Pub Date : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.033
Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang
The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (El) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (El = 150 J/mm), which significantly affects the stability and quality of robotic milling.
{"title":"Thermal effects on the material removal mechanism in laser-assisted milling of CFRP","authors":"Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang","doi":"10.1016/j.jmapro.2026.01.033","DOIUrl":"10.1016/j.jmapro.2026.01.033","url":null,"abstract":"<div><div>The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (<em>E</em><sub><em>l</em></sub>) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (<em>E</em><sub><em>l</em></sub> = 150 J/mm), which significantly affects the stability and quality of robotic milling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 199-216"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981210","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 : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.031
Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu
Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.
{"title":"Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding","authors":"Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu","doi":"10.1016/j.jmapro.2026.01.031","DOIUrl":"10.1016/j.jmapro.2026.01.031","url":null,"abstract":"<div><div>Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 188-198"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981208","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 : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.020
Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek
Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.
{"title":"Plasticity improvement by pulsed electric current during sheet metal forming of Al-Mg alloy strips in different states of hardening","authors":"Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek","doi":"10.1016/j.jmapro.2026.01.020","DOIUrl":"10.1016/j.jmapro.2026.01.020","url":null,"abstract":"<div><div>Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 166-175"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981201","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 : 2026-01-15DOI: 10.1016/j.jmapro.2026.01.018
Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao
The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (Pc) for significant formability improvement. And the PC decreases as the forming temperature increases. Below Pc, LFH exhibited negligible improvement. When stress exceeded Pc, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for PC closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.
{"title":"Enhanced formability of age-hardened 2219 aluminum alloy: role of through-thickness stress and temperature synergy","authors":"Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao","doi":"10.1016/j.jmapro.2026.01.018","DOIUrl":"10.1016/j.jmapro.2026.01.018","url":null,"abstract":"<div><div>The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (<em>P</em>c) for significant formability improvement. And the <em>P</em><sub>C</sub> decreases as the forming temperature increases. Below <em>P</em>c, LFH exhibited negligible improvement. When stress exceeded <em>P</em>c, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for <em>P</em><sub>C</sub> closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 176-187"},"PeriodicalIF":6.8,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981207","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 : 2026-01-14DOI: 10.1016/j.jmapro.2026.01.003
Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li
Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.
{"title":"Strengthening mechanism of IN 718 alloy fabricated by ultrasonic vibration-assisted laser directed energy deposition with heat treatment","authors":"Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li","doi":"10.1016/j.jmapro.2026.01.003","DOIUrl":"10.1016/j.jmapro.2026.01.003","url":null,"abstract":"<div><div>Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 107-118"},"PeriodicalIF":6.8,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981203","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 : 2026-01-14DOI: 10.1016/j.jmapro.2026.01.024
Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi
Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, λcav—defined as the ratio of gas cavity retraction timescale (τcav) to solidification timescale (τsol). Higher λcav values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.
{"title":"Internal pores in printed metal bumps: evolution mechanism and elimination strategy","authors":"Lang Wu , Jun Luo , Yunlong Zhou , Yi Zhou , Shengnan Lv , Lehua Qi","doi":"10.1016/j.jmapro.2026.01.024","DOIUrl":"10.1016/j.jmapro.2026.01.024","url":null,"abstract":"<div><div>Pore defects in metal droplet deposition, caused by gas entrainment, significantly degrade the reliability of printed bumps. While prior research has primarily addressed gas entrapment at the substrate interface leading to bottom pores, this study identifies a novel issue: droplet-top ambient gas entrainment causing internal pores within the bumps. To explore this phenomenon, we conducted bump printing experiments under varying substrate temperatures and impact velocities, inducing diverse gas-liquid interface behaviors. A three-dimensional numerical