Journal of Manufacturing Processes最新文献_第8页

In-situ monitoring of hole evolution process in ultrafast laser drilling using optical coherence tomography

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.020

Tao Sun, Wanqin Zhao, Zhengjie Fan, Jinge He, Peng Shen, Jianlei Cui, Xuesong Mei

In-situ monitoring and control of the drilling process are critical for achieving high-quality structure fabrication, optimizing the process, and gaining a deeper understanding of drilling dynamics. Optical coherence tomography (OCT), an advanced interferometric measurement technique, is now widely used for in-situ monitoring of depth information in laser welding or additive manufacturing. However, due to the complex trajectories and evolution dynamics of trepanning drilling, in-situ observation of hole evolution in ultrafast laser trepanning drilling of metals has not been realized. Here, we report a real-time monitoring technology for in-situ measurement of hole depth in ultrafast laser trepanning drilling using spectral-domain optical coherence tomography (SD-OCT). To achieve the position-synchronized acquisition of depth information, a position-encoded scanning method is proposed. Then the spatiotemporal correlation between the drilling process and the measurement results is systematically analyzed. Considering the spatial correlation and temporal continuity of laser drilling, a new method, called spatiotemporal correlation depth extraction (STC-DE) is first proposed to achieve the automatic, position synchronous in-situ measurement of hole depth in laser trepanning drilling. Finally, the effectiveness and generalization ability of this method are verified under different processing parameters. Experimental results demonstrate the measurement accuracy can reach micron level. This study fully presents the feasibility of SD-OCT in in-situ measurement of hole depth and real-time monitoring of hole evolution process in ultrafast laser drilling. It highlights the potential of this approach in revealing complex machining phenomena, optimizing processes, and achieving precise manufacturing control.

{"title":"In-situ monitoring of hole evolution process in ultrafast laser drilling using optical coherence tomography","authors":"Tao Sun, Wanqin Zhao, Zhengjie Fan, Jinge He, Peng Shen, Jianlei Cui, Xuesong Mei","doi":"10.1016/j.jmapro.2024.12.020","DOIUrl":"10.1016/j.jmapro.2024.12.020","url":null,"abstract":"<div><div>In-situ monitoring and control of the drilling process are critical for achieving high-quality structure fabrication, optimizing the process, and gaining a deeper understanding of drilling dynamics. Optical coherence tomography (OCT), an advanced interferometric measurement technique, is now widely used for in-situ monitoring of depth information in laser welding or additive manufacturing. However, due to the complex trajectories and evolution dynamics of trepanning drilling, in-situ observation of hole evolution in ultrafast laser trepanning drilling of metals has not been realized. Here, we report a real-time monitoring technology for in-situ measurement of hole depth in ultrafast laser trepanning drilling using spectral-domain optical coherence tomography (SD-OCT). To achieve the position-synchronized acquisition of depth information, a position-encoded scanning method is proposed. Then the spatiotemporal correlation between the drilling process and the measurement results is systematically analyzed. Considering the spatial correlation and temporal continuity of laser drilling, a new method, called spatiotemporal correlation depth extraction (STC-DE) is first proposed to achieve the automatic, position synchronous in-situ measurement of hole depth in laser trepanning drilling. Finally, the effectiveness and generalization ability of this method are verified under different processing parameters. Experimental results demonstrate the measurement accuracy can reach micron level. This study fully presents the feasibility of SD-OCT in in-situ measurement of hole depth and real-time monitoring of hole evolution process in ultrafast laser drilling. It highlights the potential of this approach in revealing complex machining phenomena, optimizing processes, and achieving precise manufacturing control.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1290-1299"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137787","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

Review of in-situ process monitoring for ultra-short pulse laser micromanufacturing

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.011

Kerim Yildirim , Balasubramanian Nagarajan , Tegoeh Tjahjowidodo , Sylvie Castagne

