Pub Date : 2026-02-15Epub Date: 2026-01-17DOI: 10.1016/j.jmapro.2026.01.046
Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng
The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.
{"title":"Effect of minimum quality lubrication on micromilling of TiBw/TA15 composites considering tool wear","authors":"Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng","doi":"10.1016/j.jmapro.2026.01.046","DOIUrl":"10.1016/j.jmapro.2026.01.046","url":null,"abstract":"<div><div>The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 271-285"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981114","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 : 2026-02-15Epub 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":"2026-02-15","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 : 2026-02-15Epub Date: 2026-01-20DOI: 10.1016/j.jmapro.2026.01.041
Kejian Chen , Sitong Xiang , Juntao Ni , Hainan Zhang , Jianguo Yang
With the continuous advancement of manufacturing precision requirements, the importance of machine tool accuracy inspection has become increasingly prominent. This study proposes a self-calibration approach for rotary axis geometric errors using a gear-shaped workpiece. By designing a gear-shaped workpiece featuring 12 arc surfaces, an error identification model is established, the study focuses on the contributions of the machine tool's linear axes and C-axis geometric errors to the probing deviations. Combined with on-machine measurement technology using a touch-trigger probe, this method achieves decoupled identification of linear axis errors, workpiece geometric errors, and rotary axis geometric errors. Specifically, the rotary axis geometric errors include 4 position-independent geometric errors (PIGEs) and 6 position-dependent geometric errors (PDGEs). The workpiece incorporates square groove features to facilitate re-clamping and alignment, enhancing the efficiency of periodic accuracy calibration. The proposed method's effectiveness is further confirmed through uncertainty analysis and comparative experimental verification against ball-bar and artifact-based identification methods.
{"title":"Self-calibration method for rotary axis geometric errors in five-axis machine tools using gear-shaped workpieces","authors":"Kejian Chen , Sitong Xiang , Juntao Ni , Hainan Zhang , Jianguo Yang","doi":"10.1016/j.jmapro.2026.01.041","DOIUrl":"10.1016/j.jmapro.2026.01.041","url":null,"abstract":"<div><div>With the continuous advancement of manufacturing precision requirements, the importance of machine tool accuracy inspection has become increasingly prominent. This study proposes a self-calibration approach for rotary axis geometric errors using a gear-shaped workpiece. By designing a gear-shaped workpiece featuring 12 arc surfaces, an error identification model is established, the study focuses on the contributions of the machine tool's linear axes and C-axis geometric errors to the probing deviations. Combined with on-machine measurement technology using a touch-trigger probe, this method achieves decoupled identification of linear axis errors, workpiece geometric errors, and rotary axis geometric errors. Specifically, the rotary axis geometric errors include 4 position-independent geometric errors (PIGEs) and 6 position-dependent geometric errors (PDGEs). The workpiece incorporates square groove features to facilitate re-clamping and alignment, enhancing the efficiency of periodic accuracy calibration. The proposed method's effectiveness is further confirmed through uncertainty analysis and comparative experimental verification against ball-bar and artifact-based identification methods.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 429-441"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024735","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 : 2026-02-15Epub Date: 2026-01-19DOI: 10.1016/j.jmapro.2026.01.019
Shaozhen Hua, Hui Li, Huabo Liu
Unbalanced filling in injection molding of geometrically balanced molds is a bad phenomenon that leads defects and has not been fully understanding. In this work, numerical simulation technique is taken to explore unbalanced filling. The melt during filling is considered to be incompressible, non-isothermal and viscoelastic fluids with Giesekus viscoelastic model to described its rheological character. A coupled finite volume method (FVM) and moving particle simulation (MPS) method was developed. Melt and air flow in cavity are treated as a whole flow field and solved by FVM, while the melt front is captured by the moving particles method. A benchmark case for the MPS method was then used to validate the developed algorithm. Additionally, the melt front progression, gate pressure, temperature distribution, and viscoelastic characteristics during injection molding were simulated and compared to experimental results or other numerical results. Results demonstrate that the developed algorithm can accurately simulate the non-isothermal viscoelastic injection molding process of the melt. Subsequently, the developed algorithm was applied to simulate both balanced and unbalanced filling processes during injection molding. Analysis of shear rate, temperature, and the first and second normal stress differences confirmed the validity of the established theory that shear-induced heating drives unbalanced filling. Furthermore, numerical results demonstrated that in tapered tubular runners, the first normal stress difference promotes balanced flow in naturally balanced runner systems, while the second normal stress difference induces unbalanced filling.
