Journal of Manufacturing Processes最新文献_第5页

Process optimization of paper cup bottom-forming using FEM and experimental validation 纸杯底成形工艺的有限元优化及实验验证

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-30 DOI: 10.1016/j.jmapro.2026.01.095

Moaaz Safwa, Juho Bonifer, Hemantha Kumar Yeddu, Juha Varis, Ville Leminen

The extensive use of single-use food and beverage containers continues to raise environmental concerns, particularly due to the limited recyclability of polyolefin-coated paperboards. While polyethylene-coated structures remain prevalent in current manufacturing practices, improving their formability is essential for both optimizing existing processes and enabling the future adoption of more sustainable barrier materials. This study focuses on the bottom-forming stage of paper cup production, a process critical to achieving structural integrity and sealing performance. A finite element modeling approach was employed to simulate deformation behavior and stress distribution during forming, with experimental trials conducted to validate key results. Process parameters such as curling depth and production speed were systematically varied to evaluate their influence on forming outcomes. The results demonstrate that a curling depth of 4.3 mm provides improved seal consistency and structural uniformity, particularly at lower production speeds (80 cups/min), thereby minimizing the risk of defects commonly observed in fast, high-volume manufacturing settings. These findings contribute to a better understanding of process-structure relationships in fiber-based composite forming and offer valuable insights for reducing material waste and enhancing process reliability in sustainable packaging manufacturing.

一次性食品和饮料容器的广泛使用继续引起环境问题，特别是由于聚烯烃涂层纸板的可回收性有限。虽然聚乙烯涂层结构在当前的制造实践中仍然很普遍，但提高其可成形性对于优化现有工艺和未来采用更可持续的屏障材料至关重要。本研究的重点是纸杯生产的底部成形阶段，这是实现结构完整性和密封性能的关键过程。采用有限元方法模拟成形过程中的变形行为和应力分布，并进行了试验验证。系统地改变卷曲深度和生产速度等工艺参数，以评估它们对成形结果的影响。结果表明，4.3 mm的卷曲深度可以改善密封一致性和结构均匀性，特别是在较低的生产速度（80杯/分钟）下，从而最大限度地降低了在快速、大批量生产环境中常见的缺陷风险。这些发现有助于更好地理解纤维基复合材料成型过程中的结构关系，并为减少材料浪费和提高可持续包装制造过程的可靠性提供有价值的见解。

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引用次数: 0

Improving the weldability of press hardened steel to aluminum alloy in resistance spot welding using interlayer and ultrasonic assistance 利用夹层和超声辅助提高压淬钢与铝合金的电阻点焊可焊性

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-30 DOI: 10.1016/j.jmapro.2026.01.088

Juntao Shen , Baokai Ren , Ping Yao , Kang Zhou

Vehicle light-weighting has driven growing interests in joining aluminum alloys with press hardened steel (PHS), a metal widely used for its high strength. However, the significant physical and chemical differences between aluminum and PHS lead to low welding compatibility in conventional resistance spot welding (RSW) process, and some typically hard and brittle Fe-Al intermetallic compounds (IMCs) forming during the process, which can significantly deteriorate joint performance. This work proposes an improved method for RSW process of AA6061 aluminum alloy and PHS by introducing a stainless steel interlayer (thickness: 0.25–0.5 mm) and ultrasonic longitudinal vibration. The effects of different interlayer thicknesses and process combinations: conventional RSW, with interlayer only, and with both of interlayer and ultrasonic assistance (UA) were investigated in terms of dynamic resistance, metallurgical characteristics, joint microstructure, and mechanical properties of the Al/PHS welded joint. Results show that the stainless steel interlayer could effectively prevent direct Al-PHS contact. Using 0.45 mm interlayer made the IMC thickness reduced from ∼50 μm without the interlayer to ∼2.3 μm. Ultrasonic vibration further reduced the IMC layer to ∼1.4 μm, and enhanced Fe diffusion toward the aluminum side. With a 0.45 mm thick interlayer, the joint obtained from UA-RSW process could achieve a peak load of 6.32kN, which was 65.6% higher than that of the process using the same thickness interlayer without UA. The fracture energy was increased from 4.393 J to 14.806 J, and the fracture mode of the joint changed from interfacial fracture to better button fracture. These findings demonstrate that the synergistic using of a stainless steel interlayer and ultrasonic vibration can enable effective joining of PHS and aluminum alloys, and offer a promising solution for joining dissimilar metals and ultra-high-strength steels in advanced lightweight structures.

