Journal of Manufacturing Processes最新文献_第4页

A 3D anomaly detection method based on multiscale point features for defects in vehicle stamped parts 基于多尺度点特征的汽车冲压件缺陷三维异常检测方法

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-02-02 DOI: 10.1016/j.jmapro.2026.01.102

Yi Liu , Changsheng Zhang , Xingjun Dong , Yufei Yang

In the production process of vehicle stamped parts, local deviations from the nominal geometry of stamped metal sheet, i.e. defects, may occur. The recognizability of these defects is affected by illuminations, and image-based anomaly detection methods cannot effectively detect abnormal vehicle stamped parts. To solve the effect of illuminations, this paper takes the three-dimensional (3D) point cloud of stamped parts as the research object, and proposes a Multiscale Point feature-based 3D anomaly detection method (MP3D). To extract multiscale point features, this paper proposes a local aggregation module. Local aggregation module realizes feature aggregation of disordered points, and the aggregated point features have a larger receptive field. Features of different receptive fields are aggregated for multiscale anomaly detection. In addition, this paper designs a 3D anomaly generation strategy, which generates diverse abnormal samples by constructing local defects. Since the anomaly detection task requires classifying every point of the sample, there is an imbalance in the number of normal points and abnormal points. This paper improves the cross entropy loss for the anomaly detection task. To evaluate the performance of the proposed MP3D, this paper conducts extensive experiments on the MVTec 3D Anomaly Detection (MVTec3D-AD) dataset and a real stamped part dataset. Experimental results demonstrate that MP3D achieves effective anomaly detection performance at both the sample and point levels.

在汽车冲压件的生产过程中，可能会出现与冲压金属板标称几何形状的局部偏差，即缺陷。这些缺陷的识别受到光照的影响，基于图像的异常检测方法无法有效检测出异常的汽车冲压件。为解决光照的影响，本文以冲压件的三维点云为研究对象，提出了一种基于多尺度点特征的三维异常检测方法。为了提取多尺度点特征，本文提出了一种局部聚合模块。局部聚合模块实现了无序点的特征聚合，聚合后的点特征具有更大的接受场。将不同感受野的特征聚合起来进行多尺度异常检测。此外，本文还设计了一种三维异常生成策略，通过构造局部缺陷生成多种异常样本。由于异常检测任务需要对样本的每个点进行分类，所以正常点和异常点的数量是不平衡的。本文对异常检测任务的交叉熵损失进行了改进。为了评估所提出的MP3D的性能，本文在MVTec3D异常检测（MVTec3D-AD）数据集和实际冲压件数据集上进行了大量实验。实验结果表明，MP3D在样本和点水平上都取得了有效的异常检测性能。

{"title":"A 3D anomaly detection method based on multiscale point features for defects in vehicle stamped parts","authors":"Yi Liu , Changsheng Zhang , Xingjun Dong , Yufei Yang","doi":"10.1016/j.jmapro.2026.01.102","DOIUrl":"10.1016/j.jmapro.2026.01.102","url":null,"abstract":"<div><div>In the production process of vehicle stamped parts, local deviations from the nominal geometry of stamped metal sheet, i.e. defects, may occur. The recognizability of these defects is affected by illuminations, and image-based anomaly detection methods cannot effectively detect abnormal vehicle stamped parts. To solve the effect of illuminations, this paper takes the three-dimensional (3D) point cloud of stamped parts as the research object, and proposes a <strong>M</strong>ultiscale <strong>P</strong>oint feature-based <strong>3D</strong> anomaly detection method (<strong>MP3D</strong>). To extract multiscale point features, this paper proposes a local aggregation module. Local aggregation module realizes feature aggregation of disordered points, and the aggregated point features have a larger receptive field. Features of different receptive fields are aggregated for multiscale anomaly detection. In addition, this paper designs a 3D anomaly generation strategy, which generates diverse abnormal samples by constructing local defects. Since the anomaly detection task requires classifying every point of the sample, there is an imbalance in the number of normal points and abnormal points. This paper improves the cross entropy loss for the anomaly detection task. To evaluate the performance of the proposed MP3D, this paper conducts extensive experiments on the MVTec 3D Anomaly Detection (MVTec3D-AD) dataset and a real stamped part dataset. Experimental results demonstrate that MP3D achieves effective anomaly detection performance at both the sample and point levels.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 64-78"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146190295","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

