Journal of Manufacturing Processes最新文献_第7页

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.017

Furkan Khan, Takuya Miura, Yoshiaki Morisada, Kohsaku Ushioda, Hidetoshi Fujii

In this study, conventional direct linear friction welding of SS400 steel and A7075 aluminum was proven challenging because of absence of interfacial plastic deformation towards SS400 during joining, revealing several un-jointed regions throughout the joint interface, which eventually led to a poor joint strength of 77.6 MPa with interfacial fracture. Therefore, center-driven double-sided LFW (CDDS-LFW) is employed to effectively weld SS400 and A7075, with mild steel (MS) used as the center material. Using CDDS-LFW method, a highly efficient weld revealing 100 % joint efficiency concerning MS was obtained successfully by applying different pressures each side. Additionally, the fabricated weld exhibited a base metal fracture in the MS region away from both joint interfaces. The applied pressures were determined based on the cross-point concept after analyzing the thermal dependence behaviors of materials' strengths. A pressure of 50 MPa was applied at MS/SS400 interface, where the materials were simultaneously deformed and joined at high temperature, while 300 MPa was applied at MS/A7075 interface, where both materials were simultaneously deformed and joined at low temperature. This approach enabled the control of welding temperature at both joint interfaces by changing applied pressures on each side. Subsequent mechanical and microstructure investigations were carried out both at center and edge of the fabricated joint. SEM observation confirmed the absence of un-jointed regions and weld defects throughout both the joint interfaces of dissimilar CDDS-LFW weld, ensuring a sound joining. Moreover, microstructure evolution through EBSD analysis revealed the extremely fine-grained microstructure in the joint interface region compared to coarse grain base metal regions.

{"title":"Dissimilar joining of A7075 aluminum and SS400 steel utilizing center-driven double-sided linear friction welding using mild steel as a center material: Processing, mechanical and microstructure characterization","authors":"Furkan Khan, Takuya Miura, Yoshiaki Morisada, Kohsaku Ushioda, Hidetoshi Fujii","doi":"10.1016/j.jmapro.2025.02.017","DOIUrl":"10.1016/j.jmapro.2025.02.017","url":null,"abstract":"<div><div>In this study, conventional direct linear friction welding of SS400 steel and A7075 aluminum was proven challenging because of absence of interfacial plastic deformation towards SS400 during joining, revealing several un-jointed regions throughout the joint interface, which eventually led to a poor joint strength of 77.6 MPa with interfacial fracture. Therefore, center-driven double-sided LFW (CDDS-LFW) is employed to effectively weld SS400 and A7075, with mild steel (MS) used as the center material. Using CDDS-LFW method, a highly efficient weld revealing 100 % joint efficiency concerning MS was obtained successfully by applying different pressures each side. Additionally, the fabricated weld exhibited a base metal fracture in the MS region away from both joint interfaces. The applied pressures were determined based on the cross-point concept after analyzing the thermal dependence behaviors of materials' strengths. A pressure of 50 MPa was applied at MS/SS400 interface, where the materials were simultaneously deformed and joined at high temperature, while 300 MPa was applied at MS/A7075 interface, where both materials were simultaneously deformed and joined at low temperature. This approach enabled the control of welding temperature at both joint interfaces by changing applied pressures on each side. Subsequent mechanical and microstructure investigations were carried out both at center and edge of the fabricated joint. SEM observation confirmed the absence of un-jointed regions and weld defects throughout both the joint interfaces of dissimilar CDDS-LFW weld, ensuring a sound joining. Moreover, microstructure evolution through EBSD analysis revealed the extremely fine-grained microstructure in the joint interface region compared to coarse grain base metal regions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 67-80"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421947","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}

引用次数: 0

Porosity distribution of 316 L stainless steel in laser powder bed fusion additive manufacturing due to spatial variation

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.031

Chen-Nan Sun , Beng Loon Aw , Hengfeng Gu , Danny Ming Tak Choi , Chong Teng , Sharon Mui Ling Nai , Aravind Vasanthakumar , Chengcheng Wang

Laser powder bed fusion (LPBF) is at the forefront of the additive manufacturing industry due to its ability to generate intricate and accurate objects layer-by-layer. However, maintaining low porosity (i.e., minimizing defects) remains a significant challenge. This study investigates the influence of spatial variations on porosity, independent of processing parameters, by fabricating SS316L cubes at various locations on the build platform with both identical and varying processing parameters (laser power and scan speed). Changes in printing location affect the incident angle between the surface normal and the laser, potentially leading to laser spot distortion and altered effective energy input. This, in turn, can influence the porosity of the printed part. Additionally, improper inert gas flow can hinder spatter removal, further increasing porosity. We demonstrate that, regardless of processing parameters, spatial variations on the build platform significantly impact porosity distribution. Our findings, consistent with existing literature, highlight the importance of optimizing both build location and processing parameters to achieve low porosity, particularly at the platform's periphery. By analyzing the optimal build locations and parameter combinations, this work provides valuable insights for LPBF practitioners seeking to minimize porosity and improve printing outcomes at peripheral regions.

