The demand for Al-Si-based composites in automotive industry has driven the development of near-net shape continuously cast sheets. Conventional route of fabricating composite sheets required enormous amount of energy during the secondary processes. Therefore, the present study focuses on fabricating a 3 mm thick in-situ Al-12Si-12.5(TiB2 + Al2O3) hybrid composite sheet using vertical twin-roll continuous casting (VTRC) and comparing it to 6 mm thick gravity die-casted component. The investigation involves numerical and experimental methods to understand solidification kinetics and microstructure evolution during the processing of hybrid composite sheets. The numerical study involves the multiphysics of fluid flow and heat transfer with variable viscosity and solid fraction with temperature within a three-dimensional melt pool, which promotes formation of recirculation zones and promotes homogeneous temperature distribution. While processing, the reinforcement particles inside aluminium melt were synthesized using an in-situ metal-salt reaction method at 1053 K. The processing temperature for VTRC sheet was 910 K, determined using a dendritic coherency-based solidification criterion. The composite sheet characterization showed the presence of α-Al, acicular Si, and Al2O3 particles along with TiB2 particles in the microstructure. The average grain size (43.32 μm) and TiB2 particle size (0.90 μm) in the sheet was greater than in the gravity die-cast component (35.93 and 0.59 μm) despite higher solidification rates (8.77 K/s) in the sheet. This was attributed to longer nucleation and recalescence undercooling during sheet fabrication. The composite sheet exhibited 34.3 % increase in Vickers microhardness compared to Al-12Si base alloy and an ultimate tensile strength of 218.64 MPa.
{"title":"Next-gen composite sheets: Experimental and numerical investigation of processing and solidification kinetics of continuously cast Al-12Si-(TiB2 + Al2O3) hybrid composite","authors":"Sudhir Ranjan, Dheeraj Kumar Saini, Pradeep Kumar Jha","doi":"10.1016/j.jmapro.2025.02.040","DOIUrl":"10.1016/j.jmapro.2025.02.040","url":null,"abstract":"<div><div>The demand for Al-Si-based composites in automotive industry has driven the development of near-net shape continuously cast sheets. Conventional route of fabricating composite sheets required enormous amount of energy during the secondary processes. Therefore, the present study focuses on fabricating a 3 mm thick in-situ <em>Al</em>-12Si-12.5(TiB<sub>2</sub> + Al<sub>2</sub>O<sub>3</sub>) hybrid composite sheet using vertical twin-roll continuous casting (VTRC) and comparing it to 6 mm thick gravity die-casted component. The investigation involves numerical and experimental methods to understand solidification kinetics and microstructure evolution during the processing of hybrid composite sheets. The numerical study involves the multiphysics of fluid flow and heat transfer with variable viscosity and solid fraction with temperature within a three-dimensional melt pool, which promotes formation of recirculation zones and promotes homogeneous temperature distribution. While processing, the reinforcement particles inside aluminium melt were synthesized using an in-situ metal-salt reaction method at 1053 K. The processing temperature for VTRC sheet was 910 K, determined using a dendritic coherency-based solidification criterion. The composite sheet characterization showed the presence of α-Al, acicular Si, and Al<sub>2</sub>O<sub>3</sub> particles along with TiB<sub>2</sub> particles in the microstructure. The average grain size (43.32 μm) and TiB<sub>2</sub> particle size (0.90 μm) in the sheet was greater than in the gravity die-cast component (35.93 and 0.59 μm) despite higher solidification rates (8.77 K/s) in the sheet. This was attributed to longer nucleation and recalescence undercooling during sheet fabrication. The composite sheet exhibited 34.3 % increase in Vickers microhardness compared to Al-12Si base alloy and an ultimate tensile strength of 218.64 MPa.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"140 ","pages":"Pages 14-30"},"PeriodicalIF":6.1,"publicationDate":"2025-02-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143454669","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-20DOI: 10.1016/j.jmapro.2025.02.025
Mingfei Gu, Xingzhi Xiao, Tingting Liu, Gang Li, Wenhe Liao
The surface modifiers passivation effects on silver nanoparticles limit the conductivity of silver nanoparticle ink sintered circuit. In this work, the synchronicity of surface modifiers removal and silver particle coalescence, and energy consumption by surface modifiers removal were analyzed. By pre-adding 0.015 wt% destabilizing agents (Na+Cl−) into the silver ink, sintering behaviors and energy transfer mode were changed. Reduction ratios in resistivity of 25.7 % were achieved without changing laser parameters by the proposed in-situ strategy. A minimum resistivity of 5.06 μΩ·cm was achieved. Pre-adding Cl− advanced the startup time of surface modifiers desorption and prevented the surface modifiers negative effects on sintering neck growth. Moreover, the surface modifiers desorption turned from energy consumer to energy provider, allowing more energy for silver particle coalescence. This work would shed light on improving silver ink laser sintering conductivity and enhancing the performance of printed electronics.
