Journal of Manufacturing Processes最新文献_第2页

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 : 2026-02-11 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

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 : 2026-02-10 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

Predicting submerged deflecting abrasive waterjet peening induced surface roughness based on vibration signal via a time-frequency parallel deep learning network 基于振动信号的时频并行深度学习网络预测水下偏转磨料水射流强化诱导表面粗糙度

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-09 DOI: 10.1016/j.jmapro.2026.01.103

Yu-Xin Chi , Shu-Lei Yao , Xian-Hao Zhu , Zhi-Yun Wang , Jie Qi , Ning Wang , Xian-Cheng Zhang

Waterjet peening (WJP) is an effective surface strengthening method for complex aeroengine components. However, the low stiffness of thin-walled parts, such as blades, can induce significant vibration responses during machining, which may adversely affect the final surface integrity. Therefore, process monitoring is crucial for capturing dynamic responses and providing timely feedback for quality control. However, owing to the complex working environment and strengthening mechanism, monitoring the WJP process remains challenging. In this study, vibration signals from thin-walled titanium alloy TA19 specimens were collected during submerged deflecting abrasive waterjet peening (SDAWJP). The vibration signals exhibited change trends consistent with those of surface roughness and showed clear sensitivity to variations in process parameters, thus enabling accurate prediction modeling. A time-frequency parallel deep learning network (TFPNet) was proposed, in which vibration features from both the time and frequency domains were extracted simultaneously and subsequently fused via an attention pooling mechanism to effectively predict the surface roughness. The prediction performance was evaluated under varying abrasive flow rates and water pressures. The proposed model achieved mean absolute percentage errors of 0.99% and 1.35%, respectively, which were significantly lower and more stable than those of the comparative methods. The findings are expected to provide support for the machining quality assurance in practical aviation components.

水射流强化是航空发动机复杂部件表面强化的一种有效方法。然而，薄壁零件（如叶片）的低刚度在加工过程中会引起明显的振动响应，这可能会对最终的表面完整性产生不利影响。因此，过程监控对于捕获动态响应和为质量控制提供及时反馈至关重要。然而，由于复杂的工作环境和加强机制，监测WJP进程仍然具有挑战性。本文采集了TA19薄壁钛合金试样在水下偏转磨料水射流强化（SDAWJP）过程中的振动信号。振动信号的变化趋势与表面粗糙度的变化趋势一致，对工艺参数的变化具有明显的敏感性，从而能够准确地预测建模。提出了一种时频并行深度学习网络（TFPNet），该网络同时提取时域和频域的振动特征，然后通过注意力池机制进行融合，从而有效地预测表面粗糙度。在不同的磨料流量和水压条件下，对预测效果进行了评价。该模型的平均绝对百分比误差分别为0.99%和1.35%，显著低于对比方法，且更加稳定。研究结果有望为实际航空部件的加工质量保证提供支持。

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引用次数: 0

VoxeLogic: A voxel-based, mesh-free model for fast, high-fidelity temperature prediction and process planning in directed energy deposition VoxeLogic：一种基于体素的无网格模型，用于定向能沉积中快速、高保真的温度预测和工艺规划

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-09 DOI: 10.1016/j.jmapro.2026.01.080

Marzia Saghafi , Ruth Jill Urbanic , Bob Hedrick

Directed Energy Deposition (DED) is increasingly adopted for manufacturing large-scale metal components where conventional methods are impractical. While it offers material efficiency and tailored properties, it also introduces challenges associated with repeated thermal cycles. Even for a single geometry, different decomposition strategies, toolpaths, and process parameters can significantly alter the resulting thermal histories, which in turn govern microstructure and final properties. For process plan optimization, conventional finite element (FEM) models can capture these cycles, but their reliance on meshing, specialized expertise, and long runtimes restrict use in real-world cases.

This research aimed to develop a framework that balances computational efficiency with predictive fidelity while remaining suitable for both academic and industrial deployment. To this end, the VoxeLogic Heat Model was developed: a new, mesh-free formulation built from first principles to simulate heat transfer directly from deposition toolpaths, providing complete temperature–time histories across the build. Rooted in physical principles rather than training datasets, VoxeLogic is broadly applicable across geometries and process conditions. Applications include single-layer deposition on flat and curved substrates with complex curvilinear toolpaths. Benchmarking against experimentally validated FEM simulations and thermocouple measurements showed that VoxeLogic reproduced temperature–time profiles with errors below 5% for peak temperatures and 10% for cooling rates. Microstructure-relevant thermal metrics were also captured with accuracy suitable for engineering analysis. This fidelity was achieved while reducing computation time by 99.8%, from hours to seconds. These results also establish VoxeLogic as a foundation for extending voxel-based thermal simulation to multilayer 3D deposition and future digital twin applications.