{"title":"Porosity distribution of 316 L stainless steel in laser powder bed fusion additive manufacturing due to spatial variation","authors":"Chen-Nan Sun , Beng Loon Aw , Hengfeng Gu , Danny Ming Tak Choi , Chong Teng , Sharon Mui Ling Nai , Aravind Vasanthakumar , Chengcheng Wang","doi":"10.1016/j.jmapro.2025.02.031","DOIUrl":"10.1016/j.jmapro.2025.02.031","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) is at the forefront of the additive manufacturing industry due to its ability to generate intricate and accurate objects layer-by-layer. However, maintaining low porosity (i.e., minimizing defects) remains a significant challenge. This study investigates the influence of spatial variations on porosity, independent of processing parameters, by fabricating SS316L cubes at various locations on the build platform with both identical and varying processing parameters (laser power and scan speed). Changes in printing location affect the incident angle between the surface normal and the laser, potentially leading to laser spot distortion and altered effective energy input. This, in turn, can influence the porosity of the printed part. Additionally, improper inert gas flow can hinder spatter removal, further increasing porosity. We demonstrate that, regardless of processing parameters, spatial variations on the build platform significantly impact porosity distribution. Our findings, consistent with existing literature, highlight the importance of optimizing both build location and processing parameters to achieve low porosity, particularly at the platform's periphery. By analyzing the optimal build locations and parameter combinations, this work provides valuable insights for LPBF practitioners seeking to minimize porosity and improve printing outcomes at peripheral regions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 81-89"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421948","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}

引用次数: 0

Formation mechanism of intermetallic compound in liquid steel and liquid aluminum by laser spiral fusion welding 激光螺旋熔焊在液态钢和液态铝中形成金属间化合物的机理

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.022

Shuang Huang , Han Yu , Ming Lou , Lidong Xu , Kailiang Chen , Yongbing Li

Laser spiral fusion welding was employed to connect immiscible aluminum and steel. The microstructural evolution at the interface between liquid aluminum and liquid steel was analyzed using quantitative microstructural characterization, with particular attention to the influence of fluid flow. It was revealed that the diffusion of reactive elements is predominantly influenced by Marangoni convection mechanisms. An increase in aluminum content reduces the free energy difference between δ-ferrite and γ-austenite, thereby stabilizing the δ-ferrite phase. On the steel side of the weld, a microstructure consisted of lath martensite, ferrite, and δ-ferrite. The continuous growth of interfacial intermetallic compounds (IMCs), specifically η-Fe₂Al₅ and θ-Fe₄Al₁₃ were successfully suppressed by the presence of numerous iron-rich ‘peninsula structure ‘at the interface. The formation of a single Fe₄Al₁₃ layer (the thinnest, 0.9 μm), a double layer comprising Fe₂Al₅ and Fe₄Al₁₃, and multi-layer ‘sandwich’ structure of Fe₄Al₁₃-Fe₂Al₅-Fe₄Al₁₃ was attributed to convective effects. The liquid aluminum, delayed solidification due to heat release during solidification of the molten pool of steel, can effectively make up the microcracks generated by the volume expansion of Fe₄Al₁₃ during the phase transformation process. The strength of the interface was significantly enhanced, with an average shear tensile force of 5022.41 N and a maximum peel force of 204.05 N for the joint.