{"title":"In-situ alleviation of surface modifier passivation effects in silver nanoparticle laser sintering process","authors":"Mingfei Gu, Xingzhi Xiao, Tingting Liu, Gang Li, Wenhe Liao","doi":"10.1016/j.jmapro.2025.02.025","DOIUrl":"10.1016/j.jmapro.2025.02.025","url":null,"abstract":"<div><div>The surface modifiers passivation effects on silver nanoparticles limit the conductivity of silver nanoparticle ink sintered circuit. In this work, the synchronicity of surface modifiers removal and silver particle coalescence, and energy consumption by surface modifiers removal were analyzed. By pre-adding 0.015 wt% destabilizing agents (Na<sup>+</sup>Cl<sup>−</sup>) into the silver ink, sintering behaviors and energy transfer mode were changed. Reduction ratios in resistivity of 25.7 % were achieved without changing laser parameters by the proposed in-situ strategy. A minimum resistivity of 5.06 μΩ·cm was achieved. Pre-adding Cl<sup>−</sup> advanced the startup time of surface modifiers desorption and prevented the surface modifiers negative effects on sintering neck growth. Moreover, the surface modifiers desorption turned from energy consumer to energy provider, allowing more energy for silver particle coalescence. This work would shed light on improving silver ink laser sintering conductivity and enhancing the performance of printed electronics.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 239-249"},"PeriodicalIF":6.1,"publicationDate":"2025-02-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143445954","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-19DOI: 10.1016/j.jmapro.2025.01.047
Saurabh Gairola , R. Jayaganthan
Lightweight designs have become imperative in aerospace applications, driven by the increasing focus on green aviation and the ever-growing need to reduce aviation emissions. The complex lightweight designs are typically limited by the manufacturing capability of the conventional process. Consequently, additive manufacturing has emerged as a vital tool for producing these lightweight designs, owing to its inherent design freedom as a consequence of its layer-by-layer approach. The current study explores the different lightweight design strategies derived from topology optimisation (TO) and internal lattice structure for aerospace applications. The proposed lightweight designs were examined for their mechanical performance and additive manufacturing-specific design constraints, such as support structure requirements and processing efforts. The optimal lattice infill was determined by comparing the mechanical properties of different skeletal and sheet-type triply periodic minimal surface lattice structures. Among the different lattice structures tested in the current study, the sheet-type diamond lattice structure emerged as the most suitable option for infill due to its superior mechanical properties. The TO results, coupled with the functionally graded diamond lattice structures, exhibited the best mechanical performance, yielding a maximum weight reduction of 24.3 % for bracket A and 52.5 % for bracket B.