Ultrashort pulse (USP) lasers enable machining of a wide range of materials, including hard and brittle materials such as steel, glass, silicon, and ceramics. Despite ongoing technological advances in USP laser micromachining systems, the lack of process repeatability and stability continues to hinder industrial adoption. This necessitates the development of innovative in-situ monitoring techniques capable of maintaining process stability and detecting early onset of anomalies. Besides, tight tolerances in micromanufacturing strongly require an automated, controlled, and regulated process. On the one hand, USP laser micromachining systems must be outfitted with in-situ sensing devices capable of measuring essential process signatures. On the other hand, in-process data analytics and statistical techniques are required to facilitate closed-loop process control. This paper provided a detailed literature review of in-situ monitoring of USP laser micromachining and other laser-based manufacturing processes. The mechanisms, advantages, limitations, signal processing methodologies and application in laser-based manufacturing techniques of different sensing techniques including acoustic, optical and image-based techniques are discussed. The techniques are reviewed with special focus on adaptability for USP laser micromachining towards automated process control, understanding process mechanisms and quality control.

{"title":"Review of in-situ process monitoring for ultra-short pulse laser micromanufacturing","authors":"Kerim Yildirim , Balasubramanian Nagarajan , Tegoeh Tjahjowidodo , Sylvie Castagne","doi":"10.1016/j.jmapro.2024.12.011","DOIUrl":"10.1016/j.jmapro.2024.12.011","url":null,"abstract":"<div><div>Ultrashort pulse (USP) lasers enable machining of a wide range of materials, including hard and brittle materials such as steel, glass, silicon, and ceramics. Despite ongoing technological advances in USP laser micromachining systems, the lack of process repeatability and stability continues to hinder industrial adoption. This necessitates the development of innovative in-situ monitoring techniques capable of maintaining process stability and detecting early onset of anomalies. Besides, tight tolerances in micromanufacturing strongly require an automated, controlled, and regulated process. On the one hand, USP laser micromachining systems must be outfitted with in-situ sensing devices capable of measuring essential process signatures. On the other hand, in-process data analytics and statistical techniques are required to facilitate closed-loop process control. This paper provided a detailed literature review of in-situ monitoring of USP laser micromachining and other laser-based manufacturing processes. The mechanisms, advantages, limitations, signal processing methodologies and application in laser-based manufacturing techniques of different sensing techniques including acoustic, optical and image-based techniques are discussed. The techniques are reviewed with special focus on adaptability for USP laser micromachining towards automated process control, understanding process mechanisms and quality control.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1126-1159"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138188","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

Is process damping effective in the stability of robotic milling?

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.084

Lutfi Taner Tunc , Sinem Kurnaz

Chatter stability is a major constraint in milling, where low and high cutting speeds are used. At low cutting speed regime, process damping leads to increased stability, whereas at high cutting speeds lobing effect is beneficial. Excitation frequency depends on spindle speed and the number of cutting flutes on the milling tool. Hence the vibration mode governing chatter stability varies for multi-mode milling systems. In CNC milling, low frequency structural modes are stiffer than cutting spindle-holder-tool (SHT) assembly. However, robotic milling demonstrates a distinct behavior as low frequency modes are significantly more flexible. This study investigates the effect of robot structure induced low frequency vibration modes on stability limits at low cutting speeds, where process damping is expected to increase stability limits. Time domain simulations are used to explain the variation of the dominant mode from high frequency to low frequency with the decreasing spindle speed. Simulated stability diagram for the multi-mode robotic milling system is verified by experiments. It was shown that especially the vibration modes in the range of 15 to 20 Hz do not generate enough process damping force due to long vibration waves, i.e. cutting speed – to – chatter frequency ratio, when low frequency modes govern chatter stability. Simulation of stability diagrams showed that there is a spindle speed region where the stability lobes governed by the robot structure crosscut the stability lobes governed by the THS assembly. Due to the inherent effect of tool diameter (D) and number of cutting flutes (Z) on cutting speed and excitation frequency, this region shifts according to the D/Z ratio. It was shown through simulations that D/Z ratio is a critical metric to benefit from process damping without the interference of the low frequency excitation of the robotic structure. The simulation results are used to provide suggestions for milling tool selection in robotic milling, where the main conclusion is to use lower D/Z ratio, which means that using high number of cutting flutes.