{"title":"Formation mechanism of intermetallic compound in liquid steel and liquid aluminum by laser spiral fusion welding","authors":"Shuang Huang , Han Yu , Ming Lou , Lidong Xu , Kailiang Chen , Yongbing Li","doi":"10.1016/j.jmapro.2025.02.022","DOIUrl":"10.1016/j.jmapro.2025.02.022","url":null,"abstract":"<div><div>Laser spiral fusion welding was employed to connect immiscible aluminum and steel. The microstructural evolution at the interface between liquid aluminum and liquid steel was analyzed using quantitative microstructural characterization, with particular attention to the influence of fluid flow. It was revealed that the diffusion of reactive elements is predominantly influenced by Marangoni convection mechanisms. An increase in aluminum content reduces the free energy difference between δ-ferrite and γ-austenite, thereby stabilizing the δ-ferrite phase. On the steel side of the weld, a microstructure consisted of lath martensite, ferrite, and δ-ferrite. The continuous growth of interfacial intermetallic compounds (IMCs), specifically η-Fe<sub>2</sub>Al<sub>5</sub> and θ-Fe<sub>4</sub>Al<sub>13</sub> were successfully suppressed by the presence of numerous iron-rich ‘peninsula structure ‘at the interface. The formation of a single Fe<sub>4</sub>Al<sub>13</sub> layer (the thinnest, 0.9 μm), a double layer comprising Fe<sub>2</sub>Al<sub>5</sub> and Fe<sub>4</sub>Al<sub>13</sub>, and multi-layer ‘sandwich’ structure of Fe<sub>4</sub>Al<sub>13</sub>-Fe<sub>2</sub>Al<sub>5</sub>-Fe<sub>4</sub>Al<sub>13</sub> was attributed to convective effects. The liquid aluminum, delayed solidification due to heat release during solidification of the molten pool of steel, can effectively make up the microcracks generated by the volume expansion of Fe<sub>4</sub>Al<sub>13</sub> during the phase transformation process. The strength of the interface was significantly enhanced, with an average shear tensile force of 5022.41 N and a maximum peel force of 204.05 N for the joint.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 214-224"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429273","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}

引用次数: 0

Springback mechanism and precision forming process of laser array flexible forming

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.013

Yankuo Guo , Yukui Cai , Yongjun Shi , Feng Guo

A laser array flexible forming (LAFF) method based on LTUP technology is proposed for the first time, which can economically realize rare-exotic surface forming. However, the method suffers from springback during the forming process, which will seriously affect the forming accuracy and quality. For this reason, LTUP and LAFF simulation models are established to elucidate the springback mechanisms of LTUP and LAFF, respectively. Finally, the accuracy optimization is carried out for different bending radii and laser parameters under LAFF. The results show that LAFF has a forming angle of 4.59 deg. while obtaining a springback angle of 0.48 deg. LAFF can form rare-exotic surfaces but there is a certain amount of springback. The springback of the LTUP is mainly due to the elastic strains on the distal part of the load zone, all the transition zone, and the upper surface of the heat source zone. In contrast, the springback of LAFF is due to elastic deformation at the lower surface of the load zone, the majority of the transition zone, and the upper surface of the heat source zone. LAFF can be regarded as adding longitudinal load to LTUP. The increase in load changes the elastic strain distribution in the azimuthal section of the LTUP and reduces its area. Ultimately, this results in a 38.07 % reduction in the springback of the LAFF. In addition, a small bending radius, high laser power, long heating time, and small spot diameter are beneficial to reduce the springback of LAFF and obtain the bending angle with higher forming value and accuracy. This paper fills the research gap of LTUP in terms of springback. The study of the springback of LAFF can provide a basic theoretical reference for the application of LTUP under complex working conditions.

{"title":"Springback mechanism and precision forming process of laser array flexible forming","authors":"Yankuo Guo , Yukui Cai , Yongjun Shi , Feng Guo","doi":"10.1016/j.jmapro.2025.02.013","DOIUrl":"10.1016/j.jmapro.2025.02.013","url":null,"abstract":"<div><div>A laser array flexible forming (LAFF) method based on LTUP technology is proposed for the first time, which can economically realize rare-exotic surface forming. However, the method suffers from springback during the forming process, which will seriously affect the forming accuracy and quality. For this reason, LTUP and LAFF simulation models are established to elucidate the springback mechanisms of LTUP and LAFF, respectively. Finally, the accuracy optimization is carried out for different bending radii and laser parameters under LAFF. The results show that LAFF has a forming angle of 4.59 deg. while obtaining a springback angle of 0.48 deg. LAFF can form rare-exotic surfaces but there is a certain amount of springback. The springback of the LTUP is mainly due to the elastic strains on the distal part of the load zone, all the transition zone, and the upper surface of the heat source zone. In contrast, the springback of LAFF is due to elastic deformation at the lower surface of the load zone, the majority of the transition zone, and the upper surface of the heat source zone. LAFF can be regarded as adding longitudinal load to LTUP. The increase in load changes the elastic strain distribution in the azimuthal section of the LTUP and reduces its area. Ultimately, this results in a 38.07 % reduction in the springback of the LAFF. In addition, a small bending radius, high laser power, long heating time, and small spot diameter are beneficial to reduce the springback of LAFF and obtain the bending angle with higher forming value and accuracy. This paper fills the research gap of LTUP in terms of springback. The study of the springback of LAFF can provide a basic theoretical reference for the application of LTUP under complex working conditions.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 90-104"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427736","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}