{"title":"Lattice infill strategies for topology optimisation towards achieving lightweight designs for additive manufacturing: Structural integrity, and manufacturing consideration","authors":"Saurabh Gairola , R. Jayaganthan","doi":"10.1016/j.jmapro.2025.01.047","DOIUrl":"10.1016/j.jmapro.2025.01.047","url":null,"abstract":"<div><div>Lightweight designs have become imperative in aerospace applications, driven by the increasing focus on green aviation and the ever-growing need to reduce aviation emissions. The complex lightweight designs are typically limited by the manufacturing capability of the conventional process. Consequently, additive manufacturing has emerged as a vital tool for producing these lightweight designs, owing to its inherent design freedom as a consequence of its layer-by-layer approach. The current study explores the different lightweight design strategies derived from topology optimisation (TO) and internal lattice structure for aerospace applications. The proposed lightweight designs were examined for their mechanical performance and additive manufacturing-specific design constraints, such as support structure requirements and processing efforts. The optimal lattice infill was determined by comparing the mechanical properties of different skeletal and sheet-type triply periodic minimal surface lattice structures. Among the different lattice structures tested in the current study, the sheet-type diamond lattice structure emerged as the most suitable option for infill due to its superior mechanical properties. The TO results, coupled with the functionally graded diamond lattice structures, exhibited the best mechanical performance, yielding a maximum weight reduction of 24.3 % for bracket A and 52.5 % for bracket B.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 224-238"},"PeriodicalIF":6.1,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143445953","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.030
Sang Min Yang , Yun Seok Kang , Do Young Kim , Hyung Wook Park
In advanced industries such as automotive, aerospace, and biomedical, the Ti-6Al-4 V material is widely used owing to its superior mechanical properties. However, because of inadequate thermal properties, tool wear increases rapidly, leading to persistent problems with surface integrity. Therefore, tool wear needs to be enhanced while ensuring the surface integrity during the machining. This paper investigates the surface integrity of Ti-6Al-4 V using a large pulsed electron beam (LPEB) irradiated cutting tool, examining surface integrity from a multiscale (macro, and micro) perspective. The electron beam was irradiated on the cutting tool, and the characteristics analysis of the LPEB-irradiated cutting tool was conducted, including tool surface roughness and edge radius. The flank wear was measured to identify the effect of LPEB irradiation on wear evolution. Furthermore, the influence of the LPEB-irradiated cutting tools on the work material was analyzed compared to the non-irradiated cutting tools; the machined surface roughness was reduced by 13.6 %, the plastic deformation length was reduced by 41.0 %, microhardness was improved by 44.3 %, and the residual stress of the machined surface was reduced by 27.1 %, respectively. This result is caused by the improved surface qualities of the LPEB-irradiated cutting tool in terms of reduced tool surface roughness and increased edge radius. Moreover, the reduced flank wear may positively affect the enhancement of surface integrity.
{"title":"Experimental investigation of tool wear and surface integrity using a large pulsed electron beam (LPEB) irradiated end-mill cutting tool for Ti-6Al-4 V","authors":"Sang Min Yang , Yun Seok Kang , Do Young Kim , Hyung Wook Park","doi":"10.1016/j.jmapro.2025.02.030","DOIUrl":"10.1016/j.jmapro.2025.02.030","url":null,"abstract":"<div><div>In advanced industries such as automotive, aerospace, and biomedical, the Ti-6Al-4 V material is widely used owing to its superior mechanical properties. However, because of inadequate thermal properties, tool wear increases rapidly, leading to persistent problems with surface integrity. Therefore, tool wear needs to be enhanced while ensuring the surface integrity during the machining. This paper investigates the surface integrity of Ti-6Al-4 V using a large pulsed electron beam (LPEB) irradiated cutting tool, examining surface integrity from a multiscale (macro, and micro) perspective. The electron beam was irradiated on the cutting tool, and the characteristics analysis of the LPEB-irradiated cutting tool was conducted, including tool surface roughness and edge radius. The flank wear was measured to identify the effect of LPEB irradiation on wear evolution. Furthermore, the influence of the LPEB-irradiated cutting tools on the work material was analyzed compared to the non-irradiated cutting tools; the machined surface roughness was reduced by 13.6 %, the plastic deformation length was reduced by 41.0 %, microhardness was improved by 44.3 %, and the residual stress of the machined surface was reduced by 27.1 %, respectively. This result is caused by the improved surface qualities of the LPEB-irradiated cutting tool in terms of reduced tool surface roughness and increased edge radius. Moreover, the reduced flank wear may positively affect the enhancement of surface integrity.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 172-181"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427698","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.036
