Journal of Manufacturing Processes最新文献

英文中文

An unsupervised welding quality detection method based on high-quality condition-guided diffusion reconstruction 基于高质量状态引导扩散重构的无监督焊接质量检测方法

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-27 DOI: 10.1016/j.jmapro.2026.01.059

Xin Chen , Bin Zi , Kai Tang , Wenjun Tang , Yuan Li

Radiographic testing of welds plays a critical role in ensuring the quality of welded manufacturing, because X-ray imaging technology can clearly reveal the internal structure of the weld area. However, existing mainstream detection methods rely on manual inspection or supervised detection, both of which are susceptible to limitations imposed by subjective factors and model generalization capabilities, respectively. Therefore, this paper proposes a two-stage unsupervised detection framework based on reconstruction to achieve fast and accurate detection of welding quality. First, an algorithm for generating simulated defects based on real welding defect characteristics is designed. A dataset encompassing multiple defect types is constructed, and image quality is further optimized through data augmentation algorithms. Second, a high-quality diffusion model (H-DiffuM) based on residual learning is proposed, which achieves accurate reconstruction of weld defect images through a residual-guided noise scheduling mechanism. Finally, by combining the gated mechanism with frequency domain features of X-ray images, a multi-scale frequency domain attention fusion module (MFDAFM) is designed and embedded into the discriminative network (Seg-net), thereby enhancing detection accuracy. The final experimental results demonstrated that the proposed method achieved 97.80% in pixel-level AUROC and 93.34% in AP, which surpassed the current state-of-the-art unsupervised detection approaches. Meanwhile, the inspection method described in this paper offers the advantages of rapid detection speed and high precision, demonstrating its potential for application in the rapid assessment of welding quality.

焊缝的射线检测对于保证焊接制造质量起着至关重要的作用，因为x射线成像技术可以清晰地显示焊缝区域的内部结构。然而，现有的主流检测方法依赖于人工检测或监督检测，这两种方法都容易受到主观因素和模型泛化能力的限制。为此，本文提出了一种基于重构的两阶段无监督检测框架，以实现对焊接质量的快速准确检测。首先，设计了一种基于实际焊接缺陷特征的模拟缺陷生成算法。构建了包含多种缺陷类型的数据集，并通过数据增强算法进一步优化了图像质量。其次，提出了一种基于残差学习的高质量扩散模型（H-DiffuM），该模型通过残差引导的噪声调度机制实现焊缝缺陷图像的精确重建。最后，将门控机制与x射线图像的频域特征相结合，设计了多尺度频域注意力融合模块（MFDAFM），并将其嵌入到判别网络（Seg-net）中，从而提高了检测精度。最终的实验结果表明，该方法在像素级AUROC上达到97.80%，在AP上达到93.34%，超过了目前最先进的无监督检测方法。同时，本文所描述的检测方法具有检测速度快、精度高的优点，在焊接质量的快速评估中具有应用潜力。

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引用次数: 0

Filament-assisted combined pulse laser ablation of metal targets: Mechanistic insights, efficiency enhancement, and spatial tolerance 细丝辅助联合脉冲激光烧蚀金属目标：机理见解，效率提高，和空间公差

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-26 DOI: 10.1016/j.jmapro.2026.01.050

Zhou Li , Junyang Xu , Yuyang Chen , Kai Li , Lu Zhang , Xianshi Jia , Cong Wang , Ji'an Duan

Filament-assisted combined pulse laser (CPL) ablation, coupling a millisecond laser with a nanosecond-laser-induced air filament, is demonstrated to achieve high-efficiency metal ablation under near-on-target power densities of 10³-10⁴ W/cm². An integrated diagnostic system, combining transient temperature measurement and time-resolved imaging, enables direct identification of the coupled processes of melting and filament-driven expulsion, with the assistance of post-process three-dimensional morphology analysis. The filament assistance yields nearly an order-of-magnitude enhancement in ablation volume and material removal rate compared with millisecond laser irradiation alone. Crater depth is increased by more than a factor of two, while smaller and more stable laser-supported combustion waves are maintained. Moreover, CPL exhibits pronounced spatial tolerance, sustaining significant efficiency gains even under deliberate lateral misalignment and thereby confirming its robustness for non-ideal and long-range conditions. These findings highlight both mechanistic insight and performance advancement, consolidating filament-assisted CPL as a robust and scalable strategy for efficient, stable, and spatially tolerant ablation in high-energy laser damage.