引用次数: 0

Stereolithography 3D printing ceramics for ultrahigh strength aluminum matrix composites

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.037

Minmin Zhu , Caozhuang Deng , Zhanfeng Zhang , Dan Yang , Haizhong Zhang , Linghua Wang , Xiaoqiang Lu

Aluminum alloys are renowned for their lightweight nature, resistance to oxidation, and impressive mechanical properties. Despite these advantages, their mechanical performance deteriorates significantly in extreme environments. Herein, we present an innovative solution by developing aluminum matrix composites (AMCs) that incorporate 3D printed alumina ceramic lattices. Our investigation demonstrates a remarkable 112.4 % increase in the strength of AMCs compared to pure aluminum, with a concurrent 54.8 % improvement in modulus under identical conditions. Additionally, as the volume fraction of the ceramic lattice varies from 0.21 to 0.45, the modulus of AMCs exhibits a noteworthy increase, ranging from 96.2 to 106.5 GPa, surpassing that of pure aluminum (68.8 GPa). Notably, even at temperatures of up to 300 °C, the strength of the Al₂O₃-Al composite matrix remains stable at 477.3 MPa. X-ray computed tomography analysis elucidates that the structural integrity of these composites predominantly relies on the load-bearing capacity of the ceramic lattices, complemented by the damping effect provided by the aluminum matrix. This innovative approach not only paves the way for scalable production of high-strength metal alloys in the industrial sector but also holds promise for substantial economic opportunities in the near future.

{"title":"Stereolithography 3D printing ceramics for ultrahigh strength aluminum matrix composites","authors":"Minmin Zhu , Caozhuang Deng , Zhanfeng Zhang , Dan Yang , Haizhong Zhang , Linghua Wang , Xiaoqiang Lu","doi":"10.1016/j.jmapro.2025.02.037","DOIUrl":"10.1016/j.jmapro.2025.02.037","url":null,"abstract":"<div><div>Aluminum alloys are renowned for their lightweight nature, resistance to oxidation, and impressive mechanical properties. Despite these advantages, their mechanical performance deteriorates significantly in extreme environments. Herein, we present an innovative solution by developing aluminum matrix composites (AMCs) that incorporate 3D printed alumina ceramic lattices. Our investigation demonstrates a remarkable 112.4 % increase in the strength of AMCs compared to pure aluminum, with a concurrent 54.8 % improvement in modulus under identical conditions. Additionally, as the volume fraction of the ceramic lattice varies from 0.21 to 0.45, the modulus of AMCs exhibits a noteworthy increase, ranging from 96.2 to 106.5 GPa, surpassing that of pure aluminum (68.8 GPa). Notably, even at temperatures of up to 300 °C, the strength of the Al<sub>2</sub>O<sub>3</sub>-Al composite matrix remains stable at 477.3 MPa. X-ray computed tomography analysis elucidates that the structural integrity of these composites predominantly relies on the load-bearing capacity of the ceramic lattices, complemented by the damping effect provided by the aluminum matrix. This innovative approach not only paves the way for scalable production of high-strength metal alloys in the industrial sector but also holds promise for substantial economic opportunities in the near future.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 126-132"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427734","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}

引用次数: 0

Investigation of wear behavior for large pulsed electron beam irradiated cutting tools under the turning process of Ti-6Al-4V

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-17 DOI: 10.1016/j.jmapro.2025.02.029