Wengang Zhai , Wei Zhou , Yuan Yu , Sharon Mui Ling Nai
Although there have been studies reported on TiB2 strengthened 316L via laser powder bed fusion (LPBF), none identified the decomposition of TiB2 and the collaborative influence of titanium and boron on microstructure evolution. Here, we report a unique core-shell melt pool structure in 316L enabled by introducing 1 wt%, 2 wt% and 3 wt% TiB2 particles through the LPBF process. In the LPBF-fabricated 316L-TiB2 composites, the core at the centre of the melt pool contains ultrafine grains and twin boundaries while the edge features columnar grains. The TiB2 particles undergo melting and decomposition in the steel matrix during the LPBF process as demonstrated using atom probe tomography (APT). Significant grain refinement (from 25.9 μm to about 1 μm) for LPBF-processed 316L was observed. The collaborative influence of Ti and B elements catalyses the creation of this unique core-shell structure. The LPBF-processed 316L-TiB2 exhibits an excellent combination of high strength (yield strength: 858 MPa, ultimate tensile strength: 1095 MPa) and ductility (27%). Among the various particles evaluated, TiB2 particles demonstrated superior efficiency over other ceramic particles in grain refinement and strength enhancement for 316L.
{"title":"Additive manufacturing of TiB2 particles enabled high-performance 316L with a unique core-shell melt pool structure","authors":"Wengang Zhai , Wei Zhou , Yuan Yu , Sharon Mui Ling Nai","doi":"10.1016/j.jmapro.2025.02.036","DOIUrl":"10.1016/j.jmapro.2025.02.036","url":null,"abstract":"<div><div>Although there have been studies reported on TiB<sub>2</sub> strengthened 316L via laser powder bed fusion (LPBF), none identified the decomposition of TiB<sub>2</sub> and the collaborative influence of titanium and boron on microstructure evolution. Here, we report a unique core-shell melt pool structure in 316L enabled by introducing 1 wt%, 2 wt% and 3 wt% TiB<sub>2</sub> particles through the LPBF process. In the LPBF-fabricated 316L-TiB<sub>2</sub> composites, the core at the centre of the melt pool contains ultrafine grains and twin boundaries while the edge features columnar grains. The TiB<sub>2</sub> particles undergo melting and decomposition in the steel matrix during the LPBF process as demonstrated using atom probe tomography (APT). Significant grain refinement (from 25.9 μm to about 1 μm) for LPBF-processed 316L was observed. The collaborative influence of Ti and B elements catalyses the creation of this unique core-shell structure. The LPBF-processed 316L-TiB<sub>2</sub> exhibits an excellent combination of high strength (yield strength: 858 MPa, ultimate tensile strength: 1095 MPa) and ductility (27%). Among the various particles evaluated, TiB<sub>2</sub> particles demonstrated superior efficiency over other ceramic particles in grain refinement and strength enhancement for 316L.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 144-155"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427833","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.033
Tianyu Bai , Xilong Wang , Zhaojing Gao , Shufu Wang , Chenlong Zuo , Jinyou Kang , Heng Zhang , Jinsheng Zhang
As a highly efficient tool, carbide circular saw blades are ideal for hard metal machining, but they face limitations for tooth wear and manufacturing. The study comprehensively analyzes sawing performance and tool wear mechanisms of circular saw blades in the 7075 aluminum alloy sawing process. Firstly, a mathematical model of the instantaneous undeformed chip thickness (IUCT) was developed, and sawing force models were established to explain the vibration characteristics of tools. Moreover, simulation analysis of the aluminum alloy machining process was performed by the finite element method (FEM), indicating that the sawing force decreases and the surface quality is better as the rotational speed increases. However, more heat is generated due to the high-speed friction between teeth and the machined surface. Then, sawing forces and vibration behavior of circular saw blades were studied. Experimental evidence indicates that the substrate's vibration and sawing forces increase with feed rates and sawing depths. In the axial direction, circular saw blades are the least stiff, which tends to cause severe vibration, and the sawing depth is particularly sensitive to tool vibration. A detailed account of the wear characteristics of the teeth is concluded, with the adhesion caused by the sawing heat by scanning electron microscopy (SEM) and electron dispersive spectroscopy (EDS). It was established that adhesion due to sawing heat is the dominant cause of carbide tooth wear. Adhesive wear and misaligned sawing result in scratches and laminations on the surface of the workpiece. The research systematically analyzes the wear characteristics and machining performance of teeth and provides theoretical guidance for designing saw teeth and optimizing machining parameters.