定向能沉积（DED）越来越多地用于制造大型金属部件，而传统方法是不切实际的。虽然它提供了材料效率和定制性能，但它也引入了与重复热循环相关的挑战。即使是单一几何形状，不同的分解策略、刀具路径和工艺参数也会显著改变产生的热历史，从而影响微观结构和最终性能。对于工艺计划优化，传统的有限元（FEM）模型可以捕获这些周期，但它们对网格划分、专业知识和长运行时间的依赖限制了在实际情况下的使用。本研究旨在开发一个框架，平衡计算效率和预测保真度，同时保持适合学术和工业部署。为此，开发了VoxeLogic热模型：一种新的无网格配方，从第一原理出发，直接模拟沉积刀具路径的传热，提供整个构建过程中的完整温度-时间历史。植根于物理原理而不是训练数据集，VoxeLogic广泛适用于各种几何形状和工艺条件。应用包括单层沉积在平面和弯曲的基材与复杂的曲线刀具路径。基于实验验证的FEM模拟和热电偶测量的基准测试表明，VoxeLogic再现的温度-时间曲线在峰值温度和冷却速率方面的误差分别低于5%和10%。显微结构相关的热指标也被准确捕获，适合工程分析。这种保真度是在将计算时间从几个小时减少到几秒钟的99.8%的情况下实现的。这些结果也使VoxeLogic成为将基于体素的热模拟扩展到多层3D沉积和未来数字孪生应用的基础。

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引用次数: 0

Recognition and analysis of welding images with lightweight semantic segmentation model improved by attention mechanism during ARM laser welding 基于注意机制改进的轻量化语义分割模型在ARM激光焊接过程中的图像识别与分析

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-07 DOI: 10.1016/j.jmapro.2026.01.089

Hua Liu , Chengwen Gao , Yu Chen , Yuanjie Peng , Siyang Chen , Miao Yang , Mengjia Xu

Adjustable ring mode (ARM) laser welding offers flexible heat input control, improved thermal distribution, and enhanced molten pool stability, making it well-suited for advanced manufacturing applications. Despite these advantages, the complexity of parameter adjustment and the dynamic behavior of the molten pool present significant challenges to process stability and joint quality. To address these issues, an active vision-based monitoring system was developed to capture molten pool images, and deep learning methodologies were applied for feature recognition. A transfer learning-based semantic segmentation model was proposed, and creatively incorporated with an attention gate (AG) mechanism to improve segmentation accuracy. Following segmentation, Canny edge detection was employed for contour extraction of molten pool features, facilitating analysis of the influence of process parameters on molten pool morphology evolution. Experimental results indicate that the ResNet-50 backbone offers higher accuracy and faster inference in segmenting molten pool, keyhole and penetration features. With the AG-enhanced mechanism, the proposed model achieves superior edge segmentation of molten pool, keyhole, and full-penetration hole features, attaining superior feature segmentation performance with mean Intersection over Union (mIoU) of 92.38%, precision (P) of 95.75%, and recall (R) of 95.75%. Geometric calculations of the molten pool profile indicate that the ring laser significantly contributes to the stability of both the molten pool and the keyhole. After eliminating cases of excessive penetration and burn-through, the full-penetration hole can serve as a criterion for evaluating the penetration state in ARM laser welding. These findings demonstrate the robustness and generalization capability of the model, providing critical support for ARM laser welding process optimization and intelligent control.

可调环模式（ARM）激光焊接提供灵活的热输入控制，改善热分布，增强熔池稳定性，使其非常适合先进的制造应用。尽管有这些优点，但参数调整的复杂性和熔池的动态行为对工艺稳定性和接头质量提出了重大挑战。为了解决这些问题，研究人员开发了一种基于主动视觉的监测系统来捕获熔池图像，并应用深度学习方法进行特征识别。提出了一种基于迁移学习的语义切分模型，并创造性地将注意门（attention gate， AG）机制融入其中，以提高切分精度。在分割之后，采用Canny边缘检测对熔池特征进行轮廓提取，便于分析工艺参数对熔池形态演变的影响。实验结果表明，ResNet-50骨干网在熔池、锁孔和穿透特征分割方面具有更高的精度和更快的推理速度。利用ag增强机制，该模型对熔池、锁孔和全穿透孔特征进行了较好的边缘分割，平均mIoU （Intersection over Union）为92.38%，精度(P)为95.75%，召回率(R)为95.75%。熔池轮廓的几何计算表明，环形激光对熔池和锁孔的稳定性都有显著的促进作用。在消除了过度熔透和烧穿情况后，全熔透孔可以作为评估ARM激光焊接熔透状态的标准。这些结果证明了该模型的鲁棒性和泛化能力，为ARM激光焊接工艺优化和智能控制提供了重要支持。