在接近目标的功率密度为103-104 W/cm2的情况下，将毫秒激光与纳秒激光诱导的空气灯丝耦合在一起的灯丝辅助组合脉冲激光（CPL）烧蚀可以实现高效率的金属烧蚀。一个集成的诊断系统，结合瞬态温度测量和时间分辨成像，可以直接识别熔融和细丝驱动的排出耦合过程，并辅以加工后的三维形态分析。与单独的毫秒激光照射相比，灯丝辅助在烧蚀体积和材料去除率方面几乎提高了一个数量级。弹坑深度增加了两倍以上，同时保持了更小、更稳定的激光支持燃烧波。此外，CPL表现出明显的空间容忍度，即使在故意的横向不对准下也能保持显著的效率提高，从而证实了其在非理想和远程条件下的稳健性。这些发现强调了机理的洞察和性能的进步，巩固了细丝辅助CPL作为高效、稳定和空间容忍度高的高能激光损伤烧蚀的稳健和可扩展策略。

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引用次数: 0

Machining performance and mechanism of surface-active-media-assisted milling for 18Ni300 18Ni300表面主动介质辅助铣削加工性能及机理

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-24 DOI: 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.

18Ni300马氏体时效钢难以加工，通常表现出高切削力、表面完整性退化和加速刀具磨损。为了解决这些问题，本研究研究了使用DYKEM高纯度44标记墨水的表面活性介质（SAM）辅助铣削，以激活Rehbinder效应，其中极性分子吸附在工件表面，降低表面能，促进近表面位错运动和微裂纹的形成，从而降低局部断裂韧性。通过对比铣削试验，建立了相应的ABAQUS/Explicit有限元模型，通过减小断裂能来表示r效应。在实验中，在相同条件下，SAM使平均切削力降低了25%，同时改善了表面完整性（抑制撕裂和降低粗糙度）并减少了刀具磨损。有限元分析结果证实了这一趋势，预测使用SAM后比切削力降低了39.59%。

引用次数: 0

Vat photopolymerization of high solid-content SiC slurry for near-net-shape high performance ceramic components via selective powder oxidation 高固相含量SiC浆料通过选择性粉末氧化还原光聚合制备近净形高性能陶瓷元件

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-22 DOI: 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.

本研究提出了一种利用高固含量浆料的还原光聚合（VPP）、碳热还原和反应熔融渗透（RMI）制备高性能低烧结收缩率SiC陶瓷的方法。系统研究了SiC粉体表面氧化参数，揭示并精确控制了温度-时间协同机理，实现了紫外吸收降低40%以上。此外，“细颗粒选择性氧化与粗颗粒级配”策略的实施使泥浆的固体含量达到57 vol%，固化深度为160 μm。脱脂收缩率降至2%以下。研究在1500℃下碳热还原将SiO₂转化为SiC纳米线，成功地提高了308.86 MPa的抗弯强度。该技术有效地解决了预氧化SiC系统中的紫外线屏蔽挑战和杂质形成问题，展示了高强度RB-SiC组件的近净形状制造的巨大潜力。

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引用次数: 0

Snaking chatter: Mechanism and mitigation 蛇形颤振：机制和缓解

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-21 DOI: 10.1016/j.jmapro.2026.01.037

Luke Rimac, Philip Koshy, Mohamed Elbestawi

This research investigated snaking chatter in grooving blades that causes an inconsistent increase in groove width relative to the tool width, often exceeding tolerance limits in precision applications. Contrary to the suggestion in the literature attributing snaking chatter to mode coupling, this study proposed and verified the hypothesis that it arises instead from regenerative effects on the side walls of the machined groove. With the application of a conventional stability-based process design shown infeasible in addressing snaking chatter, a counterintuitive mitigation strategy that concomitantly delivers a 450% increase in the material removal rate over the state of the art is demonstrated.

本研究调查了开槽刀片中的蛇形颤振，该颤振导致槽宽相对于刀具宽度的不一致增加，在精密应用中经常超过公差限制。与文献中将蛇形颤振归因于模态耦合的建议相反，本研究提出并验证了它是由加工槽侧壁的再生效应引起的假设。由于传统的基于稳定性的工艺设计在解决蛇形颤振问题上不可行，因此展示了一种违反直觉的缓解策略，该策略同时将材料去除率提高了450%。

引用次数: 0

Experimental and numerical investigation of shape asymmetry in slit die foam extrusion 狭缝模泡沫挤压成形不对称的实验与数值研究

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-21 DOI: 10.1016/j.jmapro.2026.01.073

Claudio Esposito, Marco Trofa, Daniele Tammaro, Lorenzo Lombardi, Gaetano D’Avino, Pier Luca Maffettone