{"title":"Is process damping effective in the stability of robotic milling?","authors":"Lutfi Taner Tunc , Sinem Kurnaz","doi":"10.1016/j.jmapro.2024.11.084","DOIUrl":"10.1016/j.jmapro.2024.11.084","url":null,"abstract":"<div><div>Chatter stability is a major constraint in milling, where low and high cutting speeds are used. At low cutting speed regime, process damping leads to increased stability, whereas at high cutting speeds lobing effect is beneficial. Excitation frequency depends on spindle speed and the number of cutting flutes on the milling tool. Hence the vibration mode governing chatter stability varies for multi-mode milling systems. In CNC milling, low frequency structural modes are stiffer than cutting spindle-holder-tool (SHT) assembly. However, robotic milling demonstrates a distinct behavior as low frequency modes are significantly more flexible. This study investigates the effect of robot structure induced low frequency vibration modes on stability limits at low cutting speeds, where process damping is expected to increase stability limits. Time domain simulations are used to explain the variation of the dominant mode from high frequency to low frequency with the decreasing spindle speed. Simulated stability diagram for the multi-mode robotic milling system is verified by experiments. It was shown that especially the vibration modes in the range of 15 to 20 Hz do not generate enough process damping force due to long vibration waves, i.e. cutting speed – to – chatter frequency ratio, when low frequency modes govern chatter stability. Simulation of stability diagrams showed that there is a spindle speed region where the stability lobes governed by the robot structure crosscut the stability lobes governed by the THS assembly. Due to the inherent effect of tool diameter (D) and number of cutting flutes (Z) on cutting speed and excitation frequency, this region shifts according to the D/Z ratio. It was shown through simulations that D/Z ratio is a critical metric to benefit from process damping without the interference of the low frequency excitation of the robotic structure. The simulation results are used to provide suggestions for milling tool selection in robotic milling, where the main conclusion is to use lower D/Z ratio, which means that using high number of cutting flutes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 879-890"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137740","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

The process of combined abrasive jet blasting for cutting-edge preparation of carbide cutting inserts

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.089

Lirong Huang , Yong Peng , Han Chen , Zhuopeng Tan , Xuehuai Huang , Jianliang Jiao , Zhiqiang Zhong

Wet abrasive blasting offers excellent surface quality for cutting-edge preparation; however, it is characterized by low efficiency and high cost. Dry abrasive blasting is a cost-effective and efficient method, this is because it has a high material erosion rate; nevertheless, it results in poor surface quality and is environmentally unfriendly due to dust pollution. This study proposed the Combined Abrasive Jet Blasting process for cutting-edge preparation to ensure high-quality cutting-edge surfaces while improving efficiency and reducing cost. The process involves initially preparing the cutting-edge through dry abrasive blasting, followed by wet abrasive blasting. Using an Alicona EdgeMaster, the cutting-edge surface roughness—which comprises the roughness of the cutting-edge, rake, and flank face—was measured following edge preparation. Using X-ray diffraction, the surface residual stress was measured, furthermore, the edge surface topography, and embedded abrasive were qualitatively analyzed using scanning electron microscopy (SEM). The results showed that the rake face roughness was similar to that obtained by wet abrasive blasting, moreover, Combined Abrasive Jet Blasting produced the lowest cutting-edge roughness and flank face roughness. In addition, Combined Abrasive Jet Blasting enhanced the cutting-edge preparation efficiency by 42.6 % compared with wet abrasive blasting. SEM analysis indicates that Combined Abrasive Jet Blasting yields excellent surface quality. Therefore, Combined Abrasive Jet Blasting represents a promising strategy for the preparation of cutting-edge with high efficiency and superior surface quality.