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引用次数: 0

Machining of thin-walled components of fiber-reinforced titanium matrix composites—Dynamic response mechanism of fiber orientation 纤维增强钛基复合材料薄壁构件的加工&纤维取向的动态响应机制

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-06 DOI: 10.1016/j.jmapro.2026.02.005

Liyu Wang , Yutao Wang , Songmei Yuan , Longpeng Li , Hanjun Gao , Obaid Muhammad , Qilin Li , Zhen Li

Thin-walled structural components are widely used in aerospace industries due to their lightweight and high-strength properties. However, their low-rigidity structural characteristics cause machining deformation during processing. For thin-walled components made of continuous silicon carbide fiber-reinforced titanium matrix composites (SiC_f/Ti), the simultaneous existence of both metal and fibers, lead to more complex machining deformation than traditional titanium materials or other composites and their deformation mechanism remains unclear. This paper investigates side-milling of SiC_f/Ti thin-walled components and revealed that, compared to titanium alloy, their machining process shows global dynamic instability. Specifically, SiC_f/Ti components with vertically and horizontally aligned fibers exhibited displacement reductions of 33.2% and 56.93%, respectively, compared to Ti baseline. The machined surface demonstrates the material-response dominance. For vertically aligned fibers, the cutting inlet of SiC_f/Ti exhibits lowest stiffness and dominates dynamic instability, with a peak vibration amplitude of 154.3 m/s². In contrast, horizontally aligned fibers show more severe stiffness collapse at the cutting outlet, reaching 160.7 m/s². With vertically aligned fibers, the deformation mechanism of SiC_f/Ti is dominated by constrained plastic flow of matrix and elastic coordination at interface. Energy is dissipated efficiently through the friction at fiber-matrix interface and propagation of stress wave along fiber direction, which shows a stable dynamic response. In contrast, horizontally aligned fibers induce the cross-scale laminate bending and interlaminar shear deformation. Energy repeatedly superimposes and accumulates within the fibers with difficulty in dissipation, which keep the system in intense vibrational state. This study provides valuable insights for high quality machining of SiC_f/Ti thin-walled components.

薄壁结构件以其轻量化和高强度的特点在航空航天工业中得到了广泛的应用。但由于其低刚度的结构特点，在加工过程中会产生加工变形。对于由连续碳化硅纤维增强钛基复合材料（SiCf/Ti）制成的薄壁部件，金属和纤维同时存在，导致其加工变形比传统钛材料或其他复合材料更为复杂，其变形机制尚不清楚。研究了SiCf/Ti薄壁零件的侧铣加工过程，发现与钛合金相比，SiCf/Ti薄壁零件的加工过程具有全局动态不稳定性。具体来说，与Ti基线相比，垂直和水平排列纤维的SiCf/Ti组件的位移分别减少了33.2%和56.93%。加工表面表现出材料响应优势。对于垂直排列的纤维，SiCf/Ti切割入口刚度最低，动态失稳占主导地位，峰值振动幅值为154.3 m/s2。相比之下，水平排列的纤维在切割出口处表现出更严重的刚度崩溃，达到160.7 m/s2。当纤维垂直排列时，SiCf/Ti的变形机制主要是基体的约束塑性流动和界面处的弹性配位。能量通过纤维与基体界面的摩擦和应力波沿纤维方向的传播有效耗散，表现出稳定的动力响应。相反，水平排列的纤维会引起层间剪切变形和跨尺度弯曲。能量在纤维内部反复叠加和积累，难以消散，使系统处于强烈的振动状态。该研究为SiCf/Ti薄壁零件的高质量加工提供了有价值的见解。

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引用次数: 0

Surface flattening during aluminum sheet forming 铝板成形过程中的表面扁化

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-06 DOI: 10.1016/j.jmapro.2026.01.099

Farshid Jalali Moghadas , Matthijn de Rooij , Ton van den Boogaard , Javad Hazrati