{"title":"Tool wear analysis of high-speed sawing of aerospace aluminum alloy based on FEM simulation and cutting experiments","authors":"Tianyu Bai , Xilong Wang , Zhaojing Gao , Shufu Wang , Chenlong Zuo , Jinyou Kang , Heng Zhang , Jinsheng Zhang","doi":"10.1016/j.jmapro.2025.02.033","DOIUrl":"10.1016/j.jmapro.2025.02.033","url":null,"abstract":"<div><div>As a highly efficient tool, carbide circular saw blades are ideal for hard metal machining, but they face limitations for tooth wear and manufacturing. The study comprehensively analyzes sawing performance and tool wear mechanisms of circular saw blades in the 7075 aluminum alloy sawing process. Firstly, a mathematical model of the instantaneous undeformed chip thickness (IUCT) was developed, and sawing force models were established to explain the vibration characteristics of tools. Moreover, simulation analysis of the aluminum alloy machining process was performed by the finite element method (FEM), indicating that the sawing force decreases and the surface quality is better as the rotational speed increases. However, more heat is generated due to the high-speed friction between teeth and the machined surface. Then, sawing forces and vibration behavior of circular saw blades were studied. Experimental evidence indicates that the substrate's vibration and sawing forces increase with feed rates and sawing depths. In the axial direction, circular saw blades are the least stiff, which tends to cause severe vibration, and the sawing depth is particularly sensitive to tool vibration. A detailed account of the wear characteristics of the teeth is concluded, with the adhesion caused by the sawing heat by scanning electron microscopy (SEM) and electron dispersive spectroscopy (EDS). It was established that adhesion due to sawing heat is the dominant cause of carbide tooth wear. Adhesive wear and misaligned sawing result in scratches and laminations on the surface of the workpiece. The research systematically analyzes the wear characteristics and machining performance of teeth and provides theoretical guidance for designing saw teeth and optimizing machining parameters.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 193-209"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143438029","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.032
Xiaohui Jiang , Fangxu Hu , Chongjun Wu , Chao Luo , Zhijian Lin , Ermakov Boris Sergeevich
Complex thin-walled parts with variable curvature are crucial in aerospace, yet their manufacturing-induced residual stresses often lead to deformation, posing challenges in surface residual stress measurement and deformation prediction due to the complex geometric coordinate system. This study develops a model for predicting the distribution of subsurface residual stresses and the resulting deformation. By integrating the segmented polynomial fitting and random forest regression methods, a subsurface residual stress distribution prediction model is established and verified through experiments on machining and stress detection of such parts. Additionally, a special fixture for stress detection is designed. Based on ABAQUS software, a deformation simulation model considering residual stress is developed. Through continuous two-month monitoring of parts with different processing parameters, it is found that the simulation results align with the experimental trend, with an error range of 6.7 %–12.4 %. Eventually, a deformation prediction model based on process parameters is constructed, which can effectively predict the deformation of these parts and provides a theoretical foundation for deformation control.
