Journal of Manufacturing Processes最新文献_第5页

Degradation mechanism of aluminum/steel continuous drive friction welded joints under long-term thermo-electro-mechanical coupling 铝/钢连续驱动摩擦焊接接头在长期热-机电耦合作用下的退化机理

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-31 DOI: 10.1016/j.jmapro.2025.12.059

Shuwen Wang , Shujun Chen , Shun Wang , He Shan , Pengjing Zhao , Zhongmin Xiao , Tao Yuan

This study investigates the long-term reliability of continuous drive friction welded joints between 1060 pure aluminum and Q235 low-carbon steel under coupled thermal, electrical, and mechanical loading. Self-designed experiments simulated service conditions involving high temperature, direct current, and static load. The microstructural evolution, intermetallic compounds (IMCs) growth, and mechanical properties were systematically analyzed after 0, 30, and 60 days of coupling exposure. Results indicate that prolonged coupling promoted static recrystallization and grain growth on the Al side, continuous IMCs layer thickening. The thickness of IMCs in the 1/2R region increased from an initial 1.25 μm to 2.39 μm after 60-days, and the formation of Kirkendall voids and microcracks, leading to interface embrittlement. After 60-days of coupling, the tensile strength decreased by approximately 18.2 %, while the slow strain rate tensile strength in a corrosive solution plummeted by approximately 55.0 %. Consequently, the fracture location in corrosive environment shifted from the Al heat-affected zone to the weld interface, exhibiting brittle fracture characteristics. Research indicates that interface performance degradation is the dominant failure mechanism, and that the microstructure of different regions of the interface has a differentiated impact. This study provides crucial mechanistic insights and experimental support for the performance optimization and life assessment of aluminum/steel dissimilar joints under harsh operating conditions, pointing out that controlling the growth of interfacial IMCs and mitigating their brittleness is a core direction for improving long-term service reliability.

本研究考察了1060纯铝与Q235低碳钢在热、电、机械耦合载荷作用下的连续驱动摩擦焊接接头的长期可靠性。自行设计的实验模拟了高温、直流、静载等工况。系统分析了耦合暴露0、30和60天后的微观结构演变、金属间化合物（IMCs）生长和力学性能。结果表明：长时间耦合促进了Al侧的静态再结晶和晶粒生长，IMCs层不断增厚；60 d后，1/2R区的IMCs厚度由初始的1.25 μm增加到2.39 μm，并形成Kirkendall空洞和微裂纹，导致界面脆化。耦合60天后，抗拉强度下降了约18.2%，而在腐蚀溶液中的慢应变速率抗拉强度下降了约55.0%。腐蚀环境下的断口位置由Al热影响区向焊缝界面转移，呈现脆性断裂特征。研究表明，界面性能退化是主要的破坏机制，界面不同区域的微观结构对破坏的影响是不同的。本研究为铝/钢异种接头在恶劣工况下的性能优化和寿命评估提供了重要的机理见解和实验支持，指出控制界面imc的生长和降低其脆性是提高长期使用可靠性的核心方向。

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引用次数: 0

A novel approach for predicting button cracking in self-pierce riveting: Integrating material properties algorithm and cracking degree characterization model 一种预测自穿孔铆接钮扣开裂的新方法：结合材料性能算法和开裂程度表征模型

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-31 DOI: 10.1016/j.jmapro.2025.12.065

Yongquan Jia , Daxin Han , Miaojin Qu , Rui Fan , Yunling Bai , Xiang-Yang Li

The rapid increase in the use of die-cast aluminum parts in electric vehicle has led to higher demands on joining technology. Unlike traditional stamped parts, die-cast parts exhibit significant variations in material properties. However, mechanical joining methods such as self-piercing riveting (SPR) are highly sensitive to material properties, and insufficient material ductility can lead to button cracking after riveting. In this context, current standard material testing methods cannot provide comprehensive and detailed performance measurements for die-cast parts. After completing the SPR joining process, the extent of cracking assessed through subjective judgment cannot provide consistent and standardized quantitative evaluations of button cracking. To address these challenges, this study proposes an innovative solution. On one hand, algorithm development enables the measurement of tensile stress and elongation using a 6 mm-diameter punch hole, significantly enhancing measurement flexibility while maintaining accuracy. In terms of cast aluminum materials, the deviation in tensile strength calculation is only 2.8 %, and the elongation is only 5.1 %. On the other hand, this study proposes the use of semantic segmentation model to identify button cracking based on a small number of feature samples, and then employs algorithms to achieve standardized quantitative evaluation of SPR button cracking. By integrating these two technologies, it is possible to predict the quality of SPR joints through punching of the aluminum casting sheet.