汽车的轻量化推动了人们对将铝合金与冲压淬火钢（PHS）结合在一起的兴趣日益浓厚，冲压淬火钢因其高强度而被广泛使用。然而，由于铝与小铁的物理化学差异较大，导致传统的电阻点焊（RSW）工艺的焊接相容性较低，并且在此过程中会形成一些典型的硬脆的Fe-Al金属间化合物（IMCs），严重影响接头性能。本文提出了一种改进AA6061铝合金和小PHS的RSW工艺的方法，即引入不锈钢夹层（厚度为0.25 ~ 0.5 mm）和超声波纵向振动。研究了不同中间层厚度和工艺组合：常规RSW、仅添加中间层和同时添加中间层和超声辅助（UA）对Al/PHS焊接接头的动态阻力、金相特征、接头显微组织和力学性能的影响。结果表明，不锈钢夹层能有效防止铝小灵通直接接触。使用0.45 mm的中间层可以使IMC厚度从没有中间层的~ 50 μm减小到~ 2.3 μm。超声振动进一步使IMC层减小到~ 1.4 μm，并增强了Fe向铝侧的扩散。当中间层厚度为0.45 mm时，UA- rsw工艺接头的峰值载荷为6.32kN，比未添加UA的相同厚度中间层工艺接头的峰值载荷提高了65.6%。断裂能由4.393 J增加到14.806 J，接头断裂方式由界面断裂转变为更好的扣状断裂。这些发现表明，使用不锈钢夹层和超声波振动的协同作用可以有效地连接小灵通和铝合金，并为在先进的轻量化结构中连接异种金属和超高强度钢提供了一个有前途的解决方案。

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引用次数: 0

Structure, mechanical properties, and wear behavior of functionally graded hybrid AA6061-B4C-CNT composites using combined stir casting and centrifugal casting 搅拌铸造和离心铸造复合AA6061-B4C-CNT功能梯度复合材料的组织、力学性能和磨损行为

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-30 DOI: 10.1016/j.jmapro.2026.01.094

Sukanta Sarkar , Ujjal Dey , Ketan Chouhan , C.S. Kumar , Siddhartha Roy

A functionally graded hybrid Al-B₄C-CNT composite cylinder was fabricated using combined stir and centrifugal casting to improve the properties of both the outer and inner surfaces. While a dense B₄C-rich region of approx. 1 mm thickness was achieved at the outermost surface due to the higher density of B₄C particles over molten AA6061, the areas adjacent to the inner surface were preferentially reinforced by CNTs. Electron backscattered diffraction (EBSD) analysis confirmed grain refinement and increased local strain in reinforcement-rich regions, with the finest grains and highest kernel average misorientation (KAM) value observed in the region, preferentially enriched with the CNTs. Raman spectroscopy confirmed the gradient CNT distribution, and high-resolution transmission electron microscope analysis proved the strong interfacial bonding due to the formation of a thin Al₄C₃ layer. Due to the presence of high B₄C content, the highest hardness of 520 ± 30 HV was achieved at the outer periphery, while the presence of CNTs in the inner regions resulted in higher hardness in those regions compared to the reinforcement-free mid-thickness zone of the cylinder. Samples from five regions along the thickness — outer, outer-middle, middle, middle-inner, and inner were subjected to three-point bend and wear tests. The inner-middle part demonstrated the best combination of flexural strength and toughness (flexural strength ∼350 MPa and flexural strain ∼11%) along with the lowest coefficient of friction (= 0.23) and specific wear rate due to the uniformly distributed CNT reinforcement. In conventional centrifugal-cast functionally graded composites, the inner surface generally suffers from inferior properties due to the accumulation of defects. In that respect, this novel composite design with gradient distribution of hybrid reinforcements provides a methodology to reinforce both surfaces simultaneously.