{"title":"The process of combined abrasive jet blasting for cutting-edge preparation of carbide cutting inserts","authors":"Lirong Huang , Yong Peng , Han Chen , Zhuopeng Tan , Xuehuai Huang , Jianliang Jiao , Zhiqiang Zhong","doi":"10.1016/j.jmapro.2024.11.089","DOIUrl":"10.1016/j.jmapro.2024.11.089","url":null,"abstract":"<div><div>Wet abrasive blasting offers excellent surface quality for cutting-edge preparation; however, it is characterized by low efficiency and high cost. Dry abrasive blasting is a cost-effective and efficient method, this is because it has a high material erosion rate; nevertheless, it results in poor surface quality and is environmentally unfriendly due to dust pollution. This study proposed the Combined Abrasive Jet Blasting process for cutting-edge preparation to ensure high-quality cutting-edge surfaces while improving efficiency and reducing cost. The process involves initially preparing the cutting-edge through dry abrasive blasting, followed by wet abrasive blasting. Using an Alicona EdgeMaster, the cutting-edge surface roughness—which comprises the roughness of the cutting-edge, rake, and flank face—was measured following edge preparation. Using X-ray diffraction, the surface residual stress was measured, furthermore, the edge surface topography, and embedded abrasive were qualitatively analyzed using scanning electron microscopy (SEM). The results showed that the rake face roughness was similar to that obtained by wet abrasive blasting, moreover, Combined Abrasive Jet Blasting produced the lowest cutting-edge roughness and flank face roughness. In addition, Combined Abrasive Jet Blasting enhanced the cutting-edge preparation efficiency by 42.6 % compared with wet abrasive blasting. SEM analysis indicates that Combined Abrasive Jet Blasting yields excellent surface quality. Therefore, Combined Abrasive Jet Blasting represents a promising strategy for the preparation of cutting-edge with high efficiency and superior surface quality.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 969-978"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137760","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 review of double-electrode GMAW: Approaches, developments and variants

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.017

Rui Xiang , Jiankang Huang , Xiaoquan Yu , Huayu Zhao , Ding Fan

Double-electrode gas metal arc welding (DE-GMAW) is an advanced welding technology that uses a bypass torch to regulate the current through the base metal, effectively reducing the heat input to the base metal and increasing the deposition rate of the filling wire. Through precise control of the welding process, the stability of the welding arc and the welding quality are significantly improved. First, this paper provides a systematic review of the characteristics and applications of consumable and non-consumable DE-GMAW. The non-consumable DE-GMAW includes single-bypass GMAW (SB-GMAW), double-bypass GMAW (DB-GMAW), and pulsed bypass GMAW (PB-GMAW). Then, we compare the current state of various DE-GMAW technologies, highlighting differences in welding productivity, stability control, and energy efficiency. The goal is to offer practical guidance for researchers in practical applications. Furthermore, this paper explores the innovative applications of DE-GMAW technology in other welding methods, such as submerged arc welding (SAW), twin-wire indirect arc welding (TWIAW), and double-side arc welding (DSAW), and analyzes the advantages of these hybrid processes in enhancing welding performance. Finally, this paper points out that the future development of DE-GMAW technology requires further theoretical research, exploration of new material welding processes, and the application of automation systems and robotics technology to further improve the welding efficiency, accuracy, and repeatability in the application process.

{"title":"A review of double-electrode GMAW: Approaches, developments and variants","authors":"Rui Xiang , Jiankang Huang , Xiaoquan Yu , Huayu Zhao , Ding Fan","doi":"10.1016/j.jmapro.2024.12.017","DOIUrl":"10.1016/j.jmapro.2024.12.017","url":null,"abstract":"<div><div>Double-electrode gas metal arc welding (DE-GMAW) is an advanced welding technology that uses a bypass torch to regulate the current through the base metal, effectively reducing the heat input to the base metal and increasing the deposition rate of the filling wire. Through precise control of the welding process, the stability of the welding arc and the welding quality are significantly improved. First, this paper provides a systematic review of the characteristics and applications of consumable and non-consumable DE-GMAW. The non-consumable DE-GMAW includes single-bypass GMAW (SB-GMAW), double-bypass GMAW (DB-GMAW), and pulsed bypass GMAW (PB-GMAW). Then, we compare the current state of various DE-GMAW technologies, highlighting differences in welding productivity, stability control, and energy efficiency. The goal is to offer practical guidance for researchers in practical applications. Furthermore, this paper explores the innovative applications of DE-GMAW technology in other welding methods, such as submerged arc welding (SAW), twin-wire indirect arc welding (TWIAW), and double-side arc welding (DSAW), and analyzes the advantages of these hybrid processes in enhancing welding performance. Finally, this paper points out that the future development of DE-GMAW technology requires further theoretical research, exploration of new material welding processes, and the application of automation systems and robotics technology to further improve the welding efficiency, accuracy, and repeatability in the application process.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1160-1182"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138187","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