A multiscale simulation framework for composite manufacturing process: Data transfer and experimental verification 复合材料制造过程的多尺度模拟框架：数据传递与实验验证

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-02-05 DOI: 10.1016/j.jmapro.2026.01.063

Mingliang Men , Bao Meng , Jinquan Han , Min Wan

The precise forming of complex thin-walled metallic components can be achieved through composite manufacturing process, where the macroscopic mechanical response and microstructural evolution exhibit significant coupling effects. A general multiscale sequential simulation framework was developed by coupling crystal plasticity finite element (CPFE) and cellular automaton (CA) models. A bidirectional grid mapping and data transfer method was established to address grid incompatibility and physical quantity mapping between different models. During the transfer from the CPFE model to the CA model, the proposed grid refinement mapping approach achieves lossless data transmission compared with the nearest-neighbor mapping method. In the reverse transfer from CA to CPFE, the average data transmission error is also nearly negligible when the coarsened element size approaches the CA cell size. The proposed multiscale simulation framework is applicable to both 2D and 3D conditions. For simulations of a two-stage uniaxial tension with intermediate annealing, the average prediction error of the 2D and 3D models is about 5%. Although the 3D model exhibits slightly improved prediction accuracy, the computational cost is approximately six times that of the 2D model. It indicates that the 2D model provides a reasonable balance between computational efficiency and predictive accuracy. Furthermore, the multiscale framework was applied to simulate the post-heat treatment process of additively manufactured alloy. The prediction errors for the recrystallized volume fraction and average grain size are both below 10%, and the stress-strain curves during subsequent uniaxial tension is predicted with an accuracy of approximately 95%. The results from the two application cases demonstrate that the proposed coupled model can accurately capture the mechanical response during deformation as well as the static recrystallization behavior during annealing, confirming the generality and reliability of the multiscale simulation framework.

复合材料制造工艺可以实现复杂薄壁金属零件的精密成形，其宏观力学响应和微观组织演化表现出显著的耦合效应。通过晶体塑性有限元（CPFE）和元胞自动机（CA）模型的耦合，建立了一个通用的多尺度序列模拟框架。针对不同模型之间的网格不兼容和物理量映射问题，建立了一种双向网格映射和数据传输方法。在CPFE模型到CA模型的转换过程中，与最近邻映射方法相比，本文提出的网格细化映射方法实现了数据的无损传输。在从CA到CPFE的反向传输中，当粗化单元尺寸接近CA单元尺寸时，平均数据传输误差也几乎可以忽略不计。所提出的多尺度模拟框架适用于二维和三维条件。对于中间退火的两阶段单轴拉伸模拟，二维和三维模型的平均预测误差约为5%。虽然3D模型的预测精度略有提高，但计算成本大约是2D模型的6倍。这表明二维模型在计算效率和预测精度之间取得了合理的平衡。此外，采用多尺度框架对增材制造合金的后热处理过程进行了模拟。再结晶体积分数和平均晶粒尺寸的预测误差均在10%以下，后续单轴拉伸过程的应力-应变曲线预测精度约为95%。两个应用实例的结果表明，所提出的耦合模型能够准确地捕捉到变形过程中的力学响应和退火过程中的静态再结晶行为，验证了多尺度模拟框架的通用性和可靠性。

{"title":"A multiscale simulation framework for composite manufacturing process: Data transfer and experimental verification","authors":"Mingliang Men , Bao Meng , Jinquan Han , Min Wan","doi":"10.1016/j.jmapro.2026.01.063","DOIUrl":"10.1016/j.jmapro.2026.01.063","url":null,"abstract":"<div><div>The precise forming of complex thin-walled metallic components can be achieved through composite manufacturing process, where the macroscopic mechanical response and microstructural evolution exhibit significant coupling effects. A general multiscale sequential simulation framework was developed by coupling crystal plasticity finite element (CPFE) and cellular automaton (CA) models. A bidirectional grid mapping and data transfer method was established to address grid incompatibility and physical quantity mapping between different models. During the transfer from the CPFE model to the CA model, the proposed grid refinement mapping approach achieves lossless data transmission compared with the nearest-neighbor mapping method. In the reverse transfer from CA to CPFE, the average data transmission error is also nearly negligible when the coarsened element size approaches the CA cell size. The proposed multiscale simulation framework is applicable to both 2D and 3D conditions. For simulations of a two-stage uniaxial tension with intermediate annealing, the average prediction error of the 2D and 3D models is about 5%. Although the 3D model exhibits slightly improved prediction accuracy, the computational cost is approximately six times that of the 2D model. It indicates that the 2D model provides a reasonable balance between computational efficiency and predictive accuracy. Furthermore, the multiscale framework was applied to simulate the post-heat treatment process of additively manufactured alloy. The prediction errors for the recrystallized volume fraction and average grain size are both below 10%, and the stress-strain curves during subsequent uniaxial tension is predicted with an accuracy of approximately 95%. The results from the two application cases demonstrate that the proposed coupled model can accurately capture the mechanical response during deformation as well as the static recrystallization behavior during annealing, confirming the generality and reliability of the multiscale simulation framework.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 245-266"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146191360","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

