Pub Date : 2026-01-26DOI: 10.1016/j.jmapro.2026.01.076
Shuhan Li , Xinqiang Lan , Zemin Wang
Extrusion-based additive manufacturing of powder-binder feedstocks offers a cost-effective route for indirectly fabricating metallic components. However, the sintering step remains a major bottleneck, typically requiring lengthy, powder-specific optimization that can exceed the effort spent on printing parameter tuning. This study overcomes this challenge by establishing a direct correlation between macroscopic shrinkage and microscopic porosity, enabling rapid assessment of sintering quality. For H13 steel, densification proceeds through solid-phase sintering at 1000–1350 °C and liquid-phase sintering at 1400–1450 °C. Thermodynamic analysis and experimental results confirm that by increasing the sintering temperature and avoiding excessive liquid-phase sintering (1300–1400 °C), both SSAM-5 and SSAM-10 powders (with medium particle size of 5.3 μm and 11.8 μm) can achieve ideal porosities of 0.45% and 0.96% after 1–3 h of holding. Macroscopic shrinkage was observed after sintering and approached a theoretical limit as porosity decreased. A quantitative model linking shrinkage to porosity was developed, enabling the immediate assessment of internal densification using easily accessible macroscopic data.
{"title":"Revealing the sintering behavior of H13 steel in semi-solid additive manufacturing through the correlation of shrinkage and porosity","authors":"Shuhan Li , Xinqiang Lan , Zemin Wang","doi":"10.1016/j.jmapro.2026.01.076","DOIUrl":"10.1016/j.jmapro.2026.01.076","url":null,"abstract":"<div><div>Extrusion-based additive manufacturing of powder-binder feedstocks offers a cost-effective route for indirectly fabricating metallic components. However, the sintering step remains a major bottleneck, typically requiring lengthy, powder-specific optimization that can exceed the effort spent on printing parameter tuning. This study overcomes this challenge by establishing a direct correlation between macroscopic shrinkage and microscopic porosity, enabling rapid assessment of sintering quality. For H13 steel, densification proceeds through solid-phase sintering at 1000–1350 °C and liquid-phase sintering at 1400–1450 °C. Thermodynamic analysis and experimental results confirm that by increasing the sintering temperature and avoiding excessive liquid-phase sintering (1300–1400 °C), both SSAM-5 and SSAM-10 powders (with medium particle size of 5.3 μm and 11.8 μm) can achieve ideal porosities of 0.45% and 0.96% after 1–3 h of holding. Macroscopic shrinkage was observed after sintering and approached a theoretical limit as porosity decreased. A quantitative model linking shrinkage to porosity was developed, enabling the immediate assessment of internal densification using easily accessible macroscopic data.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 359-370"},"PeriodicalIF":6.8,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080407","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}
Pub Date : 2026-01-26DOI: 10.1016/j.jmapro.2026.01.069
Wanyang Li , Weiwei Liu , Huanqiang Liu , Junjie Tan , Haojun Yang , Baimao Lei , Qiang Chen , Jianrong Song , Zongyu Ma , Tao Li , Yulin Wang , Fengtao Wang , Hongchao Zhang
In this study, laser-directed energy deposition (LDED) assisted by an electromagnetic coupled field (EMF) was employed to systematically investigate the effects of current intensity and direction on melt pool dynamics, defect evolution, microstructural evolution, and tribological behavior of composite coatings. The coupled field reshaped melt pool flow patterns and effectively suppress pores and cracks, reducing the defect density to 0.075%. Electromagnetic stirring effect enhanced solute redistribution and grain morphology transformation, unveiling a coupled mechanism of “grain-boundary transformation-defect accumulation-strain release”. EBSD and TEM analyses revealed a microstructural transition from a “WC/W2C-dominated” state to a “γ-Ni matrix-Cr carbide co-dominated” configuration, which regulated interfacial carbon activity, promoted stable Cr7C3 precipitation, and facilitated the formation of Ni3Si + γ-Ni(Fe,Cr) eutectics. An appropriate current intensity further facilitated particle redistribution, suppressed fatigue spalling, and enhanced wear resistance by nearly 64.70%. These findings demonstrate that the external coupled field regulates microstructural evolution and wear behavior, providing new processing pathways for tailoring the performance of high-performance composite coatings.