Predicting friction in sheet metal forming is essential for accurate modelling of the process and therefore its optimization. Estimation of real contact area is prerequisite for reliable prediction of friction. In this paper, effects of normal load, as well as normal load combined by strain in aluminum sheet metal on the real area of contact are investigated. An earlier setup is improved to probe combined normal load and bulk strain effects on the real area of contact. Experiments are carried out on two grades of aluminum, AA6016 and AA5182 sheets with electro discharge surface textures (EDT). Fractional real area of contact at different contact pressure and strain levels is measured using confocal microscopic images of the deformed surfaces. A semi-analytical model is used to predict real area of contact evolution due to normal load using a hardness database of different asperity geometries. To account for flattening of asperities due to combined normal load and bulk strain, a new model is developed and calibrated based on the experiments. The experimental results show that extent of increase in real area of contact due to only normal load or combined normal load and strain depends on the surface texture, the material properties and contact conditions. Predictions of the new models were validated using different textures of the same aluminum grade. The results show that the models capture the evolution of real area of contact with reasonable accuracy. These models will be used to enhance friction modelling in aluminum sheet forming.

预测金属板料成形过程中的摩擦对过程的精确建模和优化至关重要。实际接触面积的估计是可靠预测摩擦的前提。本文研究了法向载荷以及法向载荷加应变对铝板实际接触面积的影响。改进了先前的设置，以探测法向载荷和体应变对实际接触面积的影响。以两种铝材AA6016和AA5182为研究对象，进行了电火花表面织构（EDT）实验。在不同的接触压力和应变水平的分数实际接触面积测量使用共聚焦显微镜图像的变形表面。采用一种半解析模型，利用不同硬度几何形状的硬度数据库来预测法向载荷引起的实际接触演化面积。为了考虑法向载荷和体应变共同作用下的凹凸不平的扁化现象，在实验的基础上建立了新的模型并进行了标定。实验结果表明，单纯法向载荷或法向载荷与应变组合作用下实际接触面积的增大程度与表面织构、材料性能和接触条件有关。使用相同铝等级的不同纹理验证了新模型的预测。结果表明，所建立的模型能较好地反映实际接触面积的演变过程。这些模型将用于增强铝板成形中的摩擦模型。

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引用次数: 0

In-situ development of nano MoS2 particles infused micro-textured tungsten carbide surfaces using spark ablation technique coupled with inhouse fabricated ultrathin electrodes for enhancing tribological performance 利用火花烧蚀技术，结合自制超薄电极，原位制备纳米二硫化钼颗粒注入微纹理碳化钨表面，以提高摩擦性能

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-06 DOI: 10.1016/j.jmapro.2026.02.004

Tejanshu Sekhar Sahu , Ranjeet Kumar Sahu , Prasad Krishna

The present study investigates the fabrication of self-lubricating textures on tungsten carbide surfaces via spark ablation micro machining, utilizing in-situ fabricated ultrathin electrodes of less than 100 μm (electrodes unavailable in the global market) with the MoS₂ nanoparticle suspended dielectric. The inhouse fabricated electrodes facilitated accurate texturing at the microscale by closely controlling the process parameters, and the addition of MoS₂ particles was found to have a significant influence on the tribological behaviour of the developed textured surfaces during interfacial interaction. The MoS₂ assisted textured WC surfaces show a mean coefficient of friction (CoF) of 0.343 ± 0.023, indicating a 37.2% and 23.2% reduction in its CoF compared to plain WC (CoF = 0.546 ± 0.037) and conventionally textured surfaces (CoF = 0.447 ± 0.035), respectively. Accordingly, the MoS₂ assisted textured WC surfaces exhibited a reduction in specific wear rate by 52.9% and 32.9% relative to the plain surface and conventionally textured surfaces, respectively. The profilometric analysis revealed that the MoS₂ assisted surfaces exhibit shallow furrows and a smooth topography. The findings are also confirmed by SEM, which revealed a significant decrease in furrows, microcracks, and adhesive wear, attributed to the development of a continuous MoS tribofilm.