{"title":"Viscoelastic modeling and mechanism analysis of unbalanced filling in geometrically balanced injection molds","authors":"Shaozhen Hua, Hui Li, Huabo Liu","doi":"10.1016/j.jmapro.2026.01.019","DOIUrl":"10.1016/j.jmapro.2026.01.019","url":null,"abstract":"<div><div>Unbalanced filling in injection molding of geometrically balanced molds is a bad phenomenon that leads defects and has not been fully understanding. In this work, numerical simulation technique is taken to explore unbalanced filling. The melt during filling is considered to be incompressible, non-isothermal and viscoelastic fluids with Giesekus viscoelastic model to described its rheological character. A coupled finite volume method (FVM) and moving particle simulation (MPS) method was developed. Melt and air flow in cavity are treated as a whole flow field and solved by FVM, while the melt front is captured by the moving particles method. A benchmark case for the MPS method was then used to validate the developed algorithm. Additionally, the melt front progression, gate pressure, temperature distribution, and viscoelastic characteristics during injection molding were simulated and compared to experimental results or other numerical results. Results demonstrate that the developed algorithm can accurately simulate the non-isothermal viscoelastic injection molding process of the melt. Subsequently, the developed algorithm was applied to simulate both balanced and unbalanced filling processes during injection molding. Analysis of shear rate, temperature, and the first and second normal stress differences confirmed the validity of the established theory that shear-induced heating drives unbalanced filling. Furthermore, numerical results demonstrated that in tapered tubular runners, the first normal stress difference promotes balanced flow in naturally balanced runner systems, while the second normal stress difference induces unbalanced filling.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 409-428"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024734","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 : 2026-02-15Epub 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":"2026-02-15","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 : 2026-02-15Epub 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":"2026-02-15","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}
Pub Date : 2026-02-15Epub 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":"2026-02-15","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 : 2026-02-15Epub Date: 2026-01-19DOI: 10.1016/j.jmapro.2026.01.022
Jian Hu , Hao Shen , Xavier Legrand , Peng Wang
Tufting is a promising technology for reinforcing composite materials, offering notable advantages in both performance and cost-effectiveness. It effectively improves the delamination resistance and impact tolerance of multi-layered composite structures, making it highly applicable across a range of industries, including transportation, construction, energy, and defence. In recent years, significant advancements have been made in the development of tufted multi-layered composites. Nevertheless, there remain gaps in the systematic understanding of the tufting process. This review provides an overview of the current stage of tufting technology, including its definition, key tufting parameters, and the potential damage to tufted composites. Additionally, the paper summarises current research on the forming and simulation of tufted preforms. Future research efforts should focus on optimising the tufting process, standardising techniques, and expanding its industrial applications.
{"title":"A review on tufting technology for 3D preforms: Manufacturing, process parameters and performance implications","authors":"Jian Hu , Hao Shen , Xavier Legrand , Peng Wang","doi":"10.1016/j.jmapro.2026.01.022","DOIUrl":"10.1016/j.jmapro.2026.01.022","url":null,"abstract":"<div><div>Tufting is a promising technology for reinforcing composite materials, offering notable advantages in both performance and cost-effectiveness. It effectively improves the delamination resistance and impact tolerance of multi-layered composite structures, making it highly applicable across a range of industries, including transportation, construction, energy, and defence. In recent years, significant advancements have been made in the development of tufted multi-layered composites. Nevertheless, there remain gaps in the systematic understanding of the tufting process. This review provides an overview of the current stage of tufting technology, including its definition, key tufting parameters, and the potential damage to tufted composites. Additionally, the paper summarises current research on the forming and simulation of tufted preforms. Future research efforts should focus on optimising the tufting process, standardising techniques, and expanding its industrial applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 377-395"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024731","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 : 2026-02-15Epub Date: 2026-01-19DOI: 10.1016/j.jmapro.2026.01.048