{"title":"Electro-magnetic coupled field-assisted laser-directed energy of Ni-based WC composite coatings: Defect suppression, microstructural evolution, and tribological behavior","authors":"Wanyang Li , Weiwei Liu , Huanqiang Liu , Junjie Tan , Haojun Yang , Baimao Lei , Qiang Chen , Jianrong Song , Zongyu Ma , Tao Li , Yulin Wang , Fengtao Wang , Hongchao Zhang","doi":"10.1016/j.jmapro.2026.01.069","DOIUrl":"10.1016/j.jmapro.2026.01.069","url":null,"abstract":"<div><div>In this study, laser-directed energy deposition (LDED) assisted by an electromagnetic coupled field (EMF) was employed to systematically investigate the effects of current intensity and direction on melt pool dynamics, defect evolution, microstructural evolution, and tribological behavior of composite coatings. The coupled field reshaped melt pool flow patterns and effectively suppress pores and cracks, reducing the defect density to 0.075%. Electromagnetic stirring effect enhanced solute redistribution and grain morphology transformation, unveiling a coupled mechanism of “grain-boundary transformation-defect accumulation-strain release”. EBSD and TEM analyses revealed a microstructural transition from a “WC/W<sub>2</sub>C-dominated” state to a “γ-Ni matrix-Cr carbide co-dominated” configuration, which regulated interfacial carbon activity, promoted stable Cr<sub>7</sub>C<sub>3</sub> precipitation, and facilitated the formation of Ni<sub>3</sub>Si + γ-Ni(Fe,Cr) eutectics. An appropriate current intensity further facilitated particle redistribution, suppressed fatigue spalling, and enhanced wear resistance by nearly 64.70%. These findings demonstrate that the external coupled field regulates microstructural evolution and wear behavior, providing new processing pathways for tailoring the performance of high-performance composite coatings.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 389-412"},"PeriodicalIF":6.8,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080391","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}
Pub Date : 2026-01-24DOI: 10.1016/j.jmapro.2026.01.042
Xufeng Tang , Zhongpeng Zheng , Tianhao Cheng , Xinyi Li , Jiancheng Zhao , Yan Wang , Xiaoming Yin , Xin Jin , Chaojiang Li , Wenhui Li
18Ni300 maraging steel is difficult to machine, commonly exhibiting high cutting forces, degraded surface integrity, and accelerated tool wear. To address these issues, this study investigate surface-active media (SAM) assisted milling using DYKEM High Purity 44 marker ink to activate the Rehbinder effect, in which polar molecules adsorb on the workpiece surface, reduce surface energy, and promote near-surface dislocation motion and microcrack initiation, thereby lowering local fracture toughness. Comparative milling experiments were conducted, and a corresponding ABAQUS/Explicit FEM model was developed by representing the R-effect via reduced fracture energy. Experimentally, SAM reduced average cutting forces by ~25%, while improving surface integrity (suppressed tearing and reduced roughness) and decreasing tool wear under identical conditions. FEM results corroborate the trend, predicting a 39.59% reduction in specific cutting force with SAM.
