Pub Date : 2025-12-17DOI: 10.1016/j.jmapro.2025.12.024
Joonhee Park , Inseo Kim , Dongwhi Park , Inseob Kong , Honglae Kim , Naksoo Kim
This study proposes a convolutional neural network (CNN)-based 3D preform design framework to prevent defects such as underfill and folding in hot forging processes while minimizing forging load and flash formation. We converted simulation data into voxels for training and constructed initial datasets using Laplace-based isosurface geometries along with cuboid and cylindrical shapes. To enhance generalization capability, deformation-based data augmentation was employed. For the quantitative evaluation of forged products regarding preform geometry, the proposed forging volume efficiency index (FVEI) integrates both geometric conformity and critical defect indicators into a single, comprehensive metric. Preforms designed for three representative geometries successfully reduced forging load and flash while eliminating defects. The proposed approach demonstrated reliable performance even for previously unseen geometries that were not included in the training set. This framework presents a fully automated design methodology independent of expert knowledge, highlighting its strong potential for direct application in industrial settings.
{"title":"A volume-driven CNN framework replacing expert intuition in 3D forging preform design","authors":"Joonhee Park , Inseo Kim , Dongwhi Park , Inseob Kong , Honglae Kim , Naksoo Kim","doi":"10.1016/j.jmapro.2025.12.024","DOIUrl":"10.1016/j.jmapro.2025.12.024","url":null,"abstract":"<div><div>This study proposes a convolutional neural network (CNN)-based 3D preform design framework to prevent defects such as underfill and folding in hot forging processes while minimizing forging load and flash formation. We converted simulation data into voxels for training and constructed initial datasets using Laplace-based isosurface geometries along with cuboid and cylindrical shapes. To enhance generalization capability, deformation-based data augmentation was employed. For the quantitative evaluation of forged products regarding preform geometry, the proposed forging volume efficiency index (FVEI) integrates both geometric conformity and critical defect indicators into a single, comprehensive metric. Preforms designed for three representative geometries successfully reduced forging load and flash while eliminating defects. The proposed approach demonstrated reliable performance even for previously unseen geometries that were not included in the training set. This framework presents a fully automated design methodology independent of expert knowledge, highlighting its strong potential for direct application in industrial settings.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 763-783"},"PeriodicalIF":6.8,"publicationDate":"2025-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787174","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.12.026
Junjie Wan , Liang Liang , Yanming Quan
The recast layer strongly influences surface quality in laser ablation, particularly for micro-textures, but existing laser ablation models fail to predict its profile effectively. To address this problem, a pulsed laser ablation model based on Support Vector Regression is proposed, achieving prediction of surface ablation profiles with recast layer. This study first established a dataset of ablation crater profiles with recast layers by systematically controlling laser power and number of pulses in spot ablation experiments. Subsequently, a spot ablation model was developed through support vector regression training. Performance evaluations demonstrated that the model achieved mean values of 5.61 μm for root mean square error, 0.92 for Dice coefficient, and 6.65 μm for Fréchet distance, indicating strong predictive performance. Based on the spot ablation model, an overlapping ablation model was developed using a geometric stitching algorithm. Experimental validation confirmed that the overlapping ablation model could accurately simulate overlapped ablation craters with recast layers under different spatial gaps and hatching distances. This research provides new theoretical foundations and technical tools for surface quality control in laser micro-machining.