{"title":"Deformation prediction model for milling residual stresses in complex thin-walled parts with variable curvature","authors":"Xiaohui Jiang , Fangxu Hu , Chongjun Wu , Chao Luo , Zhijian Lin , Ermakov Boris Sergeevich","doi":"10.1016/j.jmapro.2025.02.032","DOIUrl":"10.1016/j.jmapro.2025.02.032","url":null,"abstract":"<div><div>Complex thin-walled parts with variable curvature are crucial in aerospace, yet their manufacturing-induced residual stresses often lead to deformation, posing challenges in surface residual stress measurement and deformation prediction due to the complex geometric coordinate system. This study develops a model for predicting the distribution of subsurface residual stresses and the resulting deformation. By integrating the segmented polynomial fitting and random forest regression methods, a subsurface residual stress distribution prediction model is established and verified through experiments on machining and stress detection of such parts. Additionally, a special fixture for stress detection is designed. Based on ABAQUS software, a deformation simulation model considering residual stress is developed. Through continuous two-month monitoring of parts with different processing parameters, it is found that the simulation results align with the experimental trend, with an error range of 6.7 %–12.4 %. Eventually, a deformation prediction model based on process parameters is constructed, which can effectively predict the deformation of these parts and provides a theoretical foundation for deformation control.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 156-171"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427834","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.035
Merle Braatz , Jan Bohlen , Noomane Ben Khalifa
The main disadvantage of the dieless wire drawing process is the complex interdependence of the process parameters, which often leads to process instability. The objective of this paper is to integrate the analysis of material behaviour with process performance, thereby extending the range of applicability and enhancing process control. For this purpose, the forming zone and its length are investigated and evaluated in detail to identify stable process scenarios and to predict the occurrence of (non-)localised deformation and actual diameter reduction. It is found that elevated temperatures above about 0.6 times the melting temperature result in well localised deformation, whereas increasing the feeding speed or the reduction ratio increases the length of the forming zone. An equation is presented for calculating the length of the forming zone based on material properties and process settings. In addition, stable process conditions are given, including minimum forming zone lengths and maximum possible diameter reductions. Predictions of actual diameter reductions using different approaches are also presented.
{"title":"Comprehensive analysis of the forming zone and improvement of diameter reduction prediction in the dieless wire drawing process","authors":"Merle Braatz , Jan Bohlen , Noomane Ben Khalifa","doi":"10.1016/j.jmapro.2025.02.035","DOIUrl":"10.1016/j.jmapro.2025.02.035","url":null,"abstract":"<div><div>The main disadvantage of the dieless wire drawing process is the complex interdependence of the process parameters, which often leads to process instability. The objective of this paper is to integrate the analysis of material behaviour with process performance, thereby extending the range of applicability and enhancing process control. For this purpose, the forming zone and its length are investigated and evaluated in detail to identify stable process scenarios and to predict the occurrence of (non-)localised deformation and actual diameter reduction. It is found that elevated temperatures above about 0.6 times the melting temperature result in well localised deformation, whereas increasing the feeding speed or the reduction ratio increases the length of the forming zone. An equation is presented for calculating the length of the forming zone based on material properties and process settings. In addition, stable process conditions are given, including minimum forming zone lengths and maximum possible diameter reductions. Predictions of actual diameter reductions using different approaches are also presented.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 210-223"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143438030","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-18DOI: 10.1016/j.jmapro.2025.02.026
Jiayun Feng , Shuai Wang , Wei Wang , Jianchao Liang , Jiayue Wen , Shang Wang , Ruyu Tian , Yanhong Tian
The rapid advancement of system-in-package (SiP) technology has created urgent demands for higher integration density, smaller size, and enhanced reliability. These demands necessitate interconnection joints with superior thermal, electrical, and mechanical performance, which can endure more severe service environment and higher power loads. Copper pillar bump (CPB) technology, as an advanced packaging solution, offers excellent comprehensive properties and high reliability, thereby playing a crucial role in the integration of 3D SiP devices. However, the brittle intermetallic compound (IMC) layer is one of the most uncontrollable factors that may cause the degradation of CPB/solder interface in terms of heat transfer, electric conduction and structural strength. This study examined the reliability of CPBs with varying IMC layer thicknesses under isothermal high-temperature electromigration conditions, revealing the impact of initial IMC thickness and bump microstructure on reliability. Real-time resistance variation closely aligned with the transformation process from thin-IMC to half-IMC, and to full-IMC bumps, facilitating nondestructive prediction of failure times. The tests indicated that thin-IMC bumps exhibited the best thermal-electrical aging reliability, while full-IMC bumps performed the worst. The results of stationary simulations for temperature, thermal stress, and current density indicated that voids and cracks in the full-IMC CPB significantly hindered heat conduction and caused thermal stress concentration. Additionally, the skin effect at the edges of voids led to severe electric current crowding, which accelerated electromigration, further promoting the expansion of voids and shortening the service life of CPBs.