Sang Min Yang , Do Young Kim , Hyung Wook Park

In this paper, a large pulsed electron beam (LPEB) was irradiated on the uncoated tungsten carbide cutting tool to enhance the tool life. The electron beam was transmitted on the rake face, flank face, and rake & flank face which refers to the shot on rake (SoR) condition, shot on flank (SoF) condition, and shot on both (SoB) condition, respectively. The characteristics of the cutting tool such as the morphology of the tool surface, surface roughness, and edge roundness were evaluated depending on the electron beam irradiation conditions. The micro-thermal cracking was observed on the SoR condition and SoF condition due to the focused energy transmission on a single area of the cutting tool, on the other hand, the uniform irradiation energy of the electron beam generated the smooth surface for the SoB condition. In addition, the edge roundness was the largest in the SoR condition because the melted tool material flows in the direction of the cutting edges orthogonally during the electron beam irradiation. These characteristics of the LPEB irradiated cutting tool were reflected in the machining process, and various wear behaviors were investigated in terms of a built-up edge (BUE), adhesion, chipping, tool breakage, flank wear, and crater wear. The severe wear behavior was observed in the untreated condition as confirmed by a micro-welded surface, catastrophic tool failure, and chipping. Specifically, the lowest wear behavior was observed with the irradiated electron beam on the rake & flank face of the cutting tool; the flank wear and crater wear were reduced up to 37.3 % and 71.9 %, respectively compared to the untreated condition, and critical wear behavior was not developed due to the low surface roughness, increased edge roundness, and the hardened surface of the cutting tool.

{"title":"Investigation of wear behavior for large pulsed electron beam irradiated cutting tools under the turning process of Ti-6Al-4V","authors":"Sang Min Yang , Do Young Kim , Hyung Wook Park","doi":"10.1016/j.jmapro.2025.02.029","DOIUrl":"10.1016/j.jmapro.2025.02.029","url":null,"abstract":"<div><div>In this paper, a large pulsed electron beam (LPEB) was irradiated on the uncoated tungsten carbide cutting tool to enhance the tool life. The electron beam was transmitted on the rake face, flank face, and rake & flank face which refers to the shot on rake (SoR) condition, shot on flank (SoF) condition, and shot on both (SoB) condition, respectively. The characteristics of the cutting tool such as the morphology of the tool surface, surface roughness, and edge roundness were evaluated depending on the electron beam irradiation conditions. The micro-thermal cracking was observed on the SoR condition and SoF condition due to the focused energy transmission on a single area of the cutting tool, on the other hand, the uniform irradiation energy of the electron beam generated the smooth surface for the SoB condition. In addition, the edge roundness was the largest in the SoR condition because the melted tool material flows in the direction of the cutting edges orthogonally during the electron beam irradiation. These characteristics of the LPEB irradiated cutting tool were reflected in the machining process, and various wear behaviors were investigated in terms of a built-up edge (BUE), adhesion, chipping, tool breakage, flank wear, and crater wear. The severe wear behavior was observed in the untreated condition as confirmed by a micro-welded surface, catastrophic tool failure, and chipping. Specifically, the lowest wear behavior was observed with the irradiated electron beam on the rake & flank face of the cutting tool; the flank wear and crater wear were reduced up to 37.3 % and 71.9 %, respectively compared to the untreated condition, and critical wear behavior was not developed due to the low surface roughness, increased edge roundness, and the hardened surface of the cutting tool.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 133-143"},"PeriodicalIF":6.1,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143427735","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}

引用次数: 0

A novel few-shot learning based feature relation model for robotic welding states monitoring

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-15 DOI: 10.1016/j.jmapro.2025.02.018

Luming Xu , Runquan Xiao , Huabin Chen

Amidst the evolution of contemporary welding technologies, real-time monitoring of the welding process has emerged as an indispensable element within intelligent welding systems. Prior research has demonstrated that welding process modeling methods based on deep neural networks exhibit high accuracy and robustness in predicting welding quality. Nevertheless, data dependency-related challenges, including the onerous task of data annotation and the paucity of model translatability, have constrained their utility in practical applications. To address these challenges, this paper proposes a feature relation model based on few-shot learning for welding state monitoring. First, we design a hybrid supervised training strategy suitable for welding monitoring models, leveraging both unlabeled data and commonly labeled data to enhance the representation ability and transferability of deep molten pool features. Thereafter, we developed a feature relational architecture leveraging attention mechanisms and Brownian distance covariance, enabling the recalibration of network feature distributions to align with specific tasks. This feature re-embedding improves the discriminative capability of the model, facilitating accurate identification of various welding states in few-shot scenarios. Experimental results indicate that our algorithm achieves a prediction accuracy of 96.5 % using only 15 samples per class, significantly reducing the data requirements for model training. Compared to traditional algorithms, this model's low dependency on sample size enhances its transferability and generalizes, thereby promoting the practical application of intelligent monitoring technologies in real-world welding environments.