Foam extrusion through slit dies often suffers from shape asymmetry that compromise product quality and increase waste. This work combines experiments and computational fluid dynamics simulations to investigate the influence of die geometry and pulling velocity on foam board morphology. Two slit dies with different central heights are tested at varying pulling speeds using low-density polyethylene with isobutane as a blowing agent. Experiments show that dies with a large central height promote nearly rectangular boards with uniform bubble morphology, whereas those with a small gap produce pronounced N-shaped distortions and surface irregularities. Higher pulling velocity mitigates asymmetry of the extrudate shape but reduces expansion and leads to smaller, more elongated bubbles due to rapid quenching. Despite employing a simplified Newtonian rheology and a reduced computational domain, simulations qualitatively reproduce the experimental trends, elucidating the contribution of the velocity and pressure gradients at the die exit that drive asymmetric expansion.

泡沫挤出通过狭缝模具往往遭受形状不对称，影响产品质量和增加浪费。本研究结合实验和计算流体动力学模拟来研究模具几何形状和拉拔速度对泡沫板形貌的影响。使用低密度聚乙烯和异丁烷作为发泡剂，在不同的拉拔速度下测试了具有不同中心高度的两个狭缝模具。实验表明，中心高度较大的凹模可形成气泡形貌均匀的近矩形板，而中心高度较小的凹模可形成明显的n形畸变和表面不规则。较高的拉伸速度减轻了挤压形状的不对称性，但由于快速淬火，减少了膨胀并导致更小、更长的气泡。尽管采用了简化的牛顿流变学和简化的计算域，但模拟定性地再现了实验趋势，阐明了驱动不对称膨胀的模具出口速度和压力梯度的贡献。

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引用次数: 0

Heterogeneous Al–Zn–Mg-Cu and Al–Cu–Li layered composite fabricated by friction deposition additive manufacturing 摩擦沉积增材制造非均相Al-Zn-Mg-Cu和Al-Cu-Li层状复合材料

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-28 DOI: 10.1016/j.jmapro.2026.01.084

Shuwei Duan , Yimeng Ye , Yuyang Zou , Tao Wang , Xiaoyang Yi , Zhongli Liu , Kenji Matsuda , Yong Zou , Fuqiang Guo

Solid-state additive manufacturing of high-strength aluminum composites offers a promising route to overcome performance trade-offs inherent in monolithic alloys. This study presents the fabrication of a layered Al–Cu–Li/Al–Zn–Mg–Cu composite via friction surfacing deposition additive manufacturing (FSD-AM). Microstructural and mechanical analyses reveal sound interfacial bonding achieved through materials plastic flow and transfer, without forming detectable intermetallic compounds or continuous diffusion layers. The Al–Zn–Mg–Cu layers exhibit a finer recrystallized grain structure and a high number density of η' (MgZn₂) precipitates, delivering a tensile strength exceeding 500 MPa. In contrast, the Al–Cu–Li layers, with coarser grains and sparse T₁ (Al₂CuLi) precipitates, provide superior ductility (>18% elongation). This architecture, comprising alternating “high-strength/low-ductility” and “medium-strength/high-ductility” layers of dissimilar high-strength aluminum alloys, coupled with a balanced corrosion performance, demonstrates a possible strategy to synergistically tailor strength, ductility, and durability for next-generation aerospace structures.

高强度铝复合材料的固态增材制造为克服单片合金固有的性能权衡提供了一条有前途的途径。本研究采用摩擦表面沉积增材制造技术（FSD-AM）制备了层状Al-Cu-Li / Al-Zn-Mg-Cu复合材料。微观结构和力学分析表明，通过材料的塑性流动和转移实现了良好的界面结合，而没有形成可检测的金属间化合物或连续扩散层。Al-Zn-Mg-Cu层具有较细的再结晶晶粒结构和较高的η′（MgZn2）析出密度，抗拉强度超过500 MPa。相比之下，Al-Cu-Li层具有较粗的晶粒和稀疏的T1 （Al2CuLi）沉淀，具有较好的延展性（伸长率>；18%）。这种结构由不同的高强度铝合金交替的“高强度/低延展性”和“中等强度/高延展性”层组成，再加上平衡的腐蚀性能，展示了一种可能的策略，可以协同定制下一代航空航天结构的强度、延展性和耐久性。

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引用次数: 0

A welding penetration prediction model for laser welding process based on self-supervised learning using physics-informed neural networks 基于物理信息神经网络的激光焊接过程自监督学习熔透预测模型

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-02-03 DOI: 10.1016/j.jmapro.2026.01.035

Sen Li , Xiaoying Liu , Xiaojian Xu , Chendong Shao , Yaqi Wang , Ling Lan , Xinhua Tang , Haichao Cui