随着电动汽车铝合金压铸件使用量的迅速增加，对连接技术提出了更高的要求。与传统冲压件不同，压铸件在材料性能上表现出显著的变化。然而，自穿孔铆接（SPR）等机械连接方式对材料性能高度敏感，材料延展性不足会导致铆接后钮扣开裂。在这种情况下，目前的标准材料测试方法无法对压铸件提供全面和详细的性能测量。在完成SPR接合过程后，通过主观判断评估的开裂程度无法提供一致的、标准化的钮扣开裂定量评价。为了应对这些挑战，本研究提出了一个创新的解决方案。一方面，算法开发可以使用6毫米直径的冲孔测量拉伸应力和伸长率，在保持精度的同时显着提高测量灵活性。在铸铝材料方面，抗拉强度计算偏差仅为2.8%，伸长率仅为5.1%。另一方面，本研究提出基于少量特征样本，利用语义分割模型对按钮裂纹进行识别，然后利用算法实现SPR按钮裂纹的标准化定量评价。将这两种技术结合起来，就可以对铝板冲压成形的SPR接头进行质量预测。

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引用次数: 0

Pythagorean-hodograph curve-based support structures in additive manufacturing 增材制造中基于毕达哥拉斯曲线的支撑结构

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-30 DOI: 10.1016/j.jmapro.2025.12.041

Emre Günaydın, Erkan Gunpinar

This study addresses the challenge of generating efficient and precise supports in additive manufacturing (AM), where traditional support structures often cause excessive material usage, poor bridging, and vibrations. We present a novel framework using Pythagorean Hodograph (PH) curves, which offer smooth geometry transitions and favorable offset properties, promoting uniform support spacing and reducing machine vibrations. We propose two distinct PH-based support design schemes (PHs and O-PHs) integrated with a Traveling Salesman Problem (TSP)-based print sequencing algorithm. Results demonstrate that both PHs and O-PHs improve geometric accuracy, minimize bridging effects, and reduce print times, highlighting the practical advantages of PH-based supports in AM.

这项研究解决了在增材制造（AM）中产生高效和精确支撑的挑战，传统的支撑结构通常会导致过度的材料使用，桥接不良和振动。我们提出了一种使用毕达哥拉斯Hodograph （PH）曲线的新框架，它提供了平滑的几何过渡和有利的偏移特性，促进了均匀的支撑间距并减少了机器振动。我们提出了两种不同的基于ph的支持设计方案（ph和o - ph），并结合了基于旅行推销员问题（TSP）的打印排序算法。结果表明，ph和o - ph都提高了几何精度，最大限度地减少了桥接效应，减少了打印时间，突出了基于ph的支架在增材制造中的实际优势。

引用次数: 0

A novel bypass coupled triple-wire gas indirect arc (BCTW-GIA) method for high-efficiency additive manufacturing of multi-layer multi-pass thick-walled components 一种新型的旁路耦合三线气体间接电弧（BCTW-GIA）方法用于多层多道次厚壁零件的高效增材制造

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-30 DOI: 10.1016/j.jmapro.2025.12.014