Enhancing the mechanical properties of FDM 3D printed PETG parts with high pressure cold isostatic pressing

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.094

Minji Ko , Young shin Kim , Euy sik Jeon

This study examined the effects of cold isostatic pressing (CIP) as a post-processing method for polyethylene terephthalate glycol-modified (PETG) parts produced by fused deposition modeling (FDM) 3D printing. To analyze the mechanical properties of CIP, 3D printed specimens were subjected to CIP at pressures ranging from 250 to 1000 bar with holding times of 1 to 10 min, followed by tensile, flexural, and interlaminar shear strength tests. Scanning electron microscope (SEM) and X-ray diffraction (XRD) analyses were performed for morphological and chemical property changes. The mechanical properties were generally optimal at 500–750 bar, indicating a significant improvement. SEM analysis revealed that the interlayer gaps and void areas decreased, with the porosity reduced by 4.46 times compared to the untreated samples. XRD analysis showed that the CIP treatment did not significantly alter the chemical structure of PETG and maintained its amorphous characteristics. These results suggest the potential of CIP as an effective post-processing technique that improves the mechanical properties while preserving the basic material characteristics of FDM-printed parts.

{"title":"Enhancing the mechanical properties of FDM 3D printed PETG parts with high pressure cold isostatic pressing","authors":"Minji Ko , Young shin Kim , Euy sik Jeon","doi":"10.1016/j.jmapro.2024.11.094","DOIUrl":"10.1016/j.jmapro.2024.11.094","url":null,"abstract":"<div><div>This study examined the effects of cold isostatic pressing (CIP) as a post-processing method for polyethylene terephthalate glycol-modified (PETG) parts produced by fused deposition modeling (FDM) 3D printing. To analyze the mechanical properties of CIP, 3D printed specimens were subjected to CIP at pressures ranging from 250 to 1000 bar with holding times of 1 to 10 min, followed by tensile, flexural, and interlaminar shear strength tests. Scanning electron microscope (SEM) and X-ray diffraction (XRD) analyses were performed for morphological and chemical property changes. The mechanical properties were generally optimal at 500–750 bar, indicating a significant improvement. SEM analysis revealed that the interlayer gaps and void areas decreased, with the porosity reduced by 4.46 times compared to the untreated samples. XRD analysis showed that the CIP treatment did not significantly alter the chemical structure of PETG and maintained its amorphous characteristics. These results suggest the potential of CIP as an effective post-processing technique that improves the mechanical properties while preserving the basic material characteristics of FDM-printed parts.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 682-691"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138713","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

Visual monitoring of weld penetration in aluminum alloy GTAW based on deep transfer learning enhanced by task-specific pre-training and semi-supervised learning

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.11.102

Boce Xue , Dong Du , Guodong Peng , Yanzhen Zhang , Runsheng Li , Zixiang Li

Appropriate weld penetration is of vital significance for ensuring the welding quality of gas tungsten arc welding (GTAW). Visual monitoring based on deep learning has been widely applied in weld penetration monitoring. However, deep learning requires a large number of labeled samples to achieve satisfactory performance. Deep transfer learning (DTL) is an effective technique to address this issue, but the famous ImageNet dataset may not be suitable for pre-training a deep learning model for weld penetration prediction. In this study, a visual monitoring approach for weld penetration of aluminum alloy GTAW based on DTL enhanced by task-specific pre-training and semi-supervised learning (SSL) is proposed to obtain better prediction accuracy of the backside bead width with limited labeled data. Firstly, an active vision method is used to capture images of the weld pool. Next, a task-specific pre-training method is designed by constructing a keypoint localization task to pre-train a deep learning model with an encoder-decoder architecture, and SSL is introduced to reduce the required number of labeled data in pre-training. Finally, an encoder-based regression model is constructed and fine-tuned to predict the backside bead width. It is found that by using SSL in task-specific pre-training, the keypoint localization model trained with only 40 labeled samples can achieve ideal performance, and the performance of SSL outperforms fully-supervised learning (FSL) in terms of both keypoint localization accuracy and robustness to the randomness of labeled training samples. Moreover, the mean prediction error of backside bead width after fine-tuning is only 0.176 mm, which is reduced by 29.9 % compared to using ImageNet for pre-training. The proposed method also has good real-time performance and thus has the capability to be applied in the real-time monitoring and control of weld penetration.