本研究利用纳米二硫化钼悬浮电介质原位制备的小于100 μm的超薄电极（目前全球市场上没有这种电极），通过火花烧蚀微加工在碳化钨表面制备自润滑织体。通过严格控制工艺参数，内部制造的电极可以在微观尺度上实现精确的织构，并且发现二硫化钼颗粒的添加对界面相互作用过程中形成的织构表面的摩擦学行为有显著影响。MoS2辅助织构WC表面的平均摩擦系数（CoF）为0.343±0.023，与普通WC表面（CoF = 0.546±0.037）和常规WC表面（CoF = 0.447±0.035）相比，CoF分别降低了37.2%和23.2%。因此，与普通表面和常规纹理表面相比，MoS2辅助的纹理WC表面的比磨损率分别降低了52.9%和32.9%。轮廓分析表明，二硫化钼辅助表面具有较浅的沟槽和光滑的形貌。扫描电镜也证实了这一发现，由于形成了连续的MoS摩擦膜，沟槽、微裂纹和粘着磨损显著减少。

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引用次数: 0

Feasibility study on ultrasonic vibration-assisted press-fitting assembly for titanium alloy load-bearing holes 钛合金承载孔超声振动辅助压合装配的可行性研究

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-06 DOI: 10.1016/j.jmapro.2026.01.087

Shaoqing Tian , Xiangyu Zhang , Zefeng Chen , Jianfu Zhang , Pingfa Feng

Conventional interference-fit assembly methods, including press-fitting and temperature difference methods, have been extensively applied in mechanical and aerospace manufacturing. However, with the growing demand for high precision and reliability, these conventional methods are inadequate for the interference-fit assembly of titanium alloy load-bearing holes. To address this limitation, an ultrasonic vibration-assisted press-fitting assembly (UVPA) method is proposed, which integrates ultrasonic vibration with conventional press-fitting to reduce press-fitting force and mitigate interfacial damage. Experimental investigations reveal that press-fitting speed significantly influences the effectiveness of UVPA. At a press-fitting speed of 0.05 mm/s, UVPA reduces the press-fitting force by 18.9% compared with conventional press-fitting assembly (CPA), and the rate of friction reduction decreases with increasing vibration amplitude. When the interference fits are below 6 μm, UVPA consistently reduces the press-fitting force by approximately 20% compared with CPA. Furthermore, surface roughness measurements at the material interface show that, under a vibration amplitude of 10 μm, UVPA decreases

Ra

and

Rz

by up to 44.5% and 41.1%, respectively. These findings confirm that UVPA effectively reduces press-fitting force and interfacial damage during the interference-fit assembly of titanium alloy load-bearing holes, providing a promising alternative to conventional methods for high-precision and damage-controlled assembly applications.

传统的过盈配合装配方法，包括压合法和温差法，已广泛应用于机械和航空航天制造。然而，随着对高精度和可靠性要求的不断提高，这些传统的方法已经不适用于钛合金承载孔的过盈配合装配。为了解决这一问题，提出了一种超声振动辅助压合装配（UVPA）方法，该方法将超声振动与常规压合相结合，以减小压合力并减轻界面损伤。实验研究表明，压合速度对UVPA的效果有显著影响。当压合速度为0.05 mm/s时，UVPA压合力比传统压合组件（CPA）降低了18.9%，且摩擦减少率随振动幅值的增加而减小。当过盈配合小于6 μm时，与CPA相比，UVPA持续降低了约20%的压合力。此外，对材料界面表面粗糙度的测量表明，在10 μm的振动幅值下，UVPA可使Ra和Rz分别降低44.5%和41.1%。这些研究结果证实，UVPA在钛合金承载孔干涉配合装配过程中有效地降低了压合力和界面损伤，为高精度和损伤控制装配应用提供了一种有前途的替代方法。

{"title":"Feasibility study on ultrasonic vibration-assisted press-fitting assembly for titanium alloy load-bearing holes","authors":"Shaoqing Tian , Xiangyu Zhang , Zefeng Chen , Jianfu Zhang , Pingfa Feng","doi":"10.1016/j.jmapro.2026.01.087","DOIUrl":"10.1016/j.jmapro.2026.01.087","url":null,"abstract":"<div><div>Conventional interference-fit assembly methods, including press-fitting and temperature difference methods, have been extensively applied in mechanical and aerospace manufacturing. However, with the growing demand for high precision and reliability, these conventional methods are inadequate for the interference-fit assembly of titanium alloy load-bearing holes. To address this limitation, an ultrasonic vibration-assisted press-fitting assembly (UVPA) method is proposed, which integrates ultrasonic vibration with conventional press-fitting to reduce press-fitting force and mitigate interfacial damage. Experimental investigations reveal that press-fitting speed significantly influences the effectiveness of UVPA. At a press-fitting speed of 0.05 mm/s, UVPA reduces the press-fitting force by 18.9% compared with conventional press-fitting assembly (CPA), and the rate of friction reduction decreases with increasing vibration amplitude. When the interference fits are below 6 μm, UVPA consistently reduces the press-fitting force by approximately 20% compared with CPA. Furthermore, surface roughness measurements at the material interface show that, under a vibration amplitude of 10 μm, UVPA decreases <span><math><mi>Ra</mi></math></span> and <span><math><mi>Rz</mi></math></span> by up to 44.5% and 41.1%, respectively. These findings confirm that UVPA effectively reduces press-fitting force and interfacial damage during the interference-fit assembly of titanium alloy load-bearing holes, providing a promising alternative to conventional methods for high-precision and damage-controlled assembly applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 371-385"},"PeriodicalIF":6.8,"publicationDate":"2026-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146191449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Solid state friction-based additive manufacturing of heterogeneous metallic composites: Recent progress and future prospects 基于固体摩擦的非均相金属复合材料的增材制造：最新进展和未来展望