{"title":"Machining performance and mechanism of surface-active-media-assisted milling for 18Ni300","authors":"Xufeng Tang , Zhongpeng Zheng , Tianhao Cheng , Xinyi Li , Jiancheng Zhao , Yan Wang , Xiaoming Yin , Xin Jin , Chaojiang Li , Wenhui Li","doi":"10.1016/j.jmapro.2026.01.042","DOIUrl":"10.1016/j.jmapro.2026.01.042","url":null,"abstract":"<div><div>18Ni300 maraging steel is difficult to machine, commonly exhibiting high cutting forces, degraded surface integrity, and accelerated tool wear. To address these issues, this study investigate surface-active media (SAM) assisted milling using DYKEM High Purity 44 marker ink to activate the Rehbinder effect, in which polar molecules adsorb on the workpiece surface, reduce surface energy, and promote near-surface dislocation motion and microcrack initiation, thereby lowering local fracture toughness. Comparative milling experiments were conducted, and a corresponding ABAQUS/Explicit FEM model was developed by representing the R-effect via reduced fracture energy. Experimentally, SAM reduced average cutting forces by ~25%, while improving surface integrity (suppressed tearing and reduced roughness) and decreasing tool wear under identical conditions. FEM results corroborate the trend, predicting a 39.59% reduction in specific cutting force with SAM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 317-331"},"PeriodicalIF":6.8,"publicationDate":"2026-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036785","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}
Pub Date : 2026-01-24DOI: 10.1016/j.jmapro.2026.01.072
Brandon Jones , Jyhwen Wang , Bruce Tai , Albert E. Patterson
This study explores the debinding and sintering behavior of copper powder material extrusion (PME) parts with a polylactide (PLA) binder. PME, sometimes known as toolless powder injection molding, is an extrusion-based additive manufacturing (AM) method that produces green parts with high powder loadings (around 90% by weight). These parts require debinding and sintering to be useful, similar to those produced by many traditional methods that use powder and binder as their feedstock. A design-of-experiments (DOE) approach was employed to evaluate the effects of different debinding ramp rates, crucible materials, and ballast types. The processing envelope used in the study reflects the simplified, low-complexity debinding and sintering workflow that is one of the common features of PME, rather than more complex ones focused on optimizing metallurgy. The data showed that the debinding with the alumina ballast produced better mechanical properties, while the sintering with a talc ballast at optimized ramp speeds led to greater density and strength of the parts. The highest ultimate tensile strength (UTS) achieved was 63.98 MPa with a sintered density of 67.55%. The results outline a realistic performance envelope for copper PME processed under these constraints, both revealing and taking advantage of key tradeoffs between debinding strategy, thermal history, and final part integrity. Microscopy analysis revealed that part quality depended heavily on debinding and sintering conditions, with talc ballast producing more consistent surface integrity for sintered parts.
{"title":"Debinding and sintering of copper powder material extrusion parts with a polylactide binder","authors":"Brandon Jones , Jyhwen Wang , Bruce Tai , Albert E. Patterson","doi":"10.1016/j.jmapro.2026.01.072","DOIUrl":"10.1016/j.jmapro.2026.01.072","url":null,"abstract":"<div><div>This study explores the debinding and sintering behavior of copper powder material extrusion (PME) parts with a polylactide (PLA) binder. PME, sometimes known as toolless powder injection molding, is an extrusion-based additive manufacturing (AM) method that produces green parts with high powder loadings (around 90% by weight). These parts require debinding and sintering to be useful, similar to those produced by many traditional methods that use powder and binder as their feedstock. A design-of-experiments (DOE) approach was employed to evaluate the effects of different debinding ramp rates, crucible materials, and ballast types. The processing envelope used in the study reflects the simplified, low-complexity debinding and sintering workflow that is one of the common features of PME, rather than more complex ones focused on optimizing metallurgy. The data showed that the debinding with the alumina ballast produced better mechanical properties, while the sintering with a talc ballast at optimized ramp speeds led to greater density and strength of the parts. The highest ultimate tensile strength (UTS) achieved was 63.98 MPa with a sintered density of 67.55%. The results outline a realistic performance envelope for copper PME processed under these constraints, both revealing and taking advantage of key tradeoffs between debinding strategy, thermal history, and final part integrity. Microscopy analysis revealed that part quality depended heavily on debinding and sintering conditions, with talc ballast producing more consistent surface integrity for sintered parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 332-344"},"PeriodicalIF":6.8,"publicationDate":"2026-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080408","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}