Peng Han , Jiaxing Duan , Qianzhi Ma , Jia Lin , Fengming Qiang , Wen Wang , Ke Qiao , Kuaishe Wang
To overcome the poor strength-ductility trade-off in ceramic particle-reinforced aluminum matrix composites (AMCs), this study fabricated CoCrFeNi particle-reinforced AMCs using cold spray and cold spray-friction stir processing composite additive manufacturing (CFAM) technology, respectively. The microstructures and mechanical properties of the AMCs were systematically optimized through a short-time T6 heat treatment. A comprehensive microstructural characterization of the AMCs was performed using X-ray diffraction, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. The tensile strength was evaluated and the strengthening mechanism was determined. The results indicated that the cold-sprayed AMCs contained significant porosity and a highly inhomogeneous grain structure. The CoCrFeNi/Al interfaces were primarily characterized by mechanical bonding, with no significant interfacial reactions observed. Comparatively, the AMCs fabricated by CFAM demonstrated significantly refined, homogenized, and densified microstructures, with an average grain size of 1.46 μm. Enhanced elemental interdiffusion occurred at the CoCrFeNi/Al interface, and numerous intermetallic compounds, specifically Al7Cr and Al9(Co,Fe,Ni)2, were found to be homogeneously dispersed within the Al matrix. After short-time T6 heat treatment, the average grain size of the AMCs fabricated by CFAM experienced slight growth, reaching an average of 1.92 μm. Concurrently, interfacial reaction at the CoCrFeNi/Al interface intensified, leading to the formation of a dual-layer interfacial reaction zone. This zone consisted of an inner layer enriched with α-Al(Co,Cr,Fe,Ni)Si and an outer layer enriched with Al9(Co,Fe,Ni)2 and Al13(Co,Fe,Ni)4. Meanwhile, the tensile strength of the AMCs fabricated by CFAM improved by 98 MPa compared to the pre-heat-treated state, reaching 368 MPa. This enhancement was primarily attributed to the short-time T6 heat treatment achieving concurrent optimization of the CoCrFeNi/Al interfacial reaction products and the precipitated phase within the Al matrix, thereby achieving excellent strength and elongation in the AMCs. In summary, this study developed an effective approach for fabricating high-performance AMCs reinforced with CoCrFeNi particles.
{"title":"High-performance CoCrFeNi/6061 aluminum matrix composites fabricated by cold spray-friction stir processing composite additive manufacturing","authors":"Peng Han , Jiaxing Duan , Qianzhi Ma , Jia Lin , Fengming Qiang , Wen Wang , Ke Qiao , Kuaishe Wang","doi":"10.1016/j.jmapro.2026.01.048","DOIUrl":"10.1016/j.jmapro.2026.01.048","url":null,"abstract":"<div><div>To overcome the poor strength-ductility trade-off in ceramic particle-reinforced aluminum matrix composites (AMCs), this study fabricated CoCrFeNi particle-reinforced AMCs using cold spray and cold spray-friction stir processing composite additive manufacturing (CFAM) technology, respectively. The microstructures and mechanical properties of the AMCs were systematically optimized through a short-time T6 heat treatment. A comprehensive microstructural characterization of the AMCs was performed using X-ray diffraction, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. The tensile strength was evaluated and the strengthening mechanism was determined. The results indicated that the cold-sprayed AMCs contained significant porosity and a highly inhomogeneous grain structure. The CoCrFeNi/Al interfaces were primarily characterized by mechanical bonding, with no significant interfacial reactions observed. Comparatively, the AMCs fabricated by CFAM demonstrated significantly refined, homogenized, and densified microstructures, with an average grain size of 1.46 μm. Enhanced elemental interdiffusion occurred at the CoCrFeNi/Al interface, and numerous intermetallic compounds, specifically Al<sub>7</sub>Cr and Al<sub>9</sub>(Co,Fe,Ni)<sub>2</sub>, were found to be homogeneously dispersed within the Al matrix. After short-time T6 heat treatment, the average grain size of the AMCs fabricated by CFAM experienced slight growth, reaching an average of 1.92 μm. Concurrently, interfacial reaction at the CoCrFeNi/Al interface intensified, leading to the formation of a dual-layer interfacial reaction zone. This zone consisted of an inner layer enriched with α-Al(<em>Co</em>,<em>Cr</em>,<em>Fe</em>,<em>Ni</em>)Si and an outer layer enriched with Al<sub>9</sub>(Co,Fe,Ni)<sub>2</sub> and Al<sub>13</sub>(Co,Fe,Ni)<sub>4</sub>. Meanwhile, the tensile strength of the AMCs fabricated by CFAM improved by 98 MPa compared to the pre-heat-treated state, reaching 368 MPa. This enhancement was primarily attributed to the short-time T6 heat treatment achieving concurrent optimization of the CoCrFeNi/Al interfacial reaction products and the precipitated phase within the Al matrix, thereby achieving excellent strength and elongation in the AMCs. In summary, this study developed an effective approach for fabricating high-performance AMCs reinforced with CoCrFeNi particles.