model, developed using the VOF method, analyzed the two-phase gas-liquid flow and solidification interface evolution within the droplet. Quantitative analysis, combining one-dimensional heat conduction and gas cavity collapse theories, revealed a strong link between internal pore formation and the thermodynamic coupling ratio of gas cavity retraction, <em>λ</em><sub>cav</sub>—defined as the ratio of gas cavity retraction timescale (<em>τ</em><sub>cav</sub>) to solidification timescale (<em>τ</em><sub>sol</sub>). Higher <em>λ</em><sub>cav</sub> values increase viscous shear forces, impeding gas cavity retraction and promoting solidification during slow retraction, thereby generating internal pore defects. To address this defect, we developed a “Thermal-Impact dual-field regulated printing” strategy, successfully printing a bump array free of internal pore defects on a chip. These findings enhance understanding of pore formation mechanisms in droplet-based additive manufacturing and provide practical elimination strategies, especially for flip-chip bonding applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 150-165"},"PeriodicalIF":6.8,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981209","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 : 2026-01-14DOI: 10.1016/j.jmapro.2026.01.025
Cheng Shan , Yuming Xie , Xiangchen Meng , Yilong Han , Shenglong Wang , Shengnan Hu , Ruitao Guo , Yongxian Huang
The manufacturing of high-performance cooling channels is critical for advancing thermal management systems in electric vehicles and aerospace. Conventional techniques, like milling and cover-plate welding, suffer from multi-step complexity, joint corrosion risks, and design constraints. Herein, friction stir channeling (FSC) is proposed as a transformative single-step solution for monolithic internal channel manufacturing. To address the long-standing challenge of channel shape irregularity, a novel material overflow-reflux model and a tip-enlarged tool are developed, with formation mechanisms elucidated through combined numerical modeling and experimental validation. The optimized process achieves large-scale channels (10 mm width, 2 mm height) with an unprecedentedly high rectangularity of 93.0%. These monolithic channels demonstrate exceptional performance, sustaining leak-free operation under 1 MPa for 7200 s and achieving a high heat dissipation rate of 16 K/s. This work advances FSC as a robust and promising approach for creating highly efficient, reliable, and integrated cooling components, providing fundamental insights for its application in advanced thermal management systems.
{"title":"Innovation in friction stir channeling technology towards dimensional optimization with a rectangularity of 93.0%","authors":"Cheng Shan , Yuming Xie , Xiangchen Meng , Yilong Han , Shenglong Wang , Shengnan Hu , Ruitao Guo , Yongxian Huang","doi":"10.1016/j.jmapro.2026.01.025","DOIUrl":"10.1016/j.jmapro.2026.01.025","url":null,"abstract":"<div><div>The manufacturing of high-performance cooling channels is critical for advancing thermal management systems in electric vehicles and aerospace. Conventional techniques, like milling and cover-plate welding, suffer from multi-step complexity, joint corrosion risks, and design constraints. Herein, friction stir channeling (FSC) is proposed as a transformative single-step solution for monolithic internal channel manufacturing. To address the long-standing challenge of channel shape irregularity, a novel material overflow-reflux model and a tip-enlarged tool are developed, with formation mechanisms elucidated through combined numerical modeling and experimental validation. The optimized process achieves large-scale channels (10 mm width, 2 mm height) with an unprecedentedly high rectangularity of 93.0%. These monolithic channels demonstrate exceptional performance, sustaining leak-free operation under 1 MPa for 7200 s and achieving a high heat dissipation rate of 16 K/s. This work advances FSC as a robust and promising approach for creating highly efficient, reliable, and integrated cooling components, providing fundamental insights for its application in advanced thermal management systems.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 132-149"},"PeriodicalIF":6.8,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981206","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 : 2026-01-14DOI: 10.1016/j.jmapro.2026.01.023
Hyo-jeong Kim , Seoung-hwan Lee
This study presents a real-time acoustic emission (AE)-based monitoring framework for burr formation in the micro-drilling of carbon fiber reinforced plastics (CFRP). A polyvinylidene fluoride (PVDF)-based sensor is employed as a low-cost, flexible alternative to conventional AE sensors and is calibrated to ISO standards to ensure high-frequency signal fidelity. AE signals collected during drilling are analyzed using continuous wavelet transform (CWT) to capture the signal characteristics associated with fiber fracture and delamination. A convolutional neural network (CNN) is trained on time-frequency scalograms to classify machining parameters with high accuracy. Experimental validation shows that drill diameter is the most significant factor affecting burr formation, as confirmed by two-way ANOVA. The proposed PVDF-CWT-CNN framework successfully identifies process conditions in real-time and offers a scalable approach for intelligent monitoring in high-precision CFRP machining.