Xianli Ba , Zhaodong Zhang , Yao Li , Shuhang Su , Liming Liu

The triple-wire gas indirect arc (TW-GIA) represents a novel heat source. As its thermal energy predominantly melts filler wires while delivering insufficient heat input to the deposited layer, substantial lack-of-fusion defects form during thick-walled component additive manufacturing. Consequently, TW-GIA encounters significant engineering application limitations. To address this challenge, a bypass coupled triple-wire gas indirect arc additive manufacturing (BCTW-GIA-AM) process is proposed. The innovation involves redistributing current carried by the main wire in TW-GIA to establish new conductive channels between side wires and the deposition layer, generating direct arcs. Additionally, modifying bypass current enables precise regulation of coupling states between indirect and direct arcs, thereby developing a hybrid process bridging TW-GIA and tandem dual-wire (T-DW) heat sources. Investigation of arc, droplet, and molten pool behavior in BCTW-GIA revealed the mitigation mechanism for lack-of-fusion defects. Following bypass current introduction, arc coupling intensified arc pressure on the molten pool. Concurrently, altered heating modes elevated pool temperature and enhanced Marangoni effects. Therefore, lack-of-fusion defects progressively diminished with increased bypass current. Analysis of 316 L stainless steel components demonstrated that BCTW-GIA achieves a deposition efficiency of 10.24 kg/h—2.40 times higher than T-DW-AM. Furthermore, compared with T-DW-AM, BCTW-GIA-AM's reduced heat input refined austenitic dendrites and increased dislocation density, enhancing mechanical properties. Average hardness improved by 10 %, while transverse and longitudinal tensile strengths increased by 7 % and 5 %, respectively. Finally, a 390 kg thick-walled pipeline was manufactured using BCTW-GIA-AM to validate reliability. Notably, this is the first report of indirect arc technology for large-scale component additive manufacturing.

三丝气体间接电弧（TW-GIA）是一种新型热源。由于其热能主要熔化填充线，而向沉积层提供的热量不足，因此在厚壁部件增材制造过程中形成大量的不熔化缺陷。因此，TW-GIA遇到了重大的工程应用限制。为了解决这一挑战，提出了旁路耦合三线气体间接电弧增材制造（BCTW-GIA-AM）工艺。这项创新涉及重新分配TW-GIA中主导线携带的电流，以在侧导线和沉积层之间建立新的导电通道，从而产生直接电弧。此外，修改旁路电流可以精确调节间接电弧和直接电弧之间的耦合状态，从而开发出一种桥接TW-GIA和串联双线（T-DW）热源的混合工艺。通过对BCTW-GIA中电弧、熔滴和熔池行为的研究，揭示了未熔合缺陷的缓解机制。旁路电流引入后，电弧耦合加剧了熔池上的电弧压力。同时，改变加热模式提高了池温度，增强了马兰戈尼效应。因此，不融合缺陷随着旁路电流的增加而逐渐减少。对316 L不锈钢构件的分析表明，BCTW-GIA的沉积效率比T-DW-AM高10.24 kg/ h-2.40倍。此外，与T-DW-AM相比，BCTW-GIA-AM减少了热量输入，细化了奥氏体枝晶，增加了位错密度，提高了力学性能。平均硬度提高10%，横向和纵向抗拉强度分别提高7%和5%。最后，使用BCTW-GIA-AM制造了390 kg厚壁管道，以验证其可靠性。值得注意的是，这是首次报道用于大规模部件增材制造的间接电弧技术。

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引用次数: 0

Joining of copolyamide thermoplastic-coated galvanized DP600 steel sheets using ultrasonic spot welding 聚酰胺热塑性涂层镀锌DP600钢板的超声点焊连接

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-29 DOI: 10.1016/j.jmapro.2025.12.060

D. Bajaj , V.V. Nemade , A. Hajdarevic , X.F. Fang , D.Y. Li , D.L. Chen

The application of bio-coated metals in automotive structures plays an important role for lightweighting and damping purposes. However, joining organic-coated metals presents significant challenges due to the huge difference in the physical properties between metals and polymers. In this study, copolyamide thermoplastic-coated and metal zinc-coated (galvanized) dual-phase (DP600) automotive steel sheets were joined using ultrasonic spot welding to study the influence of faying surface characteristics and welding energy on the mechanical performance. For the joining of organic-coated galvanized DP600 to organic-coated galvanized DP600, the softening of copolyamide thermoplastic at a higher welding energy of 1000 J facilitated intimate contact, void reduction, and interdiffusion of polymer chains. This resulted in a combination of cohesive and adhesive failure, achieving a high tensile lap shear load of ~1736 N. Conversely, insufficient softening at a lower welding energy of 500 J hindered intimate contact and the spreading of surface asperities, resulting in a lower joint strength. Additionally, for the galvanized DP600 to organic-coated galvanized DP600 joints, minimal bonding between the galvanized Zn layer on DP600 steel and the copolyamide thermoplastic led to adhesive failure under tensile lap shear loading. The findings reveal that effective joining of bio-coated steels can be achieved while preserving the integrity of metal-polymer interfaces.