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 347-360"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024739","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 : 2026-02-15Epub Date: 2026-01-20DOI: 10.1016/j.jmapro.2026.01.027
Raja Dharavathu , Kishora Shetty , Gopinath Muvvala
Friction stir welding (FSW) is a solid-state joining technique particularly effective for alloys that are difficult to weld by conventional fusion processes. However, welding of thick plates often necessitates robust kinematic systems, and steep thermal gradients can induce high flow stress near the tool tip, leading to tunneling or void defects. This study focuses on minimizing such defects and improving the mechanical performance of 8 mm thick 2014-T6 aluminum alloy joints produced by double-sided FSW. Process optimization was achieved by varying pin lengths, reducing welding speeds, and increasing the tool tilt angle from 0° to 2°, which enhanced plastic flow and material consolidation. Defect-free joints were obtained at welding speeds of 5, 10, and 20 mm/min with a rotational speed of 900 rpm and a 2° tilt angle. Despite the absence of macroscopic defects, the as-welded joints exhibited reduced tensile strength due to overaging and coarsening of Al2Cu precipitates within the nugget zone (NZ), as confirmed by TEM. Comprehensive microstructural characterization using optical microscopy SEM, EDS and EBSD revealed precipitate dissolution and dynamic recrystallization within the NZ. Post-weld heat treatment (PWHT), consisting of solution treatment at 500 °C followed by artificial aging at 160 °C for 18 h, significantly enhanced strength and hardness owing to the re-precipitation of semi-coherent phases, though with a marginal decrease in ductility. Tensile testing with 2D digital image correlation indicated a strain hardening exponent of 0.25 in the as-welded NZ and 0.12 after PWHT, reflecting a transition from localized to more uniform plastic deformation behavior.
{"title":"A study on mitigation of tunneling defects and investigation on the mechanical behavior of double-sided friction stir welded Al 2014 plates","authors":"Raja Dharavathu , Kishora Shetty , Gopinath Muvvala","doi":"10.1016/j.jmapro.2026.01.027","DOIUrl":"10.1016/j.jmapro.2026.01.027","url":null,"abstract":"<div><div>Friction stir welding (FSW) is a solid-state joining technique particularly effective for alloys that are difficult to weld by conventional fusion processes. However, welding of thick plates often necessitates robust kinematic systems, and steep thermal gradients can induce high flow stress near the tool tip, leading to tunneling or void defects. This study focuses on minimizing such defects and improving the mechanical performance of 8 mm thick 2014-T6 aluminum alloy joints produced by double-sided FSW. Process optimization was achieved by varying pin lengths, reducing welding speeds, and increasing the tool tilt angle from 0° to 2°, which enhanced plastic flow and material consolidation. Defect-free joints were obtained at welding speeds of 5, 10, and 20 mm/min with a rotational speed of 900 rpm and a 2° tilt angle. Despite the absence of macroscopic defects, the as-welded joints exhibited reduced tensile strength due to overaging and coarsening of Al<sub>2</sub>Cu precipitates within the nugget zone (NZ), as confirmed by TEM. Comprehensive microstructural characterization using optical microscopy SEM, EDS and EBSD revealed precipitate dissolution and dynamic recrystallization within the NZ. Post-weld heat treatment (PWHT), consisting of solution treatment at 500 °C followed by artificial aging at 160 °C for 18 h, significantly enhanced strength and hardness owing to the re-precipitation of semi-coherent <span><math><msup><mi>θ</mi><mo>′</mo></msup></math></span> phases, though with a marginal decrease in ductility. Tensile testing with 2D digital image correlation indicated a strain hardening exponent of 0.25 in the as-welded NZ and 0.12 after PWHT, reflecting a transition from localized to more uniform plastic deformation behavior.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"159 ","pages":"Pages 460-480"},"PeriodicalIF":6.8,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024737","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}