geometry was embedded into stochastic FEM, reproducing measured deformation patterns, confirming more uniform stress propagation, and delayed fracture initiation. This study establishes a micro-CT calibrated design methodology that transforms high-resolution microstructural information into mechanical performance optimization, offering the predictive engineering of reliable, lightweight architectures for aerospace, biomedical, and energy-absorbing systems.

通过激光粉末床熔合（LPBF）增材制造Ti-6Al-4V晶格通常受到无法量化的几何偏差和工艺引起的孔隙率的限制，从而降低了机械可靠性和设计可预测性。这项工作引入了一个计量校准的Micro-CT驱动框架，该框架定量地将测量到的缺陷形态和尺寸不确定性与几何精化联系起来，同时集成了有限元和数字图像相关（DIC）验证，以确保应力分布和应变局部化的实验相关性。制作了带有工程支撑变化和可控孔隙度区域（2-8%）的定制校准模体，以校准Micro-CT精度并建立区域不确定度图，确保整个晶格几何形状的可追溯尺寸保真度。在这些数据的指导下，研究人员重新设计了容易出现缺陷的连接处和悬垂，以改善局部散热和几何连续性，从而减轻熔池不稳定、应力分布和抑制过早断裂。在相同的相对密度（0.29）下，与初始结构（IC）相比，优化结构（OC）晶格的抗压强度提高47.5%，能量吸收提高47.1%，应变率不敏感性得到改善。ct导出的几何图形嵌入到随机FEM中，再现了测量的变形模式，确认了更均匀的应力传播和延迟的破裂起裂。本研究建立了一种微型ct校准设计方法，将高分辨率微结构信息转化为机械性能优化，为航空航天、生物医学和吸能系统提供可靠、轻量级架构的预测工程。

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引用次数: 0

Biomimetic 4D printing of heterogeneous metals: Stress-mismatch-driven self-morphing for stimuli-free dynamic architectures 异质金属的仿生4D打印：应力不匹配驱动的自变形无刺激动态架构

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-11 DOI: 10.1016/j.jmapro.2026.02.001

Chao Xu , Yan Xu , Jinmin Qi , Kaizhou Ma , Qingping Liu , Xueli Zhou , Lu Zhang , Yunlong Tang , Luquan Ren

To address the challenges in the metal intrinsic stimuli-free responsiveness and the thermal behavior mismatch between heterogeneous metals, this study proposes a biomimetic 4D printing strategy that activates the shape-morphing capabilities of inert metal through stress-mismatch-driven mechanisms. Inspired by pod-like bilayer structures, the heterogeneous bilayer precursor composed of Fe and Cu filament uses direct ink writing (DIW) alternate deposition. The precursor deformation utilizes the sintering-induced shrinkage differences between axial and radial filaments. By synergistically tuning the powder-to-binder ratio and printing parameters, such as the layer number (n), aspect ratio (L/W), porosity and printing angle (α), the bending curvature and twisting angle can be precisely programmed, creating complex shape self-morphing structures (SMSs). The mean bending curvature and twisting angle of the SMS can be controlled within the ranges of 1.0–17.6 × 10⁻⁴/mm and 16.9°–50.2°, respectively. The minimum error of curvature between the simulated and experimental values of the bending SMS is 6.7%, and the error in twisting angle is 13.7%. Microstructure analysis reveals a crack-free FeCu interface, achieved through pore-mediated stress accommodation and element diffusion. This work further demonstrates potential applications in integrated turbine blades and mold-assisted forming, providing a new paradigm for high-strength and shape-programmable metal structures in fields such as aerospace and microsystems. This work extends the 4D printing material system to metals without response to stimulation, opening a new path for heterogeneous material design and multi-functional structure manufacturing.

为了解决金属固有的无刺激响应性和异质金属之间的热行为不匹配的挑战，本研究提出了一种仿生4D打印策略，通过应力错配驱动机制激活惰性金属的形状变形能力。受豆荚状双层结构的启发，由铁和铜丝组成的非均相双层前驱体采用直接墨水书写（DIW）交替沉积。前驱体变形利用了轴向和径向细丝之间烧结引起的收缩差异。通过协同调节粉料比和打印参数，如层数(n)、纵横比（L/W）、孔隙率和打印角度（α），可以精确地编程弯曲曲率和扭曲角度，形成复杂形状的自变形结构（SMSs）。SMS的平均弯曲曲率和平均扭转角分别控制在1.0 ~ 17.6 × 10−4/mm和16.9°~ 50.2°范围内。弯曲模态曲线的曲率值与实验值的最小误差为6.7%，扭转角误差为13.7%。微观结构分析表明，通过孔隙介导的应力调节和元素扩散，FeCu界面无裂纹。这项工作进一步展示了在集成涡轮叶片和模具辅助成型方面的潜在应用，为航空航天和微系统等领域的高强度和形状可编程金属结构提供了新的范例。本工作将4D打印材料系统扩展到金属，无需对刺激做出反应，为异质材料设计和多功能结构制造开辟了新的途径。