{"title":"Thermal-electrical coupling effect on the reliability of copper pillar bump joints with different initial IMC thickness and microstructure","authors":"Jiayun Feng , Shuai Wang , Wei Wang , Jianchao Liang , Jiayue Wen , Shang Wang , Ruyu Tian , Yanhong Tian","doi":"10.1016/j.jmapro.2025.02.026","DOIUrl":"10.1016/j.jmapro.2025.02.026","url":null,"abstract":"<div><div>The rapid advancement of system-in-package (SiP) technology has created urgent demands for higher integration density, smaller size, and enhanced reliability. These demands necessitate interconnection joints with superior thermal, electrical, and mechanical performance, which can endure more severe service environment and higher power loads. Copper pillar bump (CPB) technology, as an advanced packaging solution, offers excellent comprehensive properties and high reliability, thereby playing a crucial role in the integration of 3D SiP devices. However, the brittle intermetallic compound (IMC) layer is one of the most uncontrollable factors that may cause the degradation of CPB/solder interface in terms of heat transfer, electric conduction and structural strength. This study examined the reliability of CPBs with varying IMC layer thicknesses under isothermal high-temperature electromigration conditions, revealing the impact of initial IMC thickness and bump microstructure on reliability. Real-time resistance variation closely aligned with the transformation process from thin-IMC to half-IMC, and to full-IMC bumps, facilitating nondestructive prediction of failure times. The tests indicated that thin-IMC bumps exhibited the best thermal-electrical aging reliability, while full-IMC bumps performed the worst. The results of stationary simulations for temperature, thermal stress, and current density indicated that voids and cracks in the full-IMC CPB significantly hindered heat conduction and caused thermal stress concentration. Additionally, the skin effect at the edges of voids led to severe electric current crowding, which accelerated electromigration, further promoting the expansion of voids and shortening the service life of CPBs.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 182-192"},"PeriodicalIF":6.1,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143438088","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-02-17DOI: 10.1016/j.jmapro.2025.02.021
Dang Khoi Le , Shinichi Tashiro , Quang Ngoc Trinh , Tetsuo Suga , Naoki Sawamura , Kazuhiro Fukuda , Shuji Sasakura , J. Eduardo Alvarez-Rocha , Patricio Fernando Mendez , Anthony B. Murphy , Van Hanh Bui , Manabu Tanaka
This study investigates the effects of alkali elements on metal transfer behavior in rutile flux-cored arc welding. Four types of prototype flux-cored wires with different sodium contents in the flux were fabricated. By using these wires, the influence mechanism of sodium on the metal transfer behavior was elucidated through shadowgraph measurements of the metal transfer behavior as well as spectroscopic and color image observations of the arc characteristics. It was found that the metal transfer between 190 A and 310 A was in the projected transfer mode and could be further classified into two sub-modes (type A and type B) based on the droplet formation process. A larger droplet was formed on the side of flux column in type A, while a smaller one was formed in the center covering the flux in type B. The metal transfer frequency became larger in the latter case for the same wire feeding speed. Type A tended to dominate in the lower current and lower sodium content conditions, while type B dominated in the opposite conditions. The dominant sub-mode was determined to depend on the Lorentz force acting on the droplet. At medium currents (250 A and 280 A), both sub-modes appeared in similar proportions. The maximum metal transfer frequency occurred at a particular sodium content. When the sodium content was smaller or larger, type A or type B became dominant, respectively. The sodium content at which the maximum frequency occurred decreased when the current increased. In type A, the iron plasma was widely distributed on the droplet side of the flux, while the sodium plasma was concentrated near the flux on the opposite side, so both were separated. In contrast, in type B, the sodium plasma was concentrated around the flux at the center and the iron plasma was widely distributed in the arc column, so both overlapped around the center. Sodium has a low boiling point and low ionization potential. In type A, the sodium vapor greatly increased the electrical conductivity of plasma around the flux column, so part of the current flowed from the wire through the sodium plasma to the weld pool. Accordingly, the current flowing through the bottom of the droplet to the arc decreased, leading to a lower arc pressure and recoil pressure under the droplet, and causing the metal transfer frequency to increase with sodium content. On the other hand, in type B, the sodium vaporization increased around the center, increasing the recoil pressure. In addition, the current density at the bottom of the droplet increased due to the current concentration in the arc, causing the arc pressure to rise. Therefore, the metal transfer frequency tended to decrease with sodium content. Due to the balance of these factors, the metal transfer frequency has a maximum at a particular sodium content.