采用搅拌和离心联合铸造的方法制备了功能梯度杂化Al-B₄C-CNT复合圆柱体，提高了其内外表面的性能。而密集的富含b4c的区域大约有。由于熔融AA6061表面的B4C颗粒密度较高，最外表面的厚度达到了1mm，靠近内表面的区域优先被CNTs增强。电子背散射衍射（EBSD）分析证实，在富含碳纳米管的区域，晶粒细化，局部应变增加，晶粒细，籽粒平均取向偏差（KAM）值最高。拉曼光谱证实了碳纳米管的梯度分布，高分辨率透射电镜分析证实了由于形成薄Al4C3层而形成的强界面键合。由于B4C含量高，外边缘的硬度最高，达到520±30 HV，而内部区域存在CNTs导致这些区域的硬度高于圆柱体无增强的中厚区域。从沿厚度的五个区域——外、外-中、中、中-内和内进行三点弯曲和磨损试验。由于均匀分布的碳纳米管增强，内中部的抗弯强度和韧性组合最佳（抗弯强度~ 350mpa，抗弯应变~ 11%），摩擦系数最低（= 0.23），比磨损率最低。在传统的离心铸造功能梯度复合材料中，由于缺陷的积累，内表面通常性能较差。在这方面，这种具有梯度分布的混合增强材料的新型复合设计提供了一种同时增强两个表面的方法。

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引用次数: 0

Influence of cryogenic temperature on machining mechanisms and surface integrity of CF/PEEK composites based thermo-mechanical coupling analysis 低温对CF/PEEK复合材料加工机理和表面完整性的影响

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-30 DOI: 10.1016/j.jmapro.2026.01.093

Zhaoxin Hou , Shipeng Li , Han Lv , Hao Li , Xuda Qin , Qing Zhao , Guoyu Fu , Zhengwei Bao , Zhitong Zhou

To address the challenge of monitoring thermo-mechanical damage in CF/PEEK machining, this research establishes a pioneering high-fidelity microscale FE model. The model uniquely incorporates liquid nitrogen precooling and the heat-generation-transfer dynamics across the fiber, matrix, and interface, achieving accurate cutting temperature predictions (errors within 5% at ambient temperature and 12% under cryogenic conditions). The finding results demonstrate that liquid nitrogen cooling (−150 °C) reduces cutting temperatures by 56.4%–60.4%, effectively suppressing thermal damage effects while inducing matrix embrittlement. Under cryogenic conditions(−150 °C), chips across all four fiber orientations exhibit morphology tearing deterioration due to matrix brittleness. During ambient temperature (21 °C) machining, matrix flow forms protective overlayers that reduce fiber damage; conversely, cryogenic machining embrittles the matrix, weakening its rigid support capacity for fibers and exacerbating fiber fracture and interfacial debonding. Surface roughness parameters (Sa/Sz) increase by 31%–85% (0°-135° fiber orientations), with 135° specimens exhibiting the most severe degradation. This study elucidates the synergistic mechanism between temperature and fiber orientation on machining-induced damage in CF/PEEK composites, providing theoretical foundations for optimizing ambient temperature and cryogenic machining processes.