Pub Date : 2026-01-24DOI: 10.1016/j.jmapro.2026.01.053
Yang Sun , Shuoshuo Qu , Yuying Yang , Dongkai Chu , Peng Yao
Zirconia Toughened Alumina ceramics (ZTAs) are widely used in biomedical fields such as artificial joints due to their excellent wear resistance and biocompatibility. However, their high hardness and brittleness lead to poor surface quality and severe wheel wear during grinding. This study proposes laser pre-ablation assisted grinding (LPAG), utilizing a picosecond laser to fabricate vertical textures, checkerboard textures, and parallel textures on the surface of ZTAs to assist the grinding process. Further, by conducting multi-gradient grinding depth experiments, a laser-grinding parameters collaborative optimization model was established. Experimental results demonstrate that LPAG can significantly reduce grinding forces, with the vertical texture structures showing particularly outstanding performance. The maximum reductions in normal grinding force and tangential grinding force reached 82.4% and 95.6%, respectively. When the grinding depth is 0.6 μm, the surface roughness increases in the order of parallel textures, checkerboard textures, and vertical textures. The surface roughness of parallel-textured workpieces after grinding can reach 103.7 nm, whereas the surface roughness of vertical-textured workpieces is comparable to that of non-laser-ablated workpieces. Grinding of non-laser-ablated workpieces generates extensive fractured pits, while the laser-ablated workpieces exhibit dense pores in the heat-affected zone (HAZ) after grinding. By increasing the material removal depth, the HAZ area fraction can be reduced to 7.9%. When the grinding depth decreases from 0.5 μm to 0.1 μm, the surface roughness of vertical-textured workpieces after grinding is reduced from 103.2 nm to 58.1 nm, with the normal grinding force and tangential grinding force decreasing by an average of 29.4% and 61.1%, respectively. Under grinding depths below 0.2 μm, the vertical-textured workpieces exhibit extensive ductile removal, significantly improving the grinding quality. This study demonstrates the feasibility of LPAG combined with gradient parameter optimization to achieve high-efficiency and low-damage machining of ZTAs.
{"title":"Laser pre-ablation assisted grinding process and material removal mechanisms of ZTA ceramics","authors":"Yang Sun , Shuoshuo Qu , Yuying Yang , Dongkai Chu , Peng Yao","doi":"10.1016/j.jmapro.2026.01.053","DOIUrl":"10.1016/j.jmapro.2026.01.053","url":null,"abstract":"<div><div>Zirconia Toughened Alumina ceramics (ZTAs) are widely used in biomedical fields such as artificial joints due to their excellent wear resistance and biocompatibility. However, their high hardness and brittleness lead to poor surface quality and severe wheel wear during grinding. This study proposes laser pre-ablation assisted grinding (LPAG), utilizing a picosecond laser to fabricate vertical textures, checkerboard textures, and parallel textures on the surface of ZTAs to assist the grinding process. Further, by conducting multi-gradient grinding depth experiments, a laser-grinding parameters collaborative optimization model was established. Experimental results demonstrate that LPAG can significantly reduce grinding forces, with the vertical texture structures showing particularly outstanding performance. The maximum reductions in normal grinding force and tangential grinding force reached 82.4% and 95.6%, respectively. When the grinding depth is 0.6 μm, the surface roughness increases in the order of parallel textures, checkerboard textures, and vertical textures. The surface roughness of parallel-textured workpieces after grinding can reach 103.7 nm, whereas the surface roughness of vertical-textured workpieces is comparable to that of non-laser-ablated workpieces. Grinding of non-laser-ablated workpieces generates extensive fractured pits, while the laser-ablated workpieces exhibit dense pores in the