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 : 2026-03-15 Epub 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。

{"title":"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","authors":"Tejanshu Sekhar Sahu , Ranjeet Kumar Sahu , Prasad Krishna","doi":"10.1016/j.jmapro.2026.02.004","DOIUrl":"10.1016/j.jmapro.2026.02.004","url":null,"abstract":"<div><div>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 MoS<sub>2</sub> nanoparticle suspended dielectric. The inhouse fabricated electrodes facilitated accurate texturing at the microscale by closely controlling the process parameters, and the addition of MoS<sub>2</sub> particles was found to have a significant influence on the tribological behaviour of the developed textured surfaces during interfacial interaction. The MoS<sub>2</sub> 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 MoS<sub>2</sub> 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 MoS<sub>2</sub> 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 Mo<img>S tribofilm.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 386-403"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146191441","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

Targeted disentangling of melt pool features for layer-wise printing quality assessment in L-PBF 基于熔池特征的分层印刷质量评估

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-02-04 DOI: 10.1016/j.jmapro.2026.01.074

Hao Jiang , Zhibin Zhao , Xingwu Zhang , Chenxi Wang , Huihui Miao , Xuefeng Chen

Ensuring the stability and consistency of laser-powder bed fusion (L-PBF) additive manufacturing remains a persistent challenge in the industry, which has led to growing research interest in process monitoring in recent years. Among various monitoring techniques, coaxial melt pool imaging stands out as one of the most promising approaches. However, achieving stable and scalable print quality assessment based on coaxial melt pool images remains challenging. Deep learning methods often suffer from limited interpretability and weak generalization, while traditional image processing approaches tend to lack flexibility and exhibit low discriminative accuracy. To address these issues, this paper proposes an interpretable directional feature disentanglement framework designed to enable the extraction of strongly-correlated physical features with structures from melt pool images for printing quality assessment. Specifically, a feature anchoring module is incorporated into a variational autoencoder (VAE) generation framework to stabilize the position of the disentangled target features in the latent space. A multi-stage, multi-task training strategy is then introduced to progressively accomplish melt pool image reconstruction, feature anchoring, and feature disentanglement. Finally, the effectiveness of the proposed framework is verified by cross-device and cross-material experiments involving unsupported overhang structures, which proves that it is a technology worthy of engineering promotion.

确保激光粉末床融合（L-PBF）增材制造的稳定性和一致性仍然是行业面临的一个持续挑战，这导致近年来对过程监控的研究兴趣日益浓厚。在各种监测技术中，同轴熔池成像是最有前途的方法之一。然而，基于同轴熔池图像实现稳定和可扩展的打印质量评估仍然具有挑战性。深度学习方法往往具有有限的可解释性和弱泛化，而传统的图像处理方法往往缺乏灵活性和低判别精度。为了解决这些问题，本文提出了一个可解释的定向特征解缠框架，旨在从熔池图像中提取与结构强相关的物理特征，用于打印质量评估。具体而言，在变分自编码器（VAE）生成框架中加入特征锚定模块，以稳定解纠缠目标特征在潜在空间中的位置。然后引入一种多阶段、多任务的训练策略，逐步完成熔池图像重建、特征锚定和特征解纠缠。最后，通过无支撑悬挑结构的跨装置、跨材料试验验证了该框架的有效性，证明了该框架是一种值得工程推广的技术。