生物涂层金属在汽车结构中的应用对汽车结构的轻量化和减震起到了重要的作用。然而，由于金属和聚合物之间物理性质的巨大差异，连接有机涂层金属提出了重大挑战。本研究采用超声点焊方法，将共酰胺热塑性涂层和金属镀锌（镀锌）双相（DP600）汽车钢板进行焊接，研究焊接表面特性和焊接能量对力学性能的影响。对于有机包覆镀锌DP600与有机包覆镀锌DP600的连接，共酰胺热塑性塑料在1000 J的较高焊接能量下软化，有利于聚合物链的密切接触、空隙减少和相互扩散。这导致了内聚和粘接的结合失效，达到了~1736 n的高拉伸接剪载荷。相反，在较低的焊接能量为500 J时，软化不足阻碍了密切接触和表面凹凸的扩散，导致接头强度降低。此外，对于镀锌DP600到有机涂层镀锌DP600接头，DP600钢上的镀锌锌层与共酰胺热塑性塑料之间的结合很少，导致在拉伸接接剪切载荷下粘合剂失效。研究结果表明，生物涂层钢的有效连接可以在保持金属-聚合物界面完整性的同时实现。

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引用次数: 0

Grinding wheel wear degradation feature generation and decoupling towards well-calibrated identifications 砂轮磨损退化特征的生成与解耦，以实现标定良好的辨识

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-29 DOI: 10.1016/j.jmapro.2025.12.067

Peng Ding , Haixiao Du , Longlong Xie , Hu Zhang , Yandong Gu , Xiaoli Zhao , Chao Zhang

Gear grinding is a critical process for ensuring high precision and surface quality in gear manufacturing, yet progressive wheel wear during continuous operation compromises machining accuracy and efficiency. Traditional periodic inspections cannot capture real-time degradation, limiting predictive maintenance. The combined challenges of limited, noisy multi-source signals, together with the limited calibration ability of existing models, underscore the necessity of frameworks that jointly address data and model limitations. This study proposes a novel framework for identifying grinding wheel wear states through multi-source dynamic signal analysis, integrating vibration and force measurements. Specifically, a multi-convolutional kernel ResNet-based feature extractor is further introduced to adaptively capture scale-specific temporal patterns from signals with distinct sampling frequencies, enriching the fused representation and improving fault discrimination. The framework is validated through industrial-scale gear-grinding experiments, demonstrating its capability for real-time monitoring and precise wear-state identification. Results show that the framework not only achieves high identification accuracy for wear states but also yields consistently low expected calibration error, confirming its well-calibrated identification.

在齿轮制造中，齿轮磨削是保证高精度和表面质量的关键过程，但在连续操作过程中齿轮的渐进式磨损会影响加工精度和效率。传统的定期检查无法捕获实时劣化，限制了预测性维护。有限的、有噪声的多源信号的综合挑战，加上现有模型的有限校准能力，强调了共同解决数据和模型局限性的框架的必要性。通过多源动态信号分析，结合振动和力测量，提出了一种新的砂轮磨损状态识别框架。具体而言，引入了基于多卷积核resnet的特征提取器，从不同采样频率的信号中自适应捕获尺度特定的时间模式，丰富了融合表示，提高了故障判别能力。通过工业规模的磨齿实验验证了该框架的有效性，证明了该框架具有实时监测和精确磨损状态识别的能力。结果表明，该框架不仅具有较高的磨损状态识别精度，而且具有较低的预期标定误差，证明了该框架的标定效果良好。