{"title":"Visual monitoring of weld penetration in aluminum alloy GTAW based on deep transfer learning enhanced by task-specific pre-training and semi-supervised learning","authors":"Boce Xue , Dong Du , Guodong Peng , Yanzhen Zhang , Runsheng Li , Zixiang Li","doi":"10.1016/j.jmapro.2024.11.102","DOIUrl":"10.1016/j.jmapro.2024.11.102","url":null,"abstract":"<div><div>Appropriate weld penetration is of vital significance for ensuring the welding quality of gas tungsten arc welding (GTAW). Visual monitoring based on deep learning has been widely applied in weld penetration monitoring. However, deep learning requires a large number of labeled samples to achieve satisfactory performance. Deep transfer learning (DTL) is an effective technique to address this issue, but the famous ImageNet dataset may not be suitable for pre-training a deep learning model for weld penetration prediction. In this study, a visual monitoring approach for weld penetration of aluminum alloy GTAW based on DTL enhanced by task-specific pre-training and semi-supervised learning (SSL) is proposed to obtain better prediction accuracy of the backside bead width with limited labeled data. Firstly, an active vision method is used to capture images of the weld pool. Next, a task-specific pre-training method is designed by constructing a keypoint localization task to pre-train a deep learning model with an encoder-decoder architecture, and SSL is introduced to reduce the required number of labeled data in pre-training. Finally, an encoder-based regression model is constructed and fine-tuned to predict the backside bead width. It is found that by using SSL in task-specific pre-training, the keypoint localization model trained with only 40 labeled samples can achieve ideal performance, and the performance of SSL outperforms fully-supervised learning (FSL) in terms of both keypoint localization accuracy and robustness to the randomness of labeled training samples. Moreover, the mean prediction error of backside bead width after fine-tuning is only 0.176 mm, which is reduced by 29.9 % compared to using ImageNet for pre-training. The proposed method also has good real-time performance and thus has the capability to be applied in the real-time monitoring and control of weld penetration.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1038-1050"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138718","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 frequency on welding stability, microstructure, and mechanical performance of SUS304 welded by local dry underwater fast-frequency pulsed MIG

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.009

Zhenmin Wang , Jianliang Hu , Jianjun Jia , Zixiao Gui , Yingwei Kuang , Haipeng Liao , Qin Zhang , Xiaoming Wang

A new local dry underwater fast-frequency pulsed MIG (LDU-FFPMIG) welding method was developed for fabricating SUS304 weldments. The effect of the fast-frequency single pulsed (FFSP) waveform at different fast-frequency pulsed (FFP) frequencies (10 kHz–30 kHz) on welding stability, microstructure and mechanical performance were studied, with the low-frequency pulsed (LFP) waveform serving as a comparative reference. The findings indicated that the FFSP waveform, especially at 20 kHz, enhanced the welding stability, improved the microstructure and strengthened the mechanical performance. Compared to the LFP waveform, the FFSP waveform at 20 kHz increased the droplet transfer frequency by 150 %. Additionally, the FFSP waveform at 20 kHz exhibited an optimal stirring effect on the molten pool, which significantly facilitated the transformation of skeletal ferrite into lathy ferrite and refined grains. The standard deviations of the weld element distribution obtained by the FFSP waveform at 20 kHz were reduced by 18.3 % (Fe), 29.9 % (Cr) and 30.1 % (Ni), respectively. Furthermore, with the increase of FFP frequency, the mechanical performance of weldments first increased (10 kHz–20 kHz) and then decreased (20 kHz–30 kHz). The microhardness (220 HV), tensile strength (765 MPa) and elongation (36.1 %) of weldments prepared by the FFSP waveform at 20 kHz increased by 20.2 %, 19.7 % and 43.3 %, respectively, compared to weldments prepared by the LFP waveform. This study was conducive to providing a novel method for the marine engineering field to improve the quality of SUS304.