{"title":"A method for predicting ablated surface profiles with recast layers under pulsed laser ablation","authors":"Junjie Wan , Liang Liang , Yanming Quan","doi":"10.1016/j.jmapro.2025.12.026","DOIUrl":"10.1016/j.jmapro.2025.12.026","url":null,"abstract":"<div><div>The recast layer strongly influences surface quality in laser ablation, particularly for micro-textures, but existing laser ablation models fail to predict its profile effectively. To address this problem, a pulsed laser ablation model based on Support Vector Regression is proposed, achieving prediction of surface ablation profiles with recast layer. This study first established a dataset of ablation crater profiles with recast layers by systematically controlling laser power and number of pulses in spot ablation experiments. Subsequently, a spot ablation model was developed through support vector regression training. Performance evaluations demonstrated that the model achieved mean values of 5.61 μm for root mean square error, 0.92 for Dice coefficient, and 6.65 μm for Fréchet distance, indicating strong predictive performance. Based on the spot ablation model, an overlapping ablation model was developed using a geometric stitching algorithm. Experimental validation confirmed that the overlapping ablation model could accurately simulate overlapped ablation craters with recast layers under different spatial gaps and hatching distances. This research provides new theoretical foundations and technical tools for surface quality control in laser micro-machining.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 737-746"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787293","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.12.027
Mincheoul Seong , Youngjin Seo , Dongkyoung Lee
This study investigates the removal efficiency and mechanism of welding by-products, such as heat tint, oxide layer, and slag, around the weld bead formed by arc welding using a nanosecond pulsed fiber laser. Laser cleaning experiments were performed with laser powers ranging from 110 W to 160 W, a spot size of 40 , and a fixed scanning speed of 5000 mm/s. Afterward, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) analyses were performed to investigate microstructures and chemical compositions to evaluate the removal efficiency and mechanisms. In addition, cyclic corrosion tests (CCT) were conducted to examine the improvements in corrosion resistance after laser cleaning. Consequently, most by-products were effectively removed at a laser power of 160 W. The oxygen content on the upper plate decreased from 25.1 % to 4.8 %, while the silicon and manganese in the slag decreased from 8.5 % and 3.2 % to 1.7 % and 0.6 %, respectively. Slag was completely removed from the center of the weld bead and 80 % from the bead edges. Cyclic corrosion test confirmed that laser-cleaned specimens at 160 W showed less corrosion after 95 cycles, meeting 15-year durability standards. Mechanism analysis revealed that the heat tint and oxide layer were removed through thermal ablation, while slag was removed by plasma-induced thermal stress. This study provides the potential of high-power laser cleaning for post-weld surface treatment in the automotive field.
研究了纳秒脉冲光纤激光对电弧焊焊缝周围热色、氧化层、熔渣等焊接副产物的去除效率及机理。激光清洗实验在激光功率为110 W ~ 160 W，光斑尺寸为40 μm，扫描速度为5000 mm/s的条件下进行。随后，通过扫描电子显微镜（SEM）和能量色散x射线能谱（EDX）分析来研究其微观结构和化学成分，以评估其去除效率和机制。此外，还进行了循环腐蚀试验（CCT），以检验激光清洗后耐腐蚀性能的提高。因此，在160 W的激光功率下，大多数副产物被有效地去除。炉渣中硅和锰的含量分别从8.5%和3.2%下降到1.7%和0.6%，炉渣上氧含量从25.1%下降到4.8%。熔渣完全从焊头中心去除，80%从焊头边缘去除。循环腐蚀试验证实，在160 W下激光清洗的试样经过95次循环后腐蚀较少，达到了15年的耐久性标准。机理分析表明，通过热烧蚀去除热色和氧化层，通过等离子体诱导热应力去除渣。该研究为高功率激光清洗在汽车领域的焊后表面处理提供了潜力。
{"title":"Characterization of laser cleaning for removing welding by-products from SPFH590 steel","authors":"Mincheoul Seong , Youngjin Seo , Dongkyoung Lee","doi":"10.1016/j.jmapro.2025.12.027","DOIUrl":"10.1016/j.jmapro.2025.12.027","url":null,"abstract":"<div><div>This study investigates the removal efficiency and mechanism of welding by-products, such as heat tint, oxide layer, and slag, around the weld bead formed by arc welding using a nanosecond pulsed fiber laser. Laser cleaning experiments were performed with laser powers ranging from 110 W to 160 W, a spot size of 40 <span><math><mi>μm</mi></math></span>, and a fixed scanning speed of 5000 mm/s. Afterward, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) analyses were performed to investigate microstructures and chemical compositions to evaluate the removal efficiency and mechanisms. In addition, cyclic corrosion tests (CCT) were conducted to examine the improvements in corrosion resistance after laser cleaning. Consequently, most by-products were effectively