{"title":"Targeted disentangling of melt pool features for layer-wise printing quality assessment in L-PBF","authors":"Hao Jiang , Zhibin Zhao , Xingwu Zhang , Chenxi Wang , Huihui Miao , Xuefeng Chen","doi":"10.1016/j.jmapro.2026.01.074","DOIUrl":"10.1016/j.jmapro.2026.01.074","url":null,"abstract":"<div><div>Ensuring the stability and consistency of laser-powder bed fusion (L-PBF) additive manufacturing remains a persistent challenge in the industry, which has led to growing research interest in process monitoring in recent years. Among various monitoring techniques, coaxial melt pool imaging stands out as one of the most promising approaches. However, achieving stable and scalable print quality assessment based on coaxial melt pool images remains challenging. Deep learning methods often suffer from limited interpretability and weak generalization, while traditional image processing approaches tend to lack flexibility and exhibit low discriminative accuracy. To address these issues, this paper proposes an interpretable directional feature disentanglement framework designed to enable the extraction of strongly-correlated physical features with structures from melt pool images for printing quality assessment. Specifically, a feature anchoring module is incorporated into a variational autoencoder (VAE) generation framework to stabilize the position of the disentangled target features in the latent space. A multi-stage, multi-task training strategy is then introduced to progressively accomplish melt pool image reconstruction, feature anchoring, and feature disentanglement. Finally, the effectiveness of the proposed framework is verified by cross-device and cross-material experiments involving unsupported overhang structures, which proves that it is a technology worthy of engineering promotion.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 231-244"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146191440","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

Experimental investigation and numerical validation of drilling machinability in FDM-printed PLA parts fdm打印PLA零件钻削加工性的试验研究与数值验证

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-01-31 DOI: 10.1016/j.jmapro.2026.01.079

Uğur Köklü , Levent Urtekin , Erkin Akdoğan , Faik Yılan , Murat Demiral

Fused Deposition Modeling (FDM) is a widely used additive manufacturing technique that fabricates components through layer-by-layer deposition of thermoplastic materials. Due to its biodegradability, dimensional stability, and favorable flow behavior, polylactic acid (PLA) has become one of the most commonly employed polymers in extrusion-based printing. This study investigates the influence of extrusion temperature, infill pattern, and infill density on the mechanical performance and drilling machinability of FDM-printed PLA components. Tensile tests and hardness measurements were conducted to evaluate mechanical behavior, while drilling machinability was assessed through thrust force measurements and digital microscopy. In parallel, a three-dimensional finite element model was developed using ABAQUS/Explicit to capture damage initiation and interfacial degradation, providing numerical validation of the experimental results. The findings demonstrate that infill density is the dominant parameter, with higher densities leading to significant improvements in tensile strength, elastic modulus, and surface hardness. The grid infill at full density and elevated extrusion temperature yielded the highest mechanical performance, achieving a tensile strength of 40.3 MPa and a modulus of 3050 MPa. In contrast, the hexagonal infill pattern offered a favorable balance between mechanical strength and drilling performance, exhibiting reduced thrust force and improved damage resistance. Optimal drilling conditions were identified at 3000 rpm and 150 mm/min, minimizing delamination, burr formation, and thermal damage. Overall, this work highlights the strong coupling between process parameters, internal architecture, and numerical modeling in governing the structural integrity and machinability of FDM-fabricated PLA parts.

熔融沉积建模（FDM）是一种广泛应用的增材制造技术，它通过热塑性材料的逐层沉积来制造部件。由于其可生物降解性、尺寸稳定性和良好的流动性，聚乳酸（PLA）已成为挤出打印中最常用的聚合物之一。研究了挤出温度、填充方式和填充密度对fdm打印PLA部件力学性能和钻削加工性的影响。通过拉伸试验和硬度测量来评估机械行为，而通过推力测量和数字显微镜来评估钻孔可加工性。同时，利用ABAQUS/Explicit建立三维有限元模型，捕捉损伤起裂和界面退化过程，为实验结果提供数值验证。研究结果表明，填充密度是主要参数，密度越高，抗拉强度、弹性模量和表面硬度都有显著提高。在全密度和提高挤压温度下，网格填充材料的力学性能最高，抗拉强度为40.3 MPa，模量为3050 MPa。相比之下，六边形充填模式在机械强度和钻井性能之间取得了良好的平衡，表现出较低的推力和较好的抗损伤能力。在3000转/分钟和150毫米/分钟的速度下确定了最佳钻井条件，最大限度地减少了分层、毛刺形成和热损伤。总的来说，这项工作强调了工艺参数、内部结构和数值建模之间的强耦合，以控制fdm制造的PLA零件的结构完整性和可加工性。