{"title":"Elucidation of alkali element's role in optimizing metal transfer behavior in rutile-type flux-cored arc welding","authors":"Dang Khoi Le , Shinichi Tashiro , Quang Ngoc Trinh , Tetsuo Suga , Naoki Sawamura , Kazuhiro Fukuda , Shuji Sasakura , J. Eduardo Alvarez-Rocha , Patricio Fernando Mendez , Anthony B. Murphy , Van Hanh Bui , Manabu Tanaka","doi":"10.1016/j.jmapro.2025.02.021","DOIUrl":"10.1016/j.jmapro.2025.02.021","url":null,"abstract":"<div><div>This study investigates the effects of alkali elements on metal transfer behavior in rutile flux-cored arc welding. Four types of prototype flux-cored wires with different sodium contents in the flux were fabricated. By using these wires, the influence mechanism of sodium on the metal transfer behavior was elucidated through shadowgraph measurements of the metal transfer behavior as well as spectroscopic and color image observations of the arc characteristics. It was found that the metal transfer between 190 A and 310 A was in the projected transfer mode and could be further classified into two sub-modes (type A and type B) based on the droplet formation process. A larger droplet was formed on the side of flux column in type A, while a smaller one was formed in the center covering the flux in type B. The metal transfer frequency became larger in the latter case for the same wire feeding speed. Type A tended to dominate in the lower current and lower sodium content conditions, while type B dominated in the opposite conditions. The dominant sub-mode was determined to depend on the Lorentz force acting on the droplet. At medium currents (250 A and 280 A), both sub-modes appeared in similar proportions. The maximum metal transfer frequency occurred at a particular sodium content. When the sodium content was smaller or larger, type A or type B became dominant, respectively. The sodium content at which the maximum frequency occurred decreased when the current increased. In type A, the iron plasma was widely distributed on the droplet side of the flux, while the sodium plasma was concentrated near the flux on the opposite side, so both were separated. In contrast, in type B, the sodium plasma was concentrated around the flux at the center and the iron plasma was widely distributed in the arc column, so both overlapped around the center. Sodium has a low boiling point and low ionization potential. In type A, the sodium vapor greatly increased the electrical conductivity of plasma around the flux column, so part of the current flowed from the wire through the sodium plasma to the weld pool. Accordingly, the current flowing through the bottom of the droplet to the arc decreased, leading to a lower arc pressure and recoil pressure under the droplet, and causing the metal transfer frequency to increase with sodium content. On the other hand, in type B, the sodium vaporization increased around the center, increasing the recoil pressure. In addition, the current density at the bottom of the droplet increased due to the current concentration in the arc, causing the arc pressure to rise. Therefore, the metal transfer frequency tended to decrease with sodium content. Due to the balance of these factors, the metal transfer frequency has a maximum at a particular sodium content.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 105-125"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427737","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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