removed at a laser power of 160 W. The oxygen content on the upper plate decreased from 25.1 % to 4.8 %, while the silicon and manganese in the slag decreased from 8.5 % and 3.2 % to 1.7 % and 0.6 %, respectively. Slag was completely removed from the center of the weld bead and 80 % from the bead edges. Cyclic corrosion test confirmed that laser-cleaned specimens at 160 W showed less corrosion after 95 cycles, meeting 15-year durability standards. Mechanism analysis revealed that the heat tint and oxide layer were removed through thermal ablation, while slag was removed by plasma-induced thermal stress. This study provides the potential of high-power laser cleaning for post-weld surface treatment in the automotive field.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 687-697"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787303","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.11.066
Lingxiang Quan , Ding Liu
In complex industrial processes, process data often contain noise due to sensor errors and environmental disturbances, in addition to the complex coupling features between process variables that are difficult to extract, which poses a great challenge to the traditional quality-related data-driven soft sensor models. To solve the above problems, this paper proposes a data-driven model with denoising memory adaptive spatial guidance network (DMASG). Firstly, in order to mitigate the effect of process data noise and enhance the key information memory, a denoising memory-gated spiking neural P network (DMGSNP) integrating noise suppression (NS) module and information memory (IM) units is developed to improve the robustness of the model and enrich the feature information, as well as to achieve temporal feature extraction. Consequently, an adaptive spatial guidance relation network (ASGRN) based on coupling feature extraction is designed using the two-by-two explicit modelling capability of relation network, in which adaptive subspace analysis (ASA) is used as an embedding module for extracting spatial coupling relationships between variables and a spatial guidance relation (SGR) module is introduced for efficiently capturing global dependencies of variables and local contextual information. Finally, the validity of the proposed model is verified through two case studies closely related to manufacturing processes: the Cz silicon single crystal growth process for semiconductor manufacturing, and the froth flotation process for mineral processing.
{"title":"DMASG: A denoising memory adaptive spatial guidance network for soft sensor modelling in complex manufacturing processes","authors":"Lingxiang Quan , Ding Liu","doi":"10.1016/j.jmapro.2025.11.066","DOIUrl":"10.1016/j.jmapro.2025.11.066","url":null,"abstract":"<div><div>In complex industrial processes, process data often contain noise due to sensor errors and environmental disturbances, in addition to the complex coupling features between process variables that are difficult to extract, which poses a great challenge to the traditional quality-related data-driven soft sensor models. To solve the above problems, this paper proposes a data-driven model with denoising memory adaptive spatial guidance network (DMASG). Firstly, in order to mitigate the effect of process data noise and enhance the key information memory, a denoising memory-gated spiking neural P network (DMGSNP) integrating noise suppression (NS) module and information memory (IM) units is developed to improve the robustness of the model and enrich the feature information, as well as to achieve temporal feature extraction. Consequently, an adaptive spatial guidance relation network (ASGRN) based on coupling feature extraction is designed using the two-by-two explicit modelling capability of relation network, in which adaptive subspace analysis (ASA) is used as an embedding module for extracting spatial coupling relationships between variables and a spatial guidance relation (SGR) module is introduced for efficiently capturing global dependencies of variables and local contextual information. Finally, the validity of the proposed model is verified through two case studies closely related to manufacturing processes: the Cz silicon single crystal growth process for semiconductor manufacturing, and the froth flotation process for mineral processing.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 719-736"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787292","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.12.017
Li Zhang , Jingyuan Xu , Yapeng Xu , Tao Liu , Shibo Wu , Kang Lei , Yunfei Luo , Jinghan Liu