{"title":"Experimental investigation and numerical validation of drilling machinability in FDM-printed PLA parts","authors":"Uğur Köklü , Levent Urtekin , Erkin Akdoğan , Faik Yılan , Murat Demiral","doi":"10.1016/j.jmapro.2026.01.079","DOIUrl":"10.1016/j.jmapro.2026.01.079","url":null,"abstract":"<div><div>Fused Deposition Modeling (FDM) is a widely used additive manufacturing technique that fabricates components through layer-by-layer deposition of thermoplastic materials. Due to its biodegradability, dimensional stability, and favorable flow behavior, polylactic acid (PLA) has become one of the most commonly employed polymers in extrusion-based printing. This study investigates the influence of extrusion temperature, infill pattern, and infill density on the mechanical performance and drilling machinability of FDM-printed PLA components. Tensile tests and hardness measurements were conducted to evaluate mechanical behavior, while drilling machinability was assessed through thrust force measurements and digital microscopy. In parallel, a three-dimensional finite element model was developed using ABAQUS/Explicit to capture damage initiation and interfacial degradation, providing numerical validation of the experimental results. The findings demonstrate that infill density is the dominant parameter, with higher densities leading to significant improvements in tensile strength, elastic modulus, and surface hardness. The grid infill at full density and elevated extrusion temperature yielded the highest mechanical performance, achieving a tensile strength of 40.3 MPa and a modulus of 3050 MPa. In contrast, the hexagonal infill pattern offered a favorable balance between mechanical strength and drilling performance, exhibiting reduced thrust force and improved damage resistance. Optimal drilling conditions were identified at 3000 rpm and 150 mm/min, minimizing delamination, burr formation, and thermal damage. Overall, this work highlights the strong coupling between process parameters, internal architecture, and numerical modeling in governing the structural integrity and machinability of FDM-fabricated PLA parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 34-48"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146190297","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

A high-efficiency laser processing array micro-holes method based on acousto-optic deflector and galvanometer hybrid 基于声光偏转器和振镜混合的高效激光处理阵列微孔方法

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-02-03 DOI: 10.1016/j.jmapro.2026.01.061

Zihao Feng , Yufeng Liang , Tian Zhang , Youmin Rong , Hongping Yang , Long Chen , Xiufeng Liu , Guojun Zhang , Yu Huang

Array micro-holes have been widely used as optical apertures for ambient light sensors in display panels. Existing galvanometer processing method suffers from inefficient fabrication of the vast number of micro-holes (< 30 μm) due to the scanning speed limitations imposed by the mechanical inertia of mirror oscillation. To address this issue, a laser processing method based on acousto-optic deflector (AOD) and galvanometer hybrid is proposed, centered on a discrete-trajectory partitioning framework tailored for discontinuous, high-density point arrays. The galvanometer trajectory is derived from processing area divided by fully exploiting the AOD scanning field, reducing the path length and number of galvanometer jumps. The target trajectory is determined by pulse distribution from micro-holes, and the AOD displacements are derived through coordinate transformation to the result of positional vector subtraction. The experimental results indicated that compared with galvanometer-only processing, the maximum galvanometer following errors of proposed method are reduced by up to 89.8% with better consistency and higher processing quality. Meanwhile, the total processing time of given drawings decreased from 2.157–3.813 s to 0.487–0.875 s, reduced by up to 77.4%.

阵列微孔被广泛用作显示面板环境光传感器的光学孔径。由于反射镜振荡的机械惯性限制了扫描速度，现有的振镜加工方法在制造大量微孔（< 30 μm）时效率低下。为了解决这一问题，提出了一种基于声光偏转器（AOD）和振镜混合的激光加工方法，该方法以针对不连续高密度点阵列量身定制的离散轨迹划分框架为中心。通过充分利用AOD扫描场，减少了路径长度和振镜跳跃次数，得到了加工区域划分的振镜轨迹。利用微孔脉冲分布确定目标轨迹，通过坐标变换到位置矢量减法的结果得到AOD位移。实验结果表明，与仅用振镜处理相比，该方法最大振镜跟踪误差降低了89.8%，一致性更好，加工质量更高。同时，给定图纸的总处理时间从2.157-3.813 s减少到0.487-0.875 s，减少幅度达77.4%。