The laser welding full-penetration is of critical importance, as it constitutes one of the fundamental factors in achieving defect-free welded joints. Accurate prediction of the penetration state is therefore essential for ensuring weld quality. To this end, this paper introduces SimPhysNet, a novel algorithm that achieves high classification accuracy in laser welding penetration prediction using only a limited number of labeled images. This approach effectively overcomes the limitations of supervised learning classification algorithms, which are hindered in industrial applications by their dependence on extensive, high-quality labeled data. The core of SimPhysNet is a unique self-supervised learning paradigm that embeds physical priors into a contrastive learning framework. By incorporating a physics-informed neural network (PINN), the model is guided to extract physically meaningful features of the molten pool and keyhole from a large set of unlabelled data, while three image augmentation tasks further enhance its generalization capabilities. Subsequently, a few-shot learning strategy, based on prototypical networks, enables robust classification by constructing class representations from a minimal set of labeled images. Experimental results demonstrate that SimPhysNet achieves a classification accuracy of 96.06% using only 200 labeled images (approximately 5% of the total labeled dataset), which is comparable to the performance of conventional supervised learning algorithms that utilize the entire labeled dataset. This work presents a new, efficient, and highly accurate method, providing the way for the intelligent automation of laser welding.

激光焊接的全熔透是实现焊接接头无缺陷的基本因素之一，具有十分重要的意义。因此，准确预测熔透状态对于确保焊接质量至关重要。为此，本文介绍了一种新的算法SimPhysNet，该算法仅使用有限数量的标记图像就可以实现激光焊接熔透预测的高分类精度。这种方法有效地克服了监督学习分类算法的局限性，这些算法依赖于大量高质量的标记数据，阻碍了它们在工业应用中的应用。SimPhysNet的核心是一个独特的自监督学习范例，它将物理先验嵌入到对比学习框架中。通过结合物理信息神经网络（PINN），该模型被引导从大量未标记数据中提取熔池和锁孔的物理有意义的特征，同时三个图像增强任务进一步增强其泛化能力。随后，基于原型网络的几次学习策略通过从最小的标记图像集构建类表示来实现鲁棒分类。实验结果表明，SimPhysNet仅使用200张标记图像（约占总标记数据集的5%）就实现了96.06%的分类准确率，这与使用整个标记数据集的传统监督学习算法的性能相当。提出了一种新的、高效的、高精度的方法，为激光焊接的智能化自动化提供了途径。

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引用次数: 0

Control of the centerline segregation by manipulating dendritic growth for slab casting of HSLA steel through roller-type electromagnetic stirring 利用辊式电磁搅拌控制HSLA钢板坯中线偏析的枝晶生长

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-21 DOI: 10.1016/j.jmapro.2026.01.067

Liang Chen , Pu Wang , Jinwen Jin , Shengkai Hu , Zhenjie Du , Jiaquan Zhang

Controlling centerline segregation in high-strength low-alloy (HSLA) steel slabs is essential for producing high-end automotive sheets, as this defect seriously compromises mechanical properties, fatigue resistance, and service life. Therefore, this study quantitatively investigates the mechanisms of dendrite deflection and fragmentation under roller-type electromagnetic stirring (R-EMS), and demonstrates how controlled dendritic growth can effectively mitigate centerline segregation in HSLA steel. The research shows that dendrite deflection exhibits a significant flow-aligned growth characteristic, with deflection primarily occurring in regions with a liquid fraction higher than 0.7, and is regulated by flow velocity: at low velocities, it is dominated by the asymmetry of the concentration boundary layer; at high velocities, it evolves into a competitive mechanism between fluid mechanical force and the solute field. The study further established a quantitative relationship between the critical flow velocity for dendrite fragmentation and its necking degree (characterized by the necking factor β), finding that the critical velocity is inversely proportional to β³, and the critical fragmentation velocity for a dendrite without necking is 0.582 m/s. Regarding process impact, the study found that although excessive stirring can provide a large number of heterogeneous nuclei by promoting dendrite fragmentation, thereby advancing the columnar-to-equiaxed transition (CET), it leads to coarsening of equiaxed crystals and aggravates centerline segregation. By optimizing the stirring configuration—deactivating the first pair of stirrers while maintaining a high current in the second pair—the massive nucleation of equiaxed grains was effectively delayed. This strategy yielded a suitable equiaxed grain ratio of 28.3% and stabilized centerline segregation at level C 0.5, providing a theoretical foundation and a practical strategy for producing HSLA steel slabs.