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引用次数: 0

Rapid error identification for rotary axis based on distance errors 基于距离误差的旋转轴快速误差辨识

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-29 DOI: 10.1016/j.jmapro.2025.12.056

Sihan Yao , Yuhong Dai , Wenjie Tian , Lingtao Weng , Weiguo Gao , Zuguang Huang , Dawei Zhang

The laser tracker is extensively utilized for the acquisition of actual measurement positions pertinent to the identification of geometric errors, owing to its straightforward installation and absence of fixed-length constraints. To mitigate the impact of measurement uncertainty associated with the laser tracker on the identification outcomes, multilateration techniques have been employed to achieve enhanced measurement accuracy. However, the high expense associated with deploying four laser trackers often necessitates the sequential execution of the measurement process using a single tracker positioned at various locations. This approach significantly prolongs measurement duration and renders the results vulnerable to the repeatability of the motion axes' positions. In response to these challenges, this study introduces an error identification methodology that leverages distance data from a single laser tracker, thereby obviating the need for multilateration measurements. The coordinates of the origin of the spherical coordinate system within the machine coordinate system are determined through spherical center coordinate calibration. Subsequently, the discrepancies between the ideal and actual distances from the spherical center coordinate to the measurement points are computed, facilitating the formulation of a least squares problem that correlates distance errors with unknown geometric errors. This problem is resolved utilizing the Powell algorithm. The identification outcomes are employed to forecast position errors of the measurement points, which can subsequently be verified through sequential multilateration measurements. The maximum deviation observed between the measured and predicted position errors is 7.0 μm, thereby substantiating the efficacy of the proposed identification method. Furthermore, a comparative analysis of the identification results with those derived from the conventional multilateration approach reveals consistent overall trends. The proposed method not only improves measurement efficiency but also ensures the validity of the identification results.

激光跟踪仪被广泛用于获取与几何误差识别相关的实际测量位置，因为它的安装简单，没有固定长度的限制。为了减轻与激光跟踪器相关的测量不确定度对识别结果的影响，采用了多重测量技术来提高测量精度。然而，与部署四个激光跟踪器相关的高费用通常需要使用位于不同位置的单个跟踪器连续执行测量过程。这种方法大大延长了测量时间，并使结果容易受到运动轴位置重复性的影响。为了应对这些挑战，本研究引入了一种误差识别方法，该方法利用来自单个激光跟踪器的距离数据，从而避免了对多次测量的需要。通过球心坐标标定确定机床坐标系内球坐标系原点的坐标。随后，计算出球体中心坐标到测量点的理想距离与实际距离之间的差值，便于将距离误差与未知几何误差相关联的最小二乘问题的表述。利用Powell算法解决了这个问题。识别结果用于预测测量点的位置误差，随后可通过连续多次测量进行验证。实测位置误差与预测位置误差的最大偏差为7.0 μm，验证了所提识别方法的有效性。此外，将识别结果与传统的多重方法得出的结果进行比较分析，显示出一致的总体趋势。该方法不仅提高了测量效率，而且保证了识别结果的有效性。

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引用次数: 0

Powder spreading anomaly detection in laser powder bed fusion additive manufacturing using the full-scale feature adaptive UNet++ network 基于全尺寸特征自适应UNet++网络的激光粉末床融合增材制造粉末扩散异常检测

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-27 DOI: 10.1016/j.jmapro.2025.12.051

Min Zhu , Quanquan Han , Zhenhua Zhang , Defan Wu , Peng Zhao , Xiaodan Wang , Yue Liu , Ze Ji , Shoufeng Yang