{"title":"A high-efficiency laser processing array micro-holes method based on acousto-optic deflector and galvanometer hybrid","authors":"Zihao Feng , Yufeng Liang , Tian Zhang , Youmin Rong , Hongping Yang , Long Chen , Xiufeng Liu , Guojun Zhang , Yu Huang","doi":"10.1016/j.jmapro.2026.01.061","DOIUrl":"10.1016/j.jmapro.2026.01.061","url":null,"abstract":"<div><div>Array micro-holes have been widely used as optical apertures for ambient light sensors in display panels. Existing galvanometer processing method suffers from inefficient fabrication of the vast number of micro-holes (< 30 μm) due to the scanning speed limitations imposed by the mechanical inertia of mirror oscillation. To address this issue, a laser processing method based on acousto-optic deflector (AOD) and galvanometer hybrid is proposed, centered on a discrete-trajectory partitioning framework tailored for discontinuous, high-density point arrays. The galvanometer trajectory is derived from processing area divided by fully exploiting the AOD scanning field, reducing the path length and number of galvanometer jumps. The target trajectory is determined by pulse distribution from micro-holes, and the AOD displacements are derived through coordinate transformation to the result of positional vector subtraction. The experimental results indicated that compared with galvanometer-only processing, the maximum galvanometer following errors of proposed method are reduced by up to 89.8% with better consistency and higher processing quality. Meanwhile, the total processing time of given drawings decreased from 2.157–3.813 s to 0.487–0.875 s, reduced by up to 77.4%.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 206-218"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146190737","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

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 : 2026-03-15 Epub 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。

{"title":"Recognition and analysis of welding images with lightweight semantic segmentation model improved by attention mechanism during ARM laser welding","authors":"Hua Liu , Chengwen Gao , Yu Chen , Yuanjie Peng , Siyang Chen , Miao Yang , Mengjia Xu","doi":"10.1016/j.jmapro.2026.01.089","DOIUrl":"10.1016/j.jmapro.2026.01.089","url":null,"abstract":"<div><div>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 (<em>P</em>) of 95.75%, and recall (<em>R</em>) 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.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 404-423"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146191480","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

Joint enhancement in LDED joining SLM-fabricated AlSi10Mg: A combined strategy based on ultrasonic vibration assistance, filling material and heat treatment LDED与slm制备AlSi10Mg的联合增强：基于超声振动辅助、填充材料和热处理的组合策略

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-03-15 Epub Date: 2026-02-02 DOI: 10.1016/j.jmapro.2026.01.082

Zhiguo Wang , Tianqi Zhao , Yingwei Zhang , Zhenfeng He , Yuhui Zhao , Jibin Zhao , Qiwei Wang

The high-performance joining of selective laser melted aluminum alloy by laser direct energy deposition presents a significant challenge owing to the obvious interfacial micro-performance valley, pores and microstructural differences between the joint region and base. A combined strategy based on three aspects is adopted, which includes ultrasonic vibration assistance (UVA), filling material and heat treatment. The joint microstructure evolution, defect distribution, microhardness and tensile performance of the different strategies were discussed in detail. The results showed that the joining of samples with UVA and changing the filling material strategy improved the microhardness of most areas in the joint and eliminated the pores distributed at the interface. However, the decrease in the interfacial microhardness mainly caused by eutectic silicon aggregation at the fusion line still restricted the joint strength. Fortunately, adding a post T6 heat treatment could significantly improve the weakness in the interface performance. For the high-performance laser deposition energy joining of SLM-built AlSi10Mg, each of the three regulation aspects is essential. The combined strategy based on three aspects can realize that the ultimate tensile strength of the joining samples increased to a maximum of 303 MPa, and the elongation improved to 5.7%, which was closely related to the formation of nanoscale (AlₓSi₁₋ₓ)₃(Sc,Zr) precipitates, nanoscale Si precipitates, Mg solution strengthening and low porosity. Our study offers a novel method for future high-strength welding of SLMed aluminum and the fabrication of large-sized parts via a hybrid additive manufacturing process.