控制高强度低合金（HSLA）钢板的中心线偏析对于生产高端汽车板材至关重要，因为这种缺陷严重影响机械性能、抗疲劳性能和使用寿命。因此，本研究定量研究了辊式电磁搅拌（R-EMS）下枝晶偏转和破碎的机制，并证明了控制枝晶生长如何有效地缓解HSLA钢的中心线偏析。研究表明：枝晶偏转表现出明显的流向生长特征，偏转主要发生在液体分数大于0.7的区域，并受流速的调节：低速时，主要受浓度边界层的不对称性支配；在高速下，它演变为流体机械力与溶质场之间的竞争机制。进一步建立了枝晶破碎临界流速与其颈缩程度（表征为颈缩因子β）之间的定量关系，发现临界流速与β3成反比，无颈缩的枝晶破碎临界流速为0.582 m/s。在工艺影响方面，研究发现，虽然过度搅拌可以通过促进枝晶破碎产生大量非均质核，从而促进柱状晶向等轴晶转变（CET），但也会导致等轴晶粗化，加剧中心线偏析。通过优化搅拌结构——关闭第一对搅拌器，同时保持第二对搅拌器的高电流——有效地延缓了等轴晶粒的大量成核。该策略可获得28.3%的等轴晶比，并将中心线偏析稳定在c0.5水平，为生产HSLA钢板提供了理论基础和实践策略。

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引用次数: 0

Femtosecond laser bonding of transparent polycarbonate: a study on the weld seam quality and strength 透明聚碳酸酯飞秒激光粘接：焊缝质量和强度的研究

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-02-28 Epub Date: 2026-01-27 DOI: 10.1016/j.jmapro.2026.01.070

Soheil Alee Mazreshadi , Pol Vanwersch , Tim Evens , Sylvie Castagne

Reliable bonding of transparent polymers is essential for microfluidic and biomedical devices. Ultrashort laser welding provides localized energy deposition with minimal heat-affected zones, but nonlinear absorption introduces challenges in achieving consistent weld quality. This study investigates femtosecond laser bonding of transparent polycarbonate using a 1030

nm

source, focusing on the effects of fluence per pulse, scanning speed, and repetition rate. Two degradation mechanisms are identified: excessive cumulative fluence and high per-pulse fluence, both defining operational limits. At optimized fluence values, pre-focal absorption before the focus causes a focal offset between the intended and actual weld location. Even after refocusing on the interface, the gap between plates and the distorted beam profile produce a non-uniform fluence distribution, compromising weld quality. Simulations confirm that such offsets distort beam shape and fluence delivery. To overcome this, a low-fluence with high-overscan strategy is proposed, mitigating offset effects. Uniform welds are achieved at a repetition rate of 1

MHz

with scanning speeds ranging from 10 to 30

mm / s

and fluences of 0.08–0.17

J / {cm}^{²}

, with more than five overscans. FTIR measurements are performed to monitor potential chemical changes in the bonded regions. The optimized process has a maximum shear strength of 30.2 ± 5

N / {mm}^{²}

, corresponding to 48% of pristine polycarbonate. Weibull analysis identifies a highest modulus of 5.2, confirming process reliability. Devices withstand leakage tests up to 1

bar

. This approach establishes a reproducible femtosecond welding strategy for transparent polymers, resulting in stronger, and more reliable fabrication of microfluidic and biomedical systems.

透明聚合物的可靠结合对于微流体和生物医学设备至关重要。超短激光焊接提供了局部能量沉积和最小的热影响区，但非线性吸收给实现一致的焊接质量带来了挑战。本研究使用1030nm光源研究透明聚碳酸酯的飞秒激光键合，重点研究了每脉冲影响、扫描速度和重复率的影响。确定了两种降解机制：过量的累积通量和高的每脉冲通量，两者都确定了操作极限。在优化的通量值下，焦点前的焦前吸收会导致预期和实际焊接位置之间的焦偏移。即使重新聚焦在界面上，板材之间的间隙和扭曲的光束轮廓也会产生不均匀的流量分布，从而影响焊接质量。模拟证实了这种偏移会扭曲光束的形状和能量的传递。为了克服这一问题，提出了一种低通量高过频策略，以减轻抵消效应。在1 MHz的重复频率下实现均匀焊接，扫描速度范围为10至30 mm/s，影响范围为0.08-0.17 J/cm²，超过5次扫描。FTIR测量用于监测键合区的潜在化学变化。优化工艺的最大抗剪强度为30.2±5 N/mm²，相当于原始聚碳酸酯的48%。威布尔分析确定了最高模量5.2，确认了过程的可靠性。设备可承受高达1bar的泄漏测试。这种方法为透明聚合物建立了一种可重复的飞秒焊接策略，从而产生更强、更可靠的微流体和生物医学系统制造。

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