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-05 DOI: 10.1016/j.jmapro.2026.01.096

Ashish Kumar , Lei Shi , Xiankun Zhang , Xiaochao Liu , Zhixin Xia , Swee Leong Sing , Chuansong Wu , Amitava De

Heterogeneous metallic composites fabricated from dissimilar alloys have attracted growing interest owing to their ability to combine complementary properties and achieve multifunctional performance in advanced engineering applications. Fusion-based additive manufacturing is often employed for such metallic structures, yet it remains constrained by the formation of brittle intermetallic compounds, chemical segregation, and inferior mechanical properties. Solid-state additive manufacturing (SSAM) processes, particularly friction-based techniques such as friction stir additive manufacturing (FSAM), friction surfacing (FS), additive friction stir deposition (AFSD), and additive friction extrusion deposition (AFED), have emerged as promising alternatives. Unlike fusion-based AM, these processes operate below the melting temperature and achieve metallurgical bonding through severe plastic deformation, frictional heating, and dynamic recrystallization. As a result, SSAM effectively suppresses solidification-related defects, reduces residual stresses, and improves interfacial integrity. However, a comprehensive review focused on the fabrication of heterogeneous metallic composites via solid-state friction-based additive manufacturing (SSFAM), particularly AFSD and FS, is still lacking. This article addresses this gap by critically analysing interfacial microstructural evolution, diffusion behaviour, and mechanical performance in dissimilar alloy processed by FS and AFSD. The process–structure–property relationships, identifying current limitations in interfacial control, and evaluating emerging machine learning (ML)–assisted strategies for process optimisation, defect mitigation, and property prediction in SSFAM. By integrating insights from experimental studies, mechanistic modeling, and data-driven approaches, this review highlights the growing role of ML in accelerating SSFAM design and improving the reliability of heterogeneous structures. Overall, this review seeks to serve as a state-of-the-art reference for researchers and practitioners aiming to develop structurally robust multifunctional components through data-informed, next-generation SSFAM techniques.

由异种合金制备的非均相金属复合材料由于其结合互补性能和在先进工程应用中实现多功能的能力而引起了人们越来越多的兴趣。基于融合的增材制造通常用于这种金属结构，但它仍然受到脆性金属间化合物的形成、化学偏析和较差的机械性能的限制。固态增材制造（SSAM）工艺，特别是基于摩擦的技术，如摩擦搅拌增材制造（FSAM）、摩擦表面（FS）、添加剂摩擦搅拌沉积（AFSD）和添加剂摩擦挤压沉积（AFED），已经成为有希望的替代方案。与基于熔融的增材制造不同，这些工艺在熔化温度以下运行，并通过严重的塑性变形、摩擦加热和动态再结晶实现冶金结合。因此，SSAM有效地抑制了与凝固相关的缺陷，降低了残余应力，提高了界面的完整性。然而，通过固态摩擦增材制造（SSFAM），特别是AFSD和FS制造非均相金属复合材料的综合综述仍然缺乏。本文通过批判性地分析不同合金在FS和AFSD处理下的界面微观组织演变、扩散行为和力学性能来解决这一差距。过程-结构-属性关系，识别界面控制的当前局限性，并评估SSFAM中用于过程优化、缺陷缓解和属性预测的新兴机器学习（ML）辅助策略。通过整合实验研究、机制建模和数据驱动方法的见解，本综述强调了ML在加速SSFAM设计和提高异质结构可靠性方面日益增长的作用。总的来说，本综述旨在为研究人员和从业者提供最先进的参考，旨在通过数据知情的下一代SSFAM技术开发结构坚固的多功能组件。

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引用次数: 0