Powder bed anomalies in the laser powder bed fusion (LPBF) additive manufacturing process may cause various defects, potentially reducing the mechanical properties of the fabricated components. Although deep learning methods have been successfully employed to identify various powder bed anomalies, the categorization of “powder spreading anomaly” has been oversimplified into a single class, neglecting multi-layer insufficient powder spreading conditions. The correlation between insufficient powder spreading and mechanical properties also remains unclear, and the threshold at which insufficient powder spreading leads to a decline in mechanical properties has not been investigated. This study develops a novel powder spreading anomaly detection system (PSADS) for LPBF that includes a deep learning–based segmentation algorithm, known as Full-scale Feature Adaptive UNet++ (FFA-UNet++). FFA-UNet++ addresses challenges such as brightness homogenization, texture homogenization, and boundary blurring caused by multi-layer insufficient powder spreading. The algorithm enables the detection of six types of insufficient powder spreading, achieving a mean intersection over union (mIoU) close to 57 %, representing a 4 %–11 % improvement over six widely used segmentation networks, with a maximum IoU exceeding 90 % for individual anomaly categories. The study also investigates the effects of the six types of insufficient powder spreading on the mechanical properties of LPBF-fabricated 316 L stainless steel and proposes a process control guideline: The cumulative number of insufficient powder layers per part should not exceed three layers. This study provides a novel vision-based powder spreading anomaly detection method used for LPBF process and furnishes valuable insights for LPBF quality control within industrial applications.

在激光粉末床熔合（LPBF）增材制造过程中，粉末床异常可能会导致各种缺陷，从而潜在地降低所制造部件的机械性能。虽然深度学习方法已经成功地用于识别各种粉床异常，但“粉铺异常”的分类过于简化为单一类，忽略了多层粉铺不足的情况。粉末铺展不足与机械性能之间的关系也不清楚，而粉末铺展不足导致机械性能下降的阈值尚未研究。本研究为LPBF开发了一种新的粉末扩散异常检测系统（PSADS），该系统包括一种基于深度学习的分割算法，称为全尺寸特征自适应unet++ (ffa - unet++)。ffa - unet++解决了亮度均匀化、纹理均匀化和多层粉末扩散不足导致的边界模糊等问题。该算法能够检测六种类型的未充分粉末扩散，实现接近57%的平均交叉优于联合（mIoU），比六种广泛使用的分割网络提高了4% - 11%，单个异常类别的最大IoU超过90%。研究了六种类型的粉末铺布不足对lpbf制备的316 L不锈钢力学性能的影响，并提出了工艺控制准则：每个零件的累计粉末铺布不足层数不应超过三层。本研究为LPBF工艺提供了一种新的基于视觉的粉末铺展异常检测方法，为LPBF在工业应用中的质量控制提供了有价值的见解。

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引用次数: 0

4D printing of continuous fiber composites with embedded microcircuits: Synergistic enhancement of electrothermal actuation and load-bearing performance 嵌入微电路的连续纤维复合材料的4D打印：电热驱动和承载性能的协同增强

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-26 DOI: 10.1016/j.jmapro.2025.11.017

Zhanghao Hou , Xiaokai Li , Haolin Ding , Xiaoyang Zhu , Xiaoyong Tian , Huifa Shi , Weijun Zhu , Ruihao Guo , Chuanyang Wang , Hongbo Lan

To address the long-standing trade-off between heating efficiency and mechanical performance in electrothermally driven 4D printing of continuous carbon fiber-reinforced composites (CFRCs), we propose a dual-process hybrid printing strategy that integrates Electric-Field-Driven Microscale 3D Printing with Fused Deposition Modeling. This approach enables the seamless incorporation of continuous carbon fiber structural layers and silver-paste microcircuits, yielding embedded microcircuit CFRCs (EM-CFRCs). The embedded microcircuits significantly enhance electrothermal heating efficiency while maintaining the intrinsic strength of CFRCs. Experimental results show that EM-CFRCs achieve a heating rate of 5.9 °C/s, representing a 118.5 % improvement compared with conventional CFRCs, while the tensile modulus and structural stiffness remain nearly unchanged (increased by 1.5 %). We develop a predictive model based on multilayer beam theory that accurately captures the electrothermally induced deformation behavior and underlying mechanisms. Finally, we fabricate 4D-printed origami structures with complex geometries that demonstrate rapid actuation. These results highlight the potential of EM-CFRCs for aerospace deployable structures (e.g., solar sails), intelligent morphing components, and other advanced functional devices.