{"title":"A novel few-shot learning based feature relation model for robotic welding states monitoring","authors":"Luming Xu , Runquan Xiao , Huabin Chen","doi":"10.1016/j.jmapro.2025.02.018","DOIUrl":"10.1016/j.jmapro.2025.02.018","url":null,"abstract":"<div><div>Amidst the evolution of contemporary welding technologies, real-time monitoring of the welding process has emerged as an indispensable element within intelligent welding systems. Prior research has demonstrated that welding process modeling methods based on deep neural networks exhibit high accuracy and robustness in predicting welding quality. Nevertheless, data dependency-related challenges, including the onerous task of data annotation and the paucity of model translatability, have constrained their utility in practical applications. To address these challenges, this paper proposes a feature relation model based on few-shot learning for welding state monitoring. First, we design a hybrid supervised training strategy suitable for welding monitoring models, leveraging both unlabeled data and commonly labeled data to enhance the representation ability and transferability of deep molten pool features. Thereafter, we developed a feature relational architecture leveraging attention mechanisms and Brownian distance covariance, enabling the recalibration of network feature distributions to align with specific tasks. This feature re-embedding improves the discriminative capability of the model, facilitating accurate identification of various welding states in few-shot scenarios. Experimental results indicate that our algorithm achieves a prediction accuracy of 96.5 % using only 15 samples per class, significantly reducing the data requirements for model training. Compared to traditional algorithms, this model's low dependency on sample size enhances its transferability and generalizes, thereby promoting the practical application of intelligent monitoring technologies in real-world welding environments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 203-213"},"PeriodicalIF":6.1,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143420706","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}

引用次数: 0

Achieving high machining speed and sustainability in micro-EDM using a two-phase three component dielectric

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-15 DOI: 10.1016/j.jmapro.2025.02.027

Ramver Singh , Pradeep Dixit , Akshay Dvivedi , Pradeep Kumar

This study presents a solution to the longstanding challenges of sustainability and slow material removal rate (MRR) in micro-electrical discharge machining (micro-EDM), proposing a two-phase, three-component dielectric composed of air, water, and glycerin. Significant enhancements, ranging from 7 to 19 times, are observed in machining speed (125 × 10⁻³ mm³/min), alongside a valuable reduction in environmental impact by over 7 times, compared to existing variants. Pressurized air efficiently flushes debris from the narrow inter-electrode gap, ensuring a clean machining environment. Water droplets enhance cooling and reduce the viscosity of the liquid phase, facilitating consistent material removal. Glycerin contributes additional energy through exothermic reactions, sustaining the melted puddle and boosting material removal efficiency with droplet explosions near the puddle. Single discharge crater experiments reveal unique material removal modes, indicating that complete melting before ejection of material may not be necessary. The study proposes a hypothesis suggesting that glycerin droplets burst upon contact with the work surface, promoting material spalling phenomena. Surface-sensitive morphology and chemistry analyses confirm traces of droplet explosions, validating the hypothesis. Parametric investigation demonstrates that the developed dielectric allows unprecedented use of extreme discharge energy (current up to 15 A) without concerns about damaging the machined surface or the micro-tool. The life cycle assessment (LCA) study reveals that the developed dielectric offers a sevenfold reduction in greenhouse gas emissions compared to existing variants. This research addresses challenges in micro-EDM and contributes to a circular economy by creating demand for excess glycerin, a by-product of bio-diesel synthesis. Overall, this study enhances sustainability and machining speed, aiming to pave the way for a more responsible future in micro-EDM.

{"title":"Achieving high machining speed and sustainability in micro-EDM using a two-phase three component dielectric","authors":"Ramver Singh , Pradeep Dixit , Akshay Dvivedi , Pradeep Kumar","doi":"10.1016/j.jmapro.2025.02.027","DOIUrl":"10.1016/j.jmapro.2025.02.027","url":null,"abstract":"<div><div>This study presents a solution to the longstanding challenges of sustainability and slow material removal rate (MRR) in micro-electrical discharge machining (micro-EDM), proposing a two-phase, three-component dielectric composed of air, water, and glycerin. Significant enhancements, ranging from 7 to 19 times, are observed in machining speed (125 × 10<sup>−3</sup> mm<sup>3</sup>/min), alongside a valuable reduction in environmental impact by over 7 times, compared to existing variants. Pressurized air efficiently flushes debris from the narrow inter-electrode gap, ensuring a clean machining environment. Water droplets enhance cooling and reduce the viscosity of the liquid phase, facilitating consistent material removal. Glycerin contributes additional energy through exothermic reactions, sustaining the melted puddle and boosting material removal efficiency with droplet explosions near the puddle. Single discharge crater experiments reveal unique material removal modes, indicating that complete melting before ejection of material may not be necessary. The study proposes a hypothesis suggesting that glycerin droplets burst upon contact with the work surface, promoting material spalling phenomena. Surface-sensitive morphology and chemistry analyses confirm traces of droplet explosions, validating the hypothesis. Parametric investigation demonstrates that the developed dielectric allows unprecedented use of extreme discharge energy (current up to 15 A) without concerns about damaging the machined surface or the micro-tool. The life cycle assessment (LCA) study reveals that the developed dielectric offers a sevenfold reduction in greenhouse gas emissions compared to existing variants. This research addresses challenges in micro-EDM and contributes to a circular economy by creating demand for excess glycerin, a by-product of bio-diesel synthesis. Overall, this study enhances sustainability and machining speed, aiming to pave the way for a more responsible future in micro-EDM.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 50-66"},"PeriodicalIF":6.1,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143421946","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}