{"title":"Real-time burr monitoring in CFRP micro-drilling using a PVDF-based AE sensor and CNN-assisted signal classification","authors":"Hyo-jeong Kim , Seoung-hwan Lee","doi":"10.1016/j.jmapro.2026.01.023","DOIUrl":"10.1016/j.jmapro.2026.01.023","url":null,"abstract":"<div><div>This study presents a real-time acoustic emission (AE)-based monitoring framework for burr formation in the micro-drilling of carbon fiber reinforced plastics (CFRP). A polyvinylidene fluoride (PVDF)-based sensor is employed as a low-cost, flexible alternative to conventional AE sensors and is calibrated to ISO standards to ensure high-frequency signal fidelity. AE signals collected during drilling are analyzed using continuous wavelet transform (CWT) to capture the signal characteristics associated with fiber fracture and delamination. A convolutional neural network (CNN) is trained on time-frequency scalograms to classify machining parameters with high accuracy. Experimental validation shows that drill diameter is the most significant factor affecting burr formation, as confirmed by two-way ANOVA. The proposed PVDF-CWT-CNN framework successfully identifies process conditions in real-time and offers a scalable approach for intelligent monitoring in high-precision CFRP machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 119-131"},"PeriodicalIF":6.8,"publicationDate":"2026-01-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981204","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 : 2026-01-13DOI: 10.1016/j.jmapro.2026.01.004
Yixuan Dong , Tonghui Wang , Chuang Guan , Yiqi Wang , Jinsu Yu , Tianbiao Yu
Laser cladding (LC) is widely used for high-performance surface enhancement and component repair, with its processing quality highly dependent on complex parameter configurations. However, for LC-applied high-entropy alloy (HEA) coatings, the high cost of sample acquisition and the limitations of traditional response surface methods make it difficult to achieve accurate optimization under small-sample scenarios. This study proposes a laser cladding process parameter optimization method for MoNbTaTiZr powder, integrating multimodal surrogate modeling with reinforcement learning. A conditional generative adversarial network (cGAN) is employed to generate cross-sectional feature images of the cladding layer, which are further processed using a convolutional neural network (CNN) combined with a multi-task architecture to jointly predict multiple performance metrics, including dilution rate, shape factor, and microhardness. Based on this framework, this study proposes a Soft Actor-Critic algorithm with perturbation-aware replay optimization (PRO-SAC) method, which incorporates policy perturbation sensitivity, Temporal Difference (TD) error, and Pareto-front information of samples to jointly drive experience replay, thereby improving the learning efficiency and stability of process parameter optimization strategies. Experimental results show that the proposed prediction model achieves correlation coefficients above 0.97 for all quality indicators. Compared with other classical methods, the PRO-SAC optimization results exhibit superior performance across multiple evaluation metrics. Under the constraint of maintaining the shape factor, the microhardness and dilution rate of the cladding layer are improved by 11.3 % and 0.24 %, respectively, relative to the best values in the existing training dataset, confirming the effectiveness and engineering adaptability of the proposed method for laser cladding parameter optimization.
{"title":"Laser cladding process optimization via multimodal generative prediction and reinforcement learning","authors":"Yixuan Dong , Tonghui Wang , Chuang Guan , Yiqi Wang , Jinsu Yu , Tianbiao Yu","doi":"10.1016/j.jmapro.2026.01.004","DOIUrl":"10.1016/j.jmapro.2026.01.004","url":null,"abstract":"<div><div>Laser cladding (LC) is widely used for high-performance surface enhancement and component repair, with its processing quality highly dependent on complex parameter configurations. However, for LC-applied high-entropy alloy (HEA) coatings, the high cost of sample acquisition and the limitations of traditional response surface methods make it difficult to achieve accurate optimization under small-sample scenarios. This study proposes a laser cladding process parameter optimization method for MoNbTaTiZr powder, integrating multimodal surrogate modeling with reinforcement learning. A conditional generative adversarial network (cGAN) is employed to generate cross-sectional feature images of the cladding layer, which are further processed using a convolutional neural network (CNN) combined with a multi-task architecture to jointly predict multiple performance metrics, including dilution rate, shape factor, and microhardness. Based on this framework, this study proposes a Soft Actor-Critic algorithm with perturbation-aware replay optimization (PRO-SAC) method, which incorporates policy perturbation sensitivity, Temporal Difference (TD) error, and Pareto-front information of samples to jointly drive experience replay, thereby improving the learning efficiency and stability of process parameter optimization strategies. Experimental results show that the proposed prediction model achieves correlation coefficients above 0.97 for all quality indicators. Compared with other classical methods, the PRO-SAC optimization results exhibit superior performance across multiple evaluation metrics. Under the constraint of maintaining the shape factor, the microhardness and dilution rate of the cladding layer are improved by 11.3 % and 0.24 %, respectively, relative to the best values in the existing training dataset, confirming the effectiveness and engineering adaptability of the proposed method for laser cladding parameter optimization.