heat-affected zone (HAZ) after grinding. By increasing the material removal depth, the HAZ area fraction can be reduced to 7.9%. When the grinding depth decreases from 0.5 μm to 0.1 μm, the surface roughness of vertical-textured workpieces after grinding is reduced from 103.2 nm to 58.1 nm, with the normal grinding force and tangential grinding force decreasing by an average of 29.4% and 61.1%, respectively. Under grinding depths below 0.2 μm, the vertical-textured workpieces exhibit extensive ductile removal, significantly improving the grinding quality. This study demonstrates the feasibility of LPAG combined with gradient parameter optimization to achieve high-efficiency and low-damage machining of ZTAs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 345-358"},"PeriodicalIF":6.8,"publicationDate":"2026-01-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080409","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}
Pub Date : 2026-01-23DOI: 10.1016/j.jmapro.2026.01.040
Shengtao Lin , Kai Wang , Zhengcai Zhao , Yucan Fu
Geometric deviations in near-net-shape (NNS) parts often lead to the undercut defects and demanding numerical control (NC) programming, posing challenges for high-precision machining. To address these issues, this paper proposes a Gaussian mixture model (GMM)-driven non-rigid toolpath morphing framework integrating a novel skeleton-skin strategy. First, a design intent-preserving model is developed to construct feasible machining points (skeleton points) under nonlinear constraints of machining allowance and profile tolerance, addressing undercut regions with negative machining allowance. Second, the nominal toolpath cutter locations (skin points) are morphed to conform to the skeleton points through a GMM-based non-rigid morphing algorithm, bypassing conventional point-curve-surface reconstruction and enabling direct NC programming. Importantly, a Bayesian optimization method utilizing symmetric Hausdorff distance is introduced to determine the optimal parameters for non-rigid morphing. A comprehensive case study on a 3D-printed turbine blade, including the performance evaluations and milling experiments, is conducted to validate the proposed framework. Results show that the machined areas meet the ±0.10 mm profile tolerance requirement, while toolpath generation time is reduced by 31%. This work establishes a critical link between non-rigid shape compensation and efficient NC programming for NNS parts.
{"title":"Design intent-preserving non-rigid toolpath morphing: A novel skeleton-skin method for undercut compensation and rapid numerical control programming of near-net-shape parts","authors":"Shengtao Lin , Kai Wang , Zhengcai Zhao , Yucan Fu","doi":"10.1016/j.jmapro.2026.01.040","DOIUrl":"10.1016/j.jmapro.2026.01.040","url":null,"abstract":"<div><div>Geometric deviations in near-net-shape (NNS) parts often lead to the undercut defects and demanding numerical control (NC) programming, posing challenges for high-precision machining. To address these issues, this paper proposes a Gaussian mixture model (GMM)-driven non-rigid toolpath morphing framework integrating a novel skeleton-skin strategy. First, a design intent-preserving model is developed to construct feasible machining points (skeleton points) under nonlinear constraints of machining allowance and profile tolerance, addressing undercut regions with negative machining allowance. Second, the nominal toolpath cutter locations (skin points) are morphed to conform to the skeleton points through a GMM-based non-rigid morphing algorithm, bypassing conventional point-curve-surface reconstruction and enabling direct NC programming. Importantly, a Bayesian optimization method utilizing symmetric Hausdorff distance is introduced to determine the optimal parameters for non-rigid morphing. A comprehensive case study on a 3D-printed turbine blade, including the performance evaluations and milling experiments, is conducted to validate the proposed framework. Results show that the machined areas meet the ±0.10 mm profile tolerance requirement, while toolpath generation time is reduced by 31%. This work establishes a critical link between non-rigid shape compensation and efficient NC programming for NNS parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 302-316"},"PeriodicalIF":6.8,"publicationDate":"2026-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036784","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}
Pub Date : 2026-01-23DOI: 10.1016/j.jmapro.2026.01.049
Shengyue Tan , Dongqian Wang , Yongliang Liu , Yonglin Cai , Jia Wei , Lei Wang , Uwe Teicher , Albrecht Hänel , Steffen Ihlenfeldt , Zhiqiang Liang