引用次数: 0

Effect of laser beam drift at high scanning speed on relative density, thickness and roughness of thin-walled TC11 specimen by selective laser melting

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-14 DOI: 10.1016/j.jmapro.2025.01.098

Feipeng An, Xiwang Liu, Xueliang Zeng, Linjie Zhang, Jie Ning, Suck Joo Na

Due to the width of the laser melting pool and the sintering effect on the surrounding powder, the experimental size of the selective laser melting (SLM) specimen will be larger than the design size, which will greatly affect the dimensional accuracy and surface quality of thin-walled specimen. In order to obtain dimensionally accurate SLM thin-walled TC11 specimens, an orthogonal test was designed to investigate the effects of laser power, scanning speed and hatch space on the relative density, increase of wall thickness(IWT) and surface roughness of the specimens. Unlike the results of previous studies, of which results was that IWT and roughness decreased with increasing scanning speed, it was found that the IWT and roughness of the specimens decreased and then increased with increasing scanning speed due to the presence of laser beam drift at high scanning speed conditions. The laser beam drift increased with the scanning speed. When the scanning speed was ≤400 mm/s, drift of laser beam was almost 0 mm. At a scanning speed of 5000 mm/s, the laser beam drift was 1.51 mm in the x-direction and 1.28 mm in the y-direction. The drift of the laser beam caused an increase in the cross-sectional area of the specimen, which resulted in the same energy being distributed over a larger area, leading to a reduction in the relative density; at the same time, the drift of the laser beam caused the scan paths of the different layers to not coincide exactly, which increased the roughness of the specimen. At a laser power of 350 W and a scanning speed of 1000 mm/s, the increase in specimen cross-sectional area due to the melt pool width was 1.71 mm², which was greater than that induced by the laser beam drift of 1.70 mm². In this case, the melt pool width was the dominant factor affecting the specimen size. Therefore, in order to reduce the negative effect of laser drift on the density of the specimen, the scanning speed should be ≤1000 mm/s at a laser power of 350 W.

{"title":"Effect of laser beam drift at high scanning speed on relative density, thickness and roughness of thin-walled TC11 specimen by selective laser melting","authors":"Feipeng An, Xiwang Liu, Xueliang Zeng, Linjie Zhang, Jie Ning, Suck Joo Na","doi":"10.1016/j.jmapro.2025.01.098","DOIUrl":"10.1016/j.jmapro.2025.01.098","url":null,"abstract":"<div><div>Due to the width of the laser melting pool and the sintering effect on the surrounding powder, the experimental size of the selective laser melting (SLM) specimen will be larger than the design size, which will greatly affect the dimensional accuracy and surface quality of thin-walled specimen. In order to obtain dimensionally accurate SLM thin-walled TC11 specimens, an orthogonal test was designed to investigate the effects of laser power, scanning speed and hatch space on the relative density, increase of wall thickness(IWT) and surface roughness of the specimens. Unlike the results of previous studies, of which results was that IWT and roughness decreased with increasing scanning speed, it was found that the IWT and roughness of the specimens decreased and then increased with increasing scanning speed due to the presence of laser beam drift at high scanning speed conditions. The laser beam drift increased with the scanning speed. When the scanning speed was ≤400 mm/s, drift of laser beam was almost 0 mm. At a scanning speed of 5000 mm/s, the laser beam drift was 1.51 mm in the x-direction and 1.28 mm in the y-direction. The drift of the laser beam caused an increase in the cross-sectional area of the specimen, which resulted in the same energy being distributed over a larger area, leading to a reduction in the relative density; at the same time, the drift of the laser beam caused the scan paths of the different layers to not coincide exactly, which increased the roughness of the specimen. At a laser power of 350 W and a scanning speed of 1000 mm/s, the increase in specimen cross-sectional area due to the melt pool width was 1.71 mm<sup>2</sup>, which was greater than that induced by the laser beam drift of 1.70 mm<sup>2</sup>. In this case, the melt pool width was the dominant factor affecting the specimen size. Therefore, in order to reduce the negative effect of laser drift on the density of the specimen, the scanning speed should be ≤1000 mm/s at a laser power of 350 W.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"139 ","pages":"Pages 38-49"},"PeriodicalIF":6.1,"publicationDate":"2025-02-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143402953","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}