{"title":"Effect of frequency on welding stability, microstructure, and mechanical performance of SUS304 welded by local dry underwater fast-frequency pulsed MIG","authors":"Zhenmin Wang , Jianliang Hu , Jianjun Jia , Zixiao Gui , Yingwei Kuang , Haipeng Liao , Qin Zhang , Xiaoming Wang","doi":"10.1016/j.jmapro.2024.12.009","DOIUrl":"10.1016/j.jmapro.2024.12.009","url":null,"abstract":"<div><div>A new local dry underwater fast-frequency pulsed MIG (LDU-FFPMIG) welding method was developed for fabricating SUS304 weldments. The effect of the fast-frequency single pulsed (FFSP) waveform at different fast-frequency pulsed (FFP) frequencies (10 kHz–30 kHz) on welding stability, microstructure and mechanical performance were studied, with the low-frequency pulsed (LFP) waveform serving as a comparative reference. The findings indicated that the FFSP waveform, especially at 20 kHz, enhanced the welding stability, improved the microstructure and strengthened the mechanical performance. Compared to the LFP waveform, the FFSP waveform at 20 kHz increased the droplet transfer frequency by 150 %. Additionally, the FFSP waveform at 20 kHz exhibited an optimal stirring effect on the molten pool, which significantly facilitated the transformation of skeletal ferrite into lathy ferrite and refined grains. The standard deviations of the weld element distribution obtained by the FFSP waveform at 20 kHz were reduced by 18.3 % (Fe), 29.9 % (Cr) and 30.1 % (Ni), respectively. Furthermore, with the increase of FFP frequency, the mechanical performance of weldments first increased (10 kHz–20 kHz) and then decreased (20 kHz–30 kHz). The microhardness (220 HV), tensile strength (765 MPa) and elongation (36.1 %) of weldments prepared by the FFSP waveform at 20 kHz increased by 20.2 %, 19.7 % and 43.3 %, respectively, compared to weldments prepared by the LFP waveform. This study was conducive to providing a novel method for the marine engineering field to improve the quality of SUS304.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1051-1064"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143138719","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 surface charging dynamics and effects on ink jetting behaviors for plasma-induced electrohydrodynamic printing

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.031

Yu Jiang , Bo Zhang , Wenhu Han , Xuechen Niu , Mingtao Zeng , Dong Ye , Weiwei Deng , Lianbo Guo , Guanjun Zhang , YongAn Huang

The rapid evolution of conformal electronics necessitates advancements in high-resolution printing on three-dimensional curved insulating surfaces directly. A recently developed technique, known as plasma-induced electrohydrodynamic (PiE) printing, is a promising technique that enables micron and submicron scale printing on arbitrary dielectric substrates. However, factors that govern the deposited charges and the effects of the constructed electric field on induced jetting behavior have not been fully comprehended. Here, we investigate the role of plasma-surface interaction in PiE printing and its impact on the printing process. The local electric field, constructed by site-selective deposition of positive charges on the dielectric surfaces through plasma jet impingement, forms a spatial region of effective influence. The geometrical and electrical parameters of the PiE printing system significantly influence the spreading range and intensity of plasma on the surface and hence the effective region, and therefore determines the induced ink jetting behavior and the jets/droplets traction and deflection. Our study reveals the relationship between the plasma jet and inkjet dynamics in PiE printing, providing insights into the interplay between the plasma spreading behavior and process parameters. The optimization of these parameters can enable better performance of high-quality PiE printing.