In high-speed hard milling, flank wear prediction of ultra-hard tools is necessary, where accuracy and stability are the two key indicators. Physics-Informed Neural Network (PINN) improves the prediction stability by embedding consistent physical laws into the training process. However, when low-accuracy physical models are commonly employed to constrain the solution space, optimization paths may be misled. This limits the performance of PINNs and their weighted frameworks. To address the issue of low-accuracy physical model misleading the optimization direction, a novel framework termed Physics-Informed Weighted Neural Network based on Prediction Error of Physics-driven models (PIWNN-PEP) is proposed. PIWNN-PEP can enhance the robustness of PINN against low-accuracy models. Furthermore, to capture long-term and complex dependencies over long time scales, a collaborative network xLSTM-Informer (xICNet) with a stacked mLSTM-sLSTM-Informer architecture is established, of which xICNet directly builds a mapping between multidimensional cutting forces and wear values within the PIWNN-PEP framework. The experimental result demonstrates that the proposed method prominently enhances robustness to low-accuracy physical models, compared with existing weighted PINN frameworks. The average tool wear prediction error remains below 1 μm.
{"title":"A Physics-Informed Neural Network framework with strong robustness to low-accuracy physical models for predicting adhesive wear of self-made BNNC milling tool","authors":"Shengyue Tan , Dongqian Wang , Yongliang Liu , Yonglin Cai , Jia Wei , Lei Wang , Uwe Teicher , Albrecht Hänel , Steffen Ihlenfeldt , Zhiqiang Liang","doi":"10.1016/j.jmapro.2026.01.049","DOIUrl":"10.1016/j.jmapro.2026.01.049","url":null,"abstract":"<div><div>In high-speed hard milling, flank wear prediction of ultra-hard tools is necessary, where accuracy and stability are the two key indicators. Physics-Informed Neural Network (PINN) improves the prediction stability by embedding consistent physical laws into the training process. However, when low-accuracy physical models are commonly employed to constrain the solution space, optimization paths may be misled. This limits the performance of PINNs and their weighted frameworks. To address the issue of low-accuracy physical model misleading the optimization direction, a novel framework termed Physics-Informed Weighted Neural Network based on Prediction Error of Physics-driven models (PIWNN-PEP) is proposed. PIWNN-PEP can enhance the robustness of PINN against low-accuracy models. Furthermore, to capture long-term and complex dependencies over long time scales, a collaborative network xLSTM-Informer (xICNet) with a stacked mLSTM-sLSTM-Informer architecture is established, of which xICNet directly builds a mapping between multidimensional cutting forces and wear values within the PIWNN-PEP framework. The experimental result demonstrates that the proposed method prominently enhances robustness to low-accuracy physical models, compared with existing weighted PINN frameworks. The average tool wear prediction error remains below 1 μm.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 285-301"},"PeriodicalIF":6.8,"publicationDate":"2026-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036901","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}
Pub Date : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.052
Shuyu Zhou , Shan Li , Chuanqi Hu , Qingfeng Jia , Rihan Zhang , Yuzhen Zhang , Congcong Cui , Wei Li , Ge Zhang , Xiaodong Liu , Bingshan Liu , Gong Wang
This study presents a method for producing high-performance SiC ceramics with low sintering shrinkage using vat photopolymerization (VPP) of high-solid-content slurry, followed by carbothermal reduction and reactive melt infiltration (RMI). Systematic research of SiC powder surface oxidation parameters revealed and precisely controlled the temperature-time synergy mechanism, achieving over 40% reduction in ultraviolet (UV) absorption. Furthermore, implementation of “selective oxidation of fine particles coupled with coarse particle gradation” strategy enabled formulation of a slurry with 57 vol% solid content and 160 μm curing depth. The debinding shrinkage rate was reduced to less than 2%. Research of carbothermal reduction at 1500 °C transformed SiO₂ into SiC nanowire conversion, successfully improving flexural strength of 308.86 MPa. This technique effectively addresses UV-shielding challenges and impurity formation in pre-oxidized SiC systems, demonstrating significant potential for near-net-shape manufacturing of high-strength RB-SiC components.