为了解决CF/PEEK加工中热机械损伤监测的挑战，本研究建立了一个开创性的高保真微观有限元模型。该模型独特地结合了液氮预冷和纤维、基体和界面上的热生成传递动力学，实现了准确的切割温度预测（室温下误差在5%以内，低温条件下误差在12%以内）。结果表明，液氮冷却（- 150°C）可使切削温度降低56.4% ~ 60.4%，有效抑制热损伤效应，同时诱导基体脆化。在低温条件下（- 150°C），由于基体脆性，所有四种纤维取向的切屑都表现出形貌撕裂恶化。在环境温度（21°C）加工过程中，基体流动形成保护层，减少纤维损伤；反之，低温加工使基体脆性，削弱其对纤维的刚性支撑能力，加剧纤维断裂和界面剥离。表面粗糙度参数（Sa/Sz）增加了31%-85%（0°-135°纤维取向），其中135°纤维取向的试样退化最严重。本研究阐明了温度和纤维取向对CF/PEEK复合材料加工损伤的协同作用机制，为优化环境温度和低温加工工艺提供了理论依据。

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引用次数: 0

QA-VLM: Providing human-interpretable quality assessment for wire-feed laser additive manufacturing parts with vision language models QA-VLM：利用视觉语言模型为线喂激光增材制造零件提供人类可解释的质量评估

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-30 DOI: 10.1016/j.jmapro.2026.01.071

Qiaojie Zheng , Jiucai Zhang , Joy Gockel , Michael B. Wakin , Craig Brice , Xiaoli Zhang

Image-based quality assessment (QA) in additive manufacturing (AM) often relies heavily on the expertise and constant attention of skilled human operators. While machine learning and deep learning methods have been introduced to assist in this task, they typically provide black-box outputs without interpretable justifications, limiting their trust and adoption in real-world settings. In this work, we introduce a novel QA-VLM framework that leverages the attention mechanisms and reasoning capabilities of vision-language models (VLMs), enriched with application-specific knowledge distilled from peer-reviewed journal articles, to generate human-interpretable quality assessments. When evaluated on 24 single-bead samples produced by laser wire direct energy deposition (DED-LW), our framework demonstrates higher validity and consistency in explanation quality than off-the-shelf VLMs. These findings indicate that the literature-supported quality assessment model has the potential to improve reliability for QA tasks, motivating future validation on larger, multi-layer, and multi-pass builds, and broader process/material conditions.

增材制造（AM）中基于图像的质量评估（QA）通常在很大程度上依赖于熟练操作人员的专业知识和持续关注。虽然已经引入了机器学习和深度学习方法来协助完成这项任务，但它们通常提供没有可解释理由的黑箱输出，限制了它们在现实环境中的信任和采用。在这项工作中，我们引入了一种新的QA-VLM框架，该框架利用视觉语言模型（vlm）的注意机制和推理能力，丰富了从同行评审的期刊文章中提取的应用特定知识，以生成人类可解释的质量评估。通过对24个由激光线直接能量沉积（ed - lw）产生的单头样品进行评估，我们的框架在解释质量上比现成的vlm具有更高的有效性和一致性。这些发现表明，文献支持的质量评估模型有潜力提高QA任务的可靠性，激励未来在更大、多层、多通道构建和更广泛的工艺/材料条件下进行验证。

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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 : 2026-01-29 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。

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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 : 2026-01-28 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

The modelling and compensation method for dove-prism-based laser trepanning optomechanical system 基于鸽形棱镜的激光钻孔光学机械系统建模与补偿方法

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-28 DOI: 10.1016/j.jmapro.2026.01.017

Muyang Ye , Haohua Xiu , Chung Ket Thein , Haotian Cui , Yongjie Zhao , Gongyu Liu , Jing Wang , Hao Nan Li

Laser beam drilling is widely employed in the aerospace industry due to its non-contact nature and efficient processing of various materials. While traditional fixed laser beam drilling methods such as Single Pulse Drilling (SPD) and Percussion Laser Drilling (PLD) are commonly used, mobile laser beam drilling techniques like Laser Trepanning and Helical Drilling are preferred for applications requiring precise control over hole geometric accuracy. This paper presents a new Dove-prism-based trepanning system model that enables analytical calculation of the laser trajectory within a 3D spiral domain. This model facilitates accurate prediction of drilled hole geometries, including diameter and taper. An innovative aspect of this study lies in the incorporation of a laser ablation effect into the prediction of hole geometry, which is often overlooked in other trepanning drilling research. By integrating a prediction function for ablation crater diameter, the accuracy of hole geometry prediction can be improved. The validity of the model is confirmed through extensive experiments, establishing its reliability while revealing important insights such as the impact of initial optomechanical conditions on hole geometry and the influence of laser parameters on hole circularity. Additionally, our compensation method enhances predictability and expands achievable geometry range when drilling holes. This research establishes a robust theoretical foundation for advancing mobile laser drilling technology, particularly in terms of system design and process optimization.