引用次数: 0

Frication behaviors, wear and failure mechanisms of CBN tool and machined surface morphology in high-speed turning of high strength refractory alloy cast steel

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-02-14 DOI: 10.1016/j.jmapro.2025.01.003

Haihang Wang , Chenguang Wang , Jiaqiang Dang , Pengjie Gao , Qinglong An , Tianchang Zheng , Yadi Deng , Weiwei Ming , Ming Chen , Tiao Wang , Lu Yang

High strength refractory alloy cast steel GX23CrMoV12-1 is widely used in the combustion chambers of heavy duty gas turbine due to the high strength, hardness and heat resistant. However, the poor machinability and severe tool wear seriously hinder the further application of GX23CrMoV12-1. To reduce the tool wear, the cubic boron nitride (CBN) tool was used for turning GX23CrMoV12-1 considering the extreme hardness and chemical inertness of CBN. The wear curve and evolution, frication behaviors, wear and failure mechanisms and their transformation of CBN tool, and machined surface morphology of workpiece at various cutting speed were investigated in turning of GX23CrMoV12-1. The results show that: The wear life of CBN tool increases and then decreases with the increment of cutting speed, and the optimal cutting speed is 200 m/min. The CBN tool is mainly characterized by brittle fracture and adhesive wear. At medium-low cutting speed (100–150 m/min), the tool substrate is easily peeled off due to the frication and scratch of chips, resulting in large pieces peeling off, finally, forming catastrophic fracture. At high cutting speed (200–300 m/min), the frequency of the tool substrate peeling off decreases and no catastrophic fracture forms, but abrasive wear increases. The frication coefficient of CBN tool is about 0.2 in dry turning of GX23CrMoV12-1. Additionally, roughness Sa of workpiece decreases and then increases with the increment of tool wear. These findings provide significant guidance for parameters selection and tool wear suppression in machining of heavy-duty gas turbine.

{"title":"Frication behaviors, wear and failure mechanisms of CBN tool and machined surface morphology in high-speed turning of high strength refractory alloy cast steel","authors":"Haihang Wang , Chenguang Wang , Jiaqiang Dang , Pengjie Gao , Qinglong An , Tianchang Zheng , Yadi Deng , Weiwei Ming , Ming Chen , Tiao Wang , Lu Yang","doi":"10.1016/j.jmapro.2025.01.003","DOIUrl":"10.1016/j.jmapro.2025.01.003","url":null,"abstract":"<div><div>High strength refractory alloy cast steel GX23CrMoV12-1 is widely used in the combustion chambers of heavy duty gas turbine due to the high strength, hardness and heat resistant. However, the poor machinability and severe tool wear seriously hinder the further application of GX23CrMoV12-1. To reduce the tool wear, the cubic boron nitride (CBN) tool was used for turning GX23CrMoV12-1 considering the extreme hardness and chemical inertness of CBN. The wear curve and evolution, frication behaviors, wear and failure mechanisms and their transformation of CBN tool, and machined surface morphology of workpiece at various cutting speed were investigated in turning of GX23CrMoV12-1. The results show that: The wear life of CBN tool increases and then decreases with the increment of cutting speed, and the optimal cutting speed is 200 m/min. The CBN tool is mainly characterized by brittle fracture and adhesive wear. At medium-low cutting speed (100–150 m/min), the tool substrate is easily peeled off due to the frication and scratch of chips, resulting in large pieces peeling off, finally, forming catastrophic fracture. At high cutting speed (200–300 m/min), the frequency of the tool substrate peeling off decreases and no catastrophic fracture forms, but abrasive wear increases. The frication coefficient of CBN tool is about 0.2 in dry turning of GX23CrMoV12-1. Additionally, roughness <em>Sa</em> of workpiece decreases and then increases with the increment of tool wear. These findings provide significant guidance for parameters selection and tool wear suppression in machining of heavy-duty gas turbine.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"138 ","pages":"Pages 186-202"},"PeriodicalIF":6.1,"publicationDate":"2025-02-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143403058","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}

引用次数: 0