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引用次数: 0

Low-cost thermal reshaping of carbon fibre/PEEK thick sections: Experiments and simulations 碳纤维/PEEK厚型材的低成本热成形：实验和模拟

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-12 DOI: 10.1016/j.jmapro.2026.02.002

Antreas Potsis , Fernando Álvarez-Borges , Irene Jiménez-Fortunato , Erick Montes de Oca Valle , Francisca Martínez-Hergueta

This study develops a new low-cost remoulding route to reshape thick composite waste. A coupled experimental and numerical methodology is proposed and applied to carbon fibre polyether ether ketone pipes from oil and gas industry. The experimental procedure concludes that sample flatness can be improved by up to 65% without using additional moulds and for relatively low pressures and processing temperatures, above the glass transition temperature but well below the material's melting point, minimising the energy consumption and cost of the process. Micro CT inspection reveals a significant reduction in local void content in regions subjected to transverse compression, ensuring the quality of the reshaped component. The capabilities and limitations of different processing parameters are assessed numerically. Guidelines for sustainable reshaping of composite waste for different applications are provided, opening the path for a new method of managing composite waste at a minimum cost.

本研究开发了一种低成本的复合材料垃圾重塑新途径。提出了一种实验与数值相结合的方法，并将其应用于油气行业的碳纤维聚醚醚酮管道。实验过程的结论是，在不使用额外模具的情况下，样品的平面度可以提高65%，并且在相对较低的压力和加工温度下，高于玻璃化转变温度，但远低于材料的熔点，从而最大限度地降低了工艺的能耗和成本。微CT检查显示，在受横向压缩的区域，局部空隙含量显著减少，确保了重塑部件的质量。对不同加工参数的能力和局限性进行了数值评估。为不同用途的复合废物的可持续重塑提供了指导方针，为以最低成本管理复合废物的新方法开辟了道路。

引用次数: 0

Annular-shaped laser beam directed energy deposition of a high-strength and high-plasticity Al-Zn-Mg-Cu alloy via coaxial wire feeding 同轴送丝法制备高强度高塑性Al-Zn-Mg-Cu合金的环形激光定向能沉积

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-30 Epub Date: 2026-02-12 DOI: 10.1016/j.jmapro.2026.02.009

Jie Su , Minglie Hu , Zizheng Zhao , Zhen Li , Jinglong Tang , Zhen Luo

Laser directed energy deposition (L-DED) of Al–Zn–Mg–Cu alloys is often constrained by a pronounced tendency toward solidification cracking and the formation of coarse columnar grains, which severely restrict their industrial applicability. To overcome these limitations and address the intrinsic drawbacks of conventional lateral wire-fed L-DED, this study proposes a novel DED approach that integrates an annular laser beam with coaxial wire feeding. The technique is designed to simultaneously suppress solidification cracking and promote a transition from columnar to equiaxed grain. By precisely controlling the laser output waveform and wire feeding rate, a stable and repeatable deposition process was established. Within the optimized processing window, defect-free thin-walled Al–Zn–Mg–Cu alloy structures were successfully fabricated. Multi-scale microstructural characterization reveals a distinctive hierarchical morphology composed of equiaxed grains, fine-grained bands, and columnar grains. Mechanical testing demonstrates that the proposed method substantially improves both geometric accuracy and mechanical performance relative to conventional lateral wire-fed DED. The effective material utilization of the thin wall increased by 12%. Ultimate tensile strength, yield strength and elongation increased by 18.2%, 17.6% and 32.5%, respectively. Based on the experimental observations, the synergistic mechanisms responsible for the simultaneous enhancement of strength and plasticity are elucidated. This work provides an effective processing route for precise control of geometry, microstructure and mechanical properties in Al–Zn–Mg–Cu alloy components produced by L-DED. The findings offer both theoretical insight and practical guidance for optimizing DED processes across a range of alloy systems and industrial applications.

Al-Zn-Mg-Cu合金的激光定向能沉积（L-DED）常常受到明显的凝固开裂倾向和粗柱状晶粒形成的限制，这严重限制了其工业应用。为了克服这些限制并解决传统横向送丝L-DED的固有缺陷，本研究提出了一种将环形激光束与同轴送丝相结合的新型DED方法。该技术旨在同时抑制凝固裂纹并促进从柱状晶粒到等轴晶粒的转变。通过精确控制激光输出波形和送丝速度，建立了稳定、可重复的沉积工艺。在优化的工艺窗口内，成功制备出无缺陷的Al-Zn-Mg-Cu薄壁合金结构。多尺度显微结构表征显示其具有明显的等轴晶、细晶带和柱状晶等层次结构。力学测试表明，与传统的横向送丝DED相比，该方法大大提高了几何精度和力学性能。薄壁材料的有效利用率提高了12%。极限抗拉强度、屈服强度和伸长率分别提高18.2%、17.6%和32.5%。基于实验观察，阐明了强度和塑性同时增强的协同机制。本工作为L-DED工艺生产的Al-Zn-Mg-Cu合金零件的几何结构、显微组织和力学性能的精确控制提供了一条有效的加工路线。研究结果为优化一系列合金系统和工业应用中的DED工艺提供了理论见解和实践指导。

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