激光束打孔因其非接触性和对各种材料的高效加工而广泛应用于航空航天工业。传统的固定激光束钻孔方法（如单脉冲钻孔（SPD）和冲击激光钻孔（PLD））是常用的，而移动激光束钻孔技术（如激光钻孔和螺旋钻孔）则适合需要精确控制孔几何精度的应用。本文提出了一种新的基于鸽形棱镜的钻孔系统模型，该模型能够在三维螺旋域内解析计算激光轨迹。该模型有助于准确预测钻孔几何形状，包括直径和锥度。该研究的一个创新之处在于将激光烧蚀效应纳入到孔几何形状的预测中，这在其他钻孔研究中经常被忽视。通过对烧蚀坑直径的预测函数进行积分，可以提高孔几何形状预测的精度。通过大量的实验证实了该模型的有效性，建立了该模型的可靠性，同时揭示了诸如初始光力学条件对孔几何形状的影响以及激光参数对孔圆度的影响等重要见解。此外，我们的补偿方法提高了钻井时的可预测性，扩大了可实现的几何范围。本研究为推进移动激光打孔技术，特别是在系统设计和工艺优化方面奠定了坚实的理论基础。

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引用次数: 0

Microstructure, mechanical properties and corrosion resistance of FeCoCrNiMo0.2/ER120s-G gradient structures fabricated by arcing-wire powder hybrid additive manufacturing 电弧丝粉复合增材制造feccrnimo0.2 /ER120s-G梯度结构的显微组织、力学性能及耐蚀性

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-28 DOI: 10.1016/j.jmapro.2026.01.086

Chuanqi Liu , Yugang Miao , Ji Liu , Yuyang Zhao , Yuhang Yang , Yifan Wu , Zhiqiang Gao

Functionally graded materials (FGMs) offer a pathway to reconcile conflicting requirements of strength, ductility, and corrosion resistance in structural applications. Here we report the fabrication of FeCoCrNiMo_0.2 high-entropy alloy (HEA)/ER120S-G steel gradient structures using an arcing-wire powder hybrid additive manufacturing (AWPH-AM) approach. By continuously varying the wire–powder feed ratio, we achieve in situ control of phase evolution, grain orientation, and passive-film chemistry across the compositional gradient. Microstructural analysis reveals a progressive transition from acicular ferrite to FCC-dominated solid solutions, accompanied by Mo-induced grain-boundary precipitation at high HEA fractions. Mechanical testing shows a trade-off between strength and ductility: steel-rich layers exhibit ultimate tensile strengths approximately1200 MPa with limited elongation, whereas intermediate layers achieve elongation above 30% owing to stable FCC solid solutions. At higher HEA content, precipitation of Mo-rich phases enhances hardness but induces brittle fracture. Electrochemical testing demonstrates a systematic improvement in corrosion resistance with increasing HEA fraction, culminating in the formation of a self-healing Cr₂O₃–MoO_x composite passive film that provides superior protection in chloride environments. This work establishes AWPH-AM as a versatile platform for the design of FGMs, and demonstrates composition–microstructure-property coupling as a strategy to balance strength, ductility, and corrosion resistance in demanding marine and energy applications.