{"title":"Vat photopolymerization of high solid-content SiC slurry for near-net-shape high performance ceramic components via selective powder oxidation","authors":"Shuyu Zhou , Shan Li , Chuanqi Hu , Qingfeng Jia , Rihan Zhang , Yuzhen Zhang , Congcong Cui , Wei Li , Ge Zhang , Xiaodong Liu , Bingshan Liu , Gong Wang","doi":"10.1016/j.jmapro.2026.01.052","DOIUrl":"10.1016/j.jmapro.2026.01.052","url":null,"abstract":"<div><div>This study presents a method for producing high-performance SiC ceramics with low sintering shrinkage using vat photopolymerization (VPP) of high-solid-content slurry, followed by carbothermal reduction and reactive melt infiltration (RMI). Systematic research of SiC powder surface oxidation parameters revealed and precisely controlled the temperature-time synergy mechanism, achieving over 40% reduction in ultraviolet (UV) absorption. Furthermore, implementation of “selective oxidation of fine particles coupled with coarse particle gradation” strategy enabled formulation of a slurry with 57 vol% solid content and 160 μm curing depth. The debinding shrinkage rate was reduced to less than 2%. Research of carbothermal reduction at 1500 °C transformed SiO₂ into SiC nanowire conversion, successfully improving flexural strength of 308.86 MPa. This technique effectively addresses UV-shielding challenges and impurity formation in pre-oxidized SiC systems, demonstrating significant potential for near-net-shape manufacturing of high-strength RB-SiC components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 270-284"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036900","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}
Pub Date : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.062
Fan Zhang, Wenlong Hu, Yun Wang, Ji'’an Duan
3D defect detection by multimodal representations is vital in manufacturing field, but simple concatenation from multimodal feature may result in feature interference, thereby reducing fusion effectiveness. Hereby, this study proposes a dynamic background-guided asymmetric knowledge distillation network (DAK-Net) to realize 3D defect detection by using a multimodal fusion that fuses the features of RGB and depth images. The DAK-Net mainly consists of a 2D multi-scale feature extractor, spatial reorganization downsampling, foreground mask dynamic extraction, asymmetric feature fusion, and asymmetric knowledge distillation. The 2D multiscale feature extractor realizes the extraction of RGB image features through a multiscale feature splicing. The spatial reorganization downsampling module implements the spatial-to-channel dimension information reorganization. The foreground mask dynamic extraction module realizes the calculation of anomaly scores only in the foreground region to avoid background interference. The asymmetric feature fusion module is designed for merging features from both RGB and depth images. Concurrently, the framework employs an asymmetric knowledge distillation strategy, in which the teacher network employs conditional normalizing flows to learn a mapping that transforms the complex data distribution into a standard normal distribution, while the student network focuses on regressing the teacher's output specifically on normal, defect-free data. The experiments for DAK-Net achieved average image-level AUROC of 93.6% on MVTec-3D AD dataset and 57.35% on Anomaly-ShapeNet dataset, which demonstrated excellent 3D defect detection performance.