激光直接能量沉积对选择性激光熔化铝合金的高性能连接提出了很大的挑战，因为接合区和基体之间存在明显的界面微性能谷、气孔和显微组织差异。采用超声助振（UVA）、填充材料和热处理三个方面的组合策略。详细讨论了不同策略的接头组织演变、缺陷分布、显微硬度和拉伸性能。结果表明：UVA的加入和填充材料策略的改变提高了接头大部分区域的显微硬度，消除了分布在界面处的孔隙；然而，界面显微硬度的降低主要是由熔合线上的共晶硅聚集引起的，这仍然限制了接头的强度。幸运的是，加入T6后热处理可以显著改善界面性能的弱点。对于slm构建的AlSi10Mg的高性能激光沉积能量连接，这三个方面的调节都是必不可少的。基于三方面的组合策略可以实现连接试样的极限抗拉强度提高到最大303 MPa，伸长率提高到5.7%，这与纳米级（AlₓSi₁₁ₓ）₃（Sc,Zr）析出相的形成、纳米级Si析出相的形成、Mg溶液强化和低孔隙率密切相关。我们的研究为未来SLMed铝的高强度焊接和通过混合增材制造工艺制造大型零件提供了一种新的方法。

{"title":"Joint enhancement in LDED joining SLM-fabricated AlSi10Mg: A combined strategy based on ultrasonic vibration assistance, filling material and heat treatment","authors":"Zhiguo Wang , Tianqi Zhao , Yingwei Zhang , Zhenfeng He , Yuhui Zhao , Jibin Zhao , Qiwei Wang","doi":"10.1016/j.jmapro.2026.01.082","DOIUrl":"10.1016/j.jmapro.2026.01.082","url":null,"abstract":"<div><div>The high-performance joining of selective laser melted aluminum alloy by laser direct energy deposition presents a significant challenge owing to the obvious interfacial micro-performance valley, pores and microstructural differences between the joint region and base. A combined strategy based on three aspects is adopted, which includes ultrasonic vibration assistance (UVA), filling material and heat treatment. The joint microstructure evolution, defect distribution, microhardness and tensile performance of the different strategies were discussed in detail. The results showed that the joining of samples with UVA and changing the filling material strategy improved the microhardness of most areas in the joint and eliminated the pores distributed at the interface. However, the decrease in the interfacial microhardness mainly caused by eutectic silicon aggregation at the fusion line still restricted the joint strength. Fortunately, adding a post T6 heat treatment could significantly improve the weakness in the interface performance. For the high-performance laser deposition energy joining of SLM-built AlSi10Mg, each of the three regulation aspects is essential. The combined strategy based on three aspects can realize that the ultimate tensile strength of the joining samples increased to a maximum of 303 MPa, and the elongation improved to 5.7%, which was closely related to the formation of nanoscale (AlₓSi₁₋ₓ)₃(Sc,Zr) precipitates, nanoscale Si precipitates, Mg solution strengthening and low porosity. Our study offers a novel method for future high-strength welding of SLMed aluminum and the fabrication of large-sized parts via a hybrid additive manufacturing process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"161 ","pages":"Pages 115-135"},"PeriodicalIF":6.8,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146190299","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

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 : 2026-03-15 Epub 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":"2026-03-15","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

Enhancement of the wear resistance of NiCu alloy reinforced by graphene nanoplatelets and WC particles through circular oscillating laser directed energy deposition 圆振荡激光定向能沉积法增强石墨烯纳米片和WC颗粒增强NiCu合金的耐磨性

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-29 DOI: 10.1016/j.jmapro.2026.01.092

Yining Hu , Siyu Chen , Guang Yang , Lei Zhou , Wanhui Zhao , Tao Wang , Yang Li

This study aims to develop a NiCu-based composite with superior wear resistance and self-lubricating properties for critical tribological applications in aerospace and energy sectors. The NiCu, NiCu/graphene nanoplatelets (GNPs), NiCu/WC, and NiCu/GNPs/WC composites were fabricated on A3 steel substrates using circular oscillating laser-directed energy deposition (COL-DED) technology. The high-frequency laser beam oscillation effectively stirred the molten pool, refining grain structure and enhancing material properties. Microstructural analysis revealed that four materials consisted primarily of equiaxed grains with minor columnar grains. The grain sizes of the NiCu, NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC materials were 10.74 μm, 7.80 μm, 8.35 μm, and 7.12 μm, respectively, indicating that GNPs had a superior grain refinement effect compared to WC. The main phases of the NiCu/GNPs/WC composite were Ni-Cu, C, WC, and W₂C. Under the action of the laser, GNPs melted and formed amorphous graphite-Ni-Cu (G-Ni-Cu) hybrid spheres at the grain boundaries, while WC particles embedded in the NiCu matrix partially melted to form W₂C, WC, and other carbides. Compared to NiCu, the hardness of the NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC composites increased by approximately 11.36%, 6.70%, and 22.57%, respectively, while their wear mass loss was reduced by about 62.8%, 81.4%, and 85.4%, respectively. The NiCu/GNPs/WC composite exhibited the optimal wear resistance. The G-Ni-Cu graphite spheres reduced wear by pinning grain boundaries and forming a self-lubricating film at the wear interface, while WC particles provided support. Their synergistic effect significantly enhanced the wear performance of the NiCu alloy.