功能梯度材料（fgm）为结构应用中对强度、延展性和耐腐蚀性的矛盾要求提供了一条途径。本文报道了采用电弧线粉末混合增材制造（AWPH-AM）方法制备feccrnimo0.2高熵合金(HEA)/ER120S-G钢梯度结构。通过连续改变线粉进料比，我们实现了跨成分梯度的相演化、晶粒取向和被动膜化学的原位控制。显微组织分析表明，在高HEA分数下，铁素体逐渐转变为fcc主导的固溶体，并伴有mo诱导的晶界析出。力学测试显示了强度和延性之间的权衡：富钢层的极限抗拉强度约为1200 MPa，延伸率有限，而中间层由于稳定的FCC固溶体，延伸率超过30%。在HEA含量较高时，富mo相的析出提高了硬度，但导致脆性断裂。电化学测试表明，随着HEA含量的增加，抗腐蚀性能有了系统性的提高，最终形成了自修复的Cr2O3-MoOx复合钝化膜，在氯化物环境中提供了更好的保护。这项工作建立了AWPH-AM作为fgm设计的通用平台，并证明了成分-微观结构-性能耦合是一种平衡强度、延展性和耐腐蚀性的策略，适用于要求苛刻的海洋和能源应用。

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引用次数: 0

Sensor and feature selection for cost- and time-efficient online monitoring of ultrasonic metal welding 超声金属焊接在线监测的传感器和特征选择

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-28 DOI: 10.1016/j.jmapro.2026.01.034

Kuan-Chieh Lu , Zhiqiao Dong , Chenhui Shao

Ultrasonic metal welding (UMW) is a solid-state joining process widely used in industrial applications. However, its sensitivity to tool wear, surface contamination, and material variability presents persistent challenges for ensuring weld quality. Existing online monitoring systems often emphasize predictive accuracy while neglecting practical constraints such as hardware cost, data acquisition rate, and computational latency. To overcome this gap, this paper develops a systematic framework for cost- and time-efficient sensor and feature selection in UMW monitoring. The proposed method integrates signal decomposition, feature importance analysis, cost-aware genetic algorithm optimization, and a separability-analysis-based adaptation mechanism to identify an optimal subset of sensors, features, and time segments that balance predictive accuracy with resource efficiency. Extensive case studies using a multi-sensor data acquisition system demonstrate that the framework achieves high monitoring accuracy in both weld quality prediction and mixed tool and sample surface condition classification while reducing the feature pool by 96.8%–99.4%. Even under reduced sampling frequency (6.25 kHz) and shortened time windows (0.3 s), the model maintains strong predictive performance. Furthermore, the separability-analysis-based adaptation accurately recognizes new fault types using only three samples, reducing retraining data requirements by 90%. Overall, the proposed framework provides a new, scalable solution for cost- and time-efficient UMW monitoring and establishes a foundation for adaptive, lightweight monitoring systems applicable to other manufacturing processes.

超声波金属焊接（UMW）是一种广泛应用于工业的固态焊接工艺。然而，它对工具磨损、表面污染和材料可变性的敏感性为确保焊接质量带来了持续的挑战。现有的在线监测系统往往强调预测的准确性，而忽略了实际的限制，如硬件成本、数据采集率和计算延迟。为了克服这一缺陷，本文开发了一种具有成本效益和时间效益的传感器和特征选择系统框架。该方法集成了信号分解、特征重要性分析、成本感知遗传算法优化和基于可分性分析的自适应机制，以识别传感器、特征和时间段的最优子集，从而平衡预测精度和资源效率。使用多传感器数据采集系统的大量案例研究表明，该框架在焊缝质量预测和混合工具和样品表面状况分类方面都具有很高的监测精度，同时将特征库减少了96.8%-99.4%。即使在降低采样频率（6.25 kHz）和缩短时间窗（0.3 s）的情况下，该模型仍保持较强的预测性能。此外，基于可分离性分析的自适应仅使用三个样本就能准确识别新的故障类型，将再训练数据需求减少了90%。总体而言，所提出的框架为成本和时间效率高的UMW监控提供了一种新的可扩展解决方案，并为适用于其他制造工艺的自适应轻量级监控系统奠定了基础。

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