{"title":"Dynamic background-guided asymmetric knowledge distillation network for 3D defect detection","authors":"Fan Zhang, Wenlong Hu, Yun Wang, Ji'’an Duan","doi":"10.1016/j.jmapro.2026.01.062","DOIUrl":"10.1016/j.jmapro.2026.01.062","url":null,"abstract":"<div><div>3D defect detection by multimodal representations is vital in manufacturing field, but simple concatenation from multimodal feature may result in feature interference, thereby reducing fusion effectiveness. Hereby, this study proposes a dynamic background-guided asymmetric knowledge distillation network (DAK-Net) to realize 3D defect detection by using a multimodal fusion that fuses the features of RGB and depth images. The DAK-Net mainly consists of a 2D multi-scale feature extractor, spatial reorganization downsampling, foreground mask dynamic extraction, asymmetric feature fusion, and asymmetric knowledge distillation. The 2D multiscale feature extractor realizes the extraction of RGB image features through a multiscale feature splicing. The spatial reorganization downsampling module implements the spatial-to-channel dimension information reorganization. The foreground mask dynamic extraction module realizes the calculation of anomaly scores only in the foreground region to avoid background interference. The asymmetric feature fusion module is designed for merging features from both RGB and depth images. Concurrently, the framework employs an asymmetric knowledge distillation strategy, in which the teacher network employs conditional normalizing flows to learn a mapping that transforms the complex data distribution into a standard normal distribution, while the student network focuses on regressing the teacher's output specifically on normal, defect-free data. The experiments for DAK-Net achieved average image-level AUROC of 93.6% on MVTec-3D AD dataset and 57.35% on Anomaly-ShapeNet dataset, which demonstrated excellent 3D defect detection performance.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 185-199"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036929","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}
Pub Date : 2026-01-22DOI: 10.1016/j.jmapro.2026.01.064
Sabarinathan Palaniyappan , Narain Kumar Sivakumar , Ahmed S. Dalaq
Peanut hulls (Arachis hypogaea L.) are an abundant and stable biomass resource. In this study, peanut hull powder was incorporated into polylactic acid (PLA) to enhance its recyclability, and biodegradability while imparting the antimicrobial properties of the hull particles. The AHL particles were used as a reinforcing filler to produce composite filaments suitable for fused filament fabrication (FFF) 3D printing. A detailed, step-by-step procedure was developed for preparing the AHL particles, integrating them into PLA, and extruding high-quality filaments. The resulting filaments were evaluated based on their dimensional uniformity, mechanical strength, and elastic modulus, as well as physical properties including porosity, printability, wettability, and melt flow index. Unlike other biomass-based reinforcements in PLA, AHL particles preserved the filament's tensile strength and enhanced its elastic modulus. Component's 3D-printed from the PLA–AHL filaments retained antimicrobial activity and exhibited increased surface hardness. However, higher AHL mass fractions led to greater microvoid formation and rougher surfaces, rendering the material more prone to fracture and slightly reducing its fracture toughness.
{"title":"A peanut-hull-PLA based 3D printing filament with antimicrobial effect","authors":"Sabarinathan Palaniyappan , Narain Kumar Sivakumar , Ahmed S. Dalaq","doi":"10.1016/j.jmapro.2026.01.064","DOIUrl":"10.1016/j.jmapro.2026.01.064","url":null,"abstract":"<div><div>Peanut hulls (<em>Arachis hypogaea</em> L.) are an abundant and stable biomass resource. In this study, peanut hull powder was incorporated into polylactic acid (PLA) to enhance its recyclability, and biodegradability while imparting the antimicrobial properties of the hull particles. The AHL particles were used as a reinforcing filler to produce composite filaments suitable for fused filament fabrication (FFF) 3D printing. A detailed, step-by-step procedure was developed for preparing the AHL particles, integrating them into PLA, and extruding high-quality filaments. The resulting filaments were evaluated based on their dimensional uniformity, mechanical strength, and elastic modulus, as well as physical properties including porosity, printability, wettability, and melt flow index. Unlike other biomass-based reinforcements in PLA, AHL particles preserved the filament's tensile strength and enhanced its elastic modulus. Component's 3D-printed from the PLA–AHL filaments retained antimicrobial activity and exhibited increased surface hardness. However, higher AHL mass fractions led to greater microvoid formation and rougher surfaces, rendering the material more prone to fracture and slightly reducing its fracture toughness.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 242-253"},"PeriodicalIF":6.8,"publicationDate":"2026-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146036898","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}
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