本研究旨在开发一种具有优异耐磨性和自润滑性能的nicu基复合材料，用于航空航天和能源领域的关键摩擦学应用。采用圆振荡激光定向能沉积（colded）技术在A3钢基体上制备NiCu、NiCu/石墨烯纳米片（GNPs）、NiCu/WC和NiCu/GNPs/WC复合材料。高频激光束振荡有效地搅拌熔池，细化晶粒组织，提高材料性能。显微组织分析表明，四种材料主要由等轴晶和少量柱状晶组成。NiCu、NiCu/GNPs、NiCu/WC和NiCu/GNPs/WC的晶粒尺寸分别为10.74 μm、7.80 μm、8.35 μm和7.12 μm，表明GNPs的晶粒细化效果优于WC。NiCu/GNPs/WC复合材料的主要相为Ni-Cu、C、WC和W2C。在激光作用下，GNPs在晶界处熔化形成非晶态石墨- ni - cu （G-Ni-Cu）杂化球，而嵌套在NiCu基体中的WC颗粒部分熔化形成W2C、WC等碳化物。与NiCu相比，NiCu/GNPs、NiCu/WC和NiCu/GNPs/WC复合材料的硬度分别提高了约11.36%、6.70%和22.57%，磨损质量损失分别降低了约62.8%、81.4%和85.4%。NiCu/GNPs/WC复合材料的耐磨性最佳。G-Ni-Cu石墨球通过固定晶界和在磨损界面形成自润滑膜来减少磨损，而WC颗粒则提供支撑。它们的协同作用显著提高了NiCu合金的磨损性能。

{"title":"Enhancement of the wear resistance of NiCu alloy reinforced by graphene nanoplatelets and WC particles through circular oscillating laser directed energy deposition","authors":"Yining Hu , Siyu Chen , Guang Yang , Lei Zhou , Wanhui Zhao , Tao Wang , Yang Li","doi":"10.1016/j.jmapro.2026.01.092","DOIUrl":"10.1016/j.jmapro.2026.01.092","url":null,"abstract":"<div><div>This study aims to develop a NiCu-based composite with superior wear resistance and self-lubricating properties for critical tribological applications in aerospace and energy sectors. The NiCu, NiCu/graphene nanoplatelets (GNPs), NiCu/WC, and NiCu/GNPs/WC composites were fabricated on A3 steel substrates using circular oscillating laser-directed energy deposition (COL-DED) technology. The high-frequency laser beam oscillation effectively stirred the molten pool, refining grain structure and enhancing material properties. Microstructural analysis revealed that four materials consisted primarily of equiaxed grains with minor columnar grains. The grain sizes of the NiCu, NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC materials were 10.74 μm, 7.80 μm, 8.35 μm, and 7.12 μm, respectively, indicating that GNPs had a superior grain refinement effect compared to WC. The main phases of the NiCu/GNPs/WC composite were Ni-Cu, C, WC, and W<sub>2</sub>C. Under the action of the laser, GNPs melted and formed amorphous graphite-Ni-Cu (G-Ni-Cu) hybrid spheres at the grain boundaries, while WC particles embedded in the NiCu matrix partially melted to form W<sub>2</sub>C, WC, and other carbides. Compared to NiCu, the hardness of the NiCu/GNPs, NiCu/WC, and NiCu/GNPs/WC composites increased by approximately 11.36%, 6.70%, and 22.57%, respectively, while their wear mass loss was reduced by about 62.8%, 81.4%, and 85.4%, respectively. The NiCu/GNPs/WC composite exhibited the optimal wear resistance. The G-Ni-Cu graphite spheres reduced wear by pinning grain boundaries and forming a self-lubricating film at the wear interface, while WC particles provided support. Their synergistic effect significantly enhanced the wear performance of the NiCu alloy.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"160 ","pages":"Pages 571-580"},"PeriodicalIF":6.8,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146080330","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