为了解决电热驱动的连续碳纤维增强复合材料（CFRCs） 4D打印中加热效率和机械性能之间长期存在的权衡问题，我们提出了一种双工艺混合打印策略，将电场驱动的微尺度3D打印与熔融沉积建模相结合。这种方法使连续碳纤维结构层和银糊微电路无缝结合，产生嵌入式微电路CFRCs （EM-CFRCs）。嵌入式微电路显著提高了CFRCs的电热加热效率，同时保持了CFRCs的固有强度。实验结果表明，EM-CFRCs的升温速率为5.9°C/s，与传统CFRCs相比提高了118.5%，而拉伸模量和结构刚度几乎保持不变（提高了1.5%）。我们建立了一个基于多层梁理论的预测模型，准确地捕捉了电热诱导变形的行为和潜在的机制。最后，我们制造了具有复杂几何形状的3d打印折纸结构，展示了快速驱动。这些结果突出了EM-CFRCs在航空航天可展开结构（如太阳帆）、智能变形部件和其他先进功能设备方面的潜力。

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引用次数: 0

Predictive modeling of tolerance-dependent failure behavior of self-pierce riveted joints: From coupon-level tests to sub-component validation 自穿孔铆接接头公差依赖失效行为的预测建模：从折扣级试验到子部件验证

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-12-26 DOI: 10.1016/j.jmapro.2025.12.058

Viktoria Olfert , Keke Yang , Philip Rochel , Philipp Bähr , David Hein , Silke Sommer , Gerson Meschut

Manufacturing tolerances have a measurable influence on the structural integrity of self-piercing riveted (SPR) joints in automotive applications, yet their quantitative impact on load-bearing behavior remains insufficiently resolved. This study establishes a validated hierarchical methodology to predict tolerance-dependent failure behavior of SPR joints, progressing from coupon to sub-component scale through an integrated experimental–numerical approach. Five critical manufacturing tolerances, including rivet length (±0.5 mm), rivet head position (±0.3 mm), orthogonality deviation (2.8° and 5°), lateral offset (up to 1.2 mm), and flange overlap reduction (up to 7.5 mm), were investigated. Steel–steel joints exhibited a higher sensitivity to tolerances by a factor of 2–3 compared to steel–aluminum joints. A unified effective rivet length concept was developed to consolidate the geometric effects of all tolerances into a single physically meaningful parameter, enabling load-bearing capacity prediction with R² > 0.95 across all evaluated loading directions. The sub-component validation employing T-joint specimens indicates a 2–3 fold amplification of tolerance effects at critical structural regions, providing experimental evidence for the hierarchical scaling principle. The methodology was implemented in a tolerance-dependent CONSTRAINED_SPR3 formulation, providing >99 % computational efficiency improvement while maintaining a deviation in maximum force prediction within ±7 %. This framework enables the physically consistent representation of manufacturing variation within large-scale simulations and establishes a transferable basis for tolerance-resilient virtual vehicle development.

制造公差对汽车应用中自穿孔铆接（SPR）接头的结构完整性具有可测量的影响，但其对承载性能的定量影响尚未得到充分解决。本研究建立了一种有效的分层方法来预测SPR接头的公差相关破坏行为，通过集成的实验-数值方法从轴块扩展到子部件尺度。研究了五个关键的制造公差，包括铆钉长度（±0.5 mm）、铆钉头位置（±0.3 mm）、正交度偏差（2.8°和5°）、横向偏移（最多1.2 mm）和法兰重叠减少（最多7.5 mm）。钢-钢连接对公差的敏感性比钢-铝连接高2-3倍。开发了统一的有效铆钉长度概念，将所有公差的几何影响整合到一个有物理意义的参数中，从而在所有评估的加载方向上实现R2 >； 0.95的承载能力预测。采用t形接头试件进行的子构件验证表明，在关键结构区域，公差效应放大了2-3倍，为分层标度原理提供了实验证据。该方法在与公差相关的CONSTRAINED_SPR3公式中实现，提供了>； 99%的计算效率提高，同时将最大力预测的偏差保持在±7%以内。该框架能够在大规模模拟中实现制造变化的物理一致表示，并为公差弹性虚拟车辆开发建立可转移的基础。

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引用次数: 0