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 50-64"},"PeriodicalIF":6.8,"publicationDate":"2026-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981202","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 : 2026-01-13DOI: 10.1016/j.jmapro.2026.01.012
Yongliang Lu , Jun Zhao , Anhai Li , Xujie Tang , Junfu Liu
Milling chatter can seriously reduce the surface quality and production efficiency of the workpiece being machined, so accurate chatter detection is essential. In recent years, convolutional neural networks (CNNs) have been extensively employed for chatter detection, demonstrating promising effectiveness. However, the quality of data labeling and the training process substantially affect the generalization and accuracy of CNNs. To overcome the above limitations, this paper proposed a novel hybrid deep convolutional neural network (HDCNN) named Chatter-CNN for online chatter detection in milling processes. The model integrates an Inception-Chatter module and a Squeeze-and-Excitation Residual Mutual Information (SR-MI) block, utilizing both milling force and vibration acceleration signals during datasets construction. Furthermore, an early chatter detection method based on the small-probability hypothesis combined with cumulative sum (CUSUM) is developed. Comparative milling experiments are conducted on a wedge-shaped workpiece and a thin-walled workpiece under different cutting parameters, cutting edges and tool overhang lengths to verify the detection performance of the proposed Chatter-CNN. Experimental results demonstrate that the proposed Chatter-CNN achieves 99.9 % / 94.7 % (validation/test) on the wedge-shaped workpiece and 99.8 % / 94.2 % (validation/test) on the thin-walled workpiece, outperforming existing CNNs. Further experimental results combining the proposed early detection method show that Chatter-CNN outperforms existing CNNs and threshold-based techniques by more accurately identifying machining states, including transition states, and enabling earlier detection of chatter onset, thereby facilitating chatter suppression.
{"title":"An online chatter detection for milling based on a novel convolutional neural network and small probability hypothesis method","authors":"Yongliang Lu , Jun Zhao , Anhai Li , Xujie Tang , Junfu Liu","doi":"10.1016/j.jmapro.2026.01.012","DOIUrl":"10.1016/j.jmapro.2026.01.012","url":null,"abstract":"<div><div>Milling chatter can seriously reduce the surface quality and production efficiency of the workpiece being machined, so accurate chatter detection is essential. In recent years, convolutional neural networks (CNNs) have been extensively employed for chatter detection, demonstrating promising effectiveness. However, the quality of data labeling and the training process substantially affect the generalization and accuracy of CNNs. To overcome the above limitations, this paper proposed a novel hybrid deep convolutional neural network (HDCNN) named Chatter-CNN for online chatter detection in milling processes. The model integrates an Inception-Chatter module and a Squeeze-and-Excitation Residual Mutual Information (SR-MI) block, utilizing both milling force and vibration acceleration signals during datasets construction. Furthermore, an early chatter detection method based on the small-probability hypothesis combined with cumulative sum (CUSUM) is developed. Comparative milling experiments are conducted on a wedge-shaped workpiece and a thin-walled workpiece under different cutting parameters, cutting edges and tool overhang lengths to verify the detection performance of the proposed Chatter-CNN. Experimental results demonstrate that the proposed Chatter-CNN achieves 99.9 % / 94.7 % (validation/test) on the wedge-shaped workpiece and 99.8 % / 94.2 % (validation/test) on the thin-walled workpiece, outperforming existing CNNs. Further experimental results combining the proposed early detection method show that Chatter-CNN outperforms existing CNNs and threshold-based techniques by more accurately identifying machining states, including transition states, and enabling earlier detection of chatter onset, thereby facilitating chatter suppression.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 65-106"},"PeriodicalIF":6.8,"publicationDate":"2026-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981205","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}
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