{"title":"Investigation of surface charging dynamics and effects on ink jetting behaviors for plasma-induced electrohydrodynamic printing","authors":"Yu Jiang , Bo Zhang , Wenhu Han , Xuechen Niu , Mingtao Zeng , Dong Ye , Weiwei Deng , Lianbo Guo , Guanjun Zhang , YongAn Huang","doi":"10.1016/j.jmapro.2024.12.031","DOIUrl":"10.1016/j.jmapro.2024.12.031","url":null,"abstract":"<div><div>The rapid evolution of conformal electronics necessitates advancements in high-resolution printing on three-dimensional curved insulating surfaces directly. A recently developed technique, known as plasma-induced electrohydrodynamic (PiE) printing, is a promising technique that enables micron and submicron scale printing on arbitrary dielectric substrates. However, factors that govern the deposited charges and the effects of the constructed electric field on induced jetting behavior have not been fully comprehended. Here, we investigate the role of plasma-surface interaction in PiE printing and its impact on the printing process. The local electric field, constructed by site-selective deposition of positive charges on the dielectric surfaces through plasma jet impingement, forms a spatial region of effective influence. The geometrical and electrical parameters of the PiE printing system significantly influence the spreading range and intensity of plasma on the surface and hence the effective region, and therefore determines the induced ink jetting behavior and the jets/droplets traction and deflection. Our study reveals the relationship between the plasma jet and inkjet dynamics in PiE printing, providing insights into the interplay between the plasma spreading behavior and process parameters. The optimization of these parameters can enable better performance of high-quality PiE printing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1352-1363"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137794","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

Femtosecond pulsed laser-induced covalent bonding of SWCNTs: Toward high-performance flexible bending sensors

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2025-01-17 DOI: 10.1016/j.jmapro.2024.12.024

Huanhuan Mei , Xuesong Mei , Haitao Wang , Xiaoqiao He , Jianlei Cui

Single-Walled Carbon Nanotubes (SWCNTs), with their superior nanoscale properties, are supposed to be the ideal material for next-generation wiring. However, establishing chemical bonding between SWCNTs presents a formidable challenge. The interconnection process should be executed with precision, applying a heat source that induces a chemical reaction between SWCNTs without causing damage or introducing impurities. In this study, a high-energy laser beam was introduced to activate SWCNTs, causing them to chemical bonding with each other under the action of femtosecond pulse laser energy. Based on this technique, the electrical performance of the connected SWCNTs sensor was improved by nearly 63 %. After 1000 repeated bending cycles, the response value of the sensor decreases only slightly, confirming its long-term reliability and durability. The uniqueness of femtosecond pulse lasers was utilized to overcome the limitations of traditional thermal and mechanical processes to achieve selectively effective interconnection of SWCNTs, providing a new possibility for the connection of SWCNTs in future integrated applications.

{"title":"Femtosecond pulsed laser-induced covalent bonding of SWCNTs: Toward high-performance flexible bending sensors","authors":"Huanhuan Mei , Xuesong Mei , Haitao Wang , Xiaoqiao He , Jianlei Cui","doi":"10.1016/j.jmapro.2024.12.024","DOIUrl":"10.1016/j.jmapro.2024.12.024","url":null,"abstract":"<div><div>Single-Walled Carbon Nanotubes (SWCNTs), with their superior nanoscale properties, are supposed to be the ideal material for next-generation wiring. However, establishing chemical bonding between SWCNTs presents a formidable challenge. The interconnection process should be executed with precision, applying a heat source that induces a chemical reaction between SWCNTs without causing damage or introducing impurities. In this study, a high-energy laser beam was introduced to activate SWCNTs, causing them to chemical bonding with each other under the action of femtosecond pulse laser energy. Based on this technique, the electrical performance of the connected SWCNTs sensor was improved by nearly 63 %. After 1000 repeated bending cycles, the response value of the sensor decreases only slightly, confirming its long-term reliability and durability. The uniqueness of femtosecond pulse lasers was utilized to overcome the limitations of traditional thermal and mechanical processes to achieve selectively effective interconnection of SWCNTs, providing a new possibility for the connection of SWCNTs in future integrated applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"133 ","pages":"Pages 1364-1372"},"PeriodicalIF":6.1,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137795","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