Carbon fiber-reinforced silicon carbide (C/SiC) composites hold significant application potential in the aerospace sector due to their high strength and low density characteristics. Laser processing represents an efficient, non-traditional method for machining this material. However, anisotropy and heterogeneity lead to inconsistent ablation morphology and irregular surface damage during laser processing. Furthermore, existing research methods, predominantly centered on laser processing trajectories, exhibit limitations in conducting detailed investigations into ablation morphology and thermal damage mechanisms. This study proposes a refined decomposition method to decouple the analysis of laser concentric circular micropore processing. It breaks down the complex processing mechanism, influenced by multiple factors, into studies under single factors. This clarifies how the anisotropy of heat transfer through fibers causes ablation depths to vary from 5.0 μm to 69.6 μm at different fiber angles, and the variation in ablation width from 49.1 μm to 72.5 μm. It elucidates the causes of ablation morphology differences and analyses the formation mechanism of the recast oxide layer with a C/O/Si atomic ratio of 59:22:19, and the evolution mechanism of the shell-like structure on pore walls. A finite element model incorporating material heterogeneous anisotropy characteristics was constructed to achieve multi-scale correlation analysis between macropore morphology and micro-topography. Finally, the mechanism for removing post-processing oxides was investigated. The attenuation of the SiO bond in the Si 2P peak of XPS confirmed that HF etching is an effective method for removing accumulated post-processing oxides, achieving high-quality, low-damage processing of C/SiC microporous structures.
{"title":"An investigation on laser machining method for C/SiC obtained high-quality and low-damage micropore based on path decoupling","authors":"Li Zhang , Jingyuan Xu , Yapeng Xu , Tao Liu , Shibo Wu , Kang Lei , Yunfei Luo , Jinghan Liu","doi":"10.1016/j.jmapro.2025.12.017","DOIUrl":"10.1016/j.jmapro.2025.12.017","url":null,"abstract":"<div><div>Carbon fiber-reinforced silicon carbide (C/SiC) composites hold significant application potential in the aerospace sector due to their high strength and low density characteristics. Laser processing represents an efficient, non-traditional method for machining this material. However, anisotropy and heterogeneity lead to inconsistent ablation morphology and irregular surface damage during laser processing. Furthermore, existing research methods, predominantly centered on laser processing trajectories, exhibit limitations in conducting detailed investigations into ablation morphology and thermal damage mechanisms. This study proposes a refined decomposition method to decouple the analysis of laser concentric circular micropore processing. It breaks down the complex processing mechanism, influenced by multiple factors, into studies under single factors. This clarifies how the anisotropy of heat transfer through fibers causes ablation depths to vary from 5.0 μm to 69.6 μm at different fiber angles, and the variation in ablation width from 49.1 μm to 72.5 μm. It elucidates the causes of ablation morphology differences and analyses the formation mechanism of the recast oxide layer with a C/O/Si atomic ratio of 59:22:19, and the evolution mechanism of the shell-like structure on pore walls. A finite element model incorporating material heterogeneous anisotropy characteristics was constructed to achieve multi-scale correlation analysis between macropore morphology and micro-topography. Finally, the mechanism for removing post-processing oxides was investigated. The attenuation of the Si<img>O bond in the Si 2P peak of XPS confirmed that HF etching is an effective method for removing accumulated post-processing oxides, achieving high-quality, low-damage processing of C/SiC microporous structures.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 698-718"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787304","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}
This article introduces a novel adaptive trochoidal tool path strategy for high-performance CNC milling. A dynamic, parametric tool path model is developed to continuously adjust the stepover based on tool diameter, flute count, and feed rate, enabling real-time modulation of cutter engagement. This adaptive stepover approach significantly reduces force fluctuations and minimizes sudden load variations. As a key contribution, a custom G-code is developed to eliminate non-cutting tool path segments, enabling the creation of compact and efficient trajectories. Two strategies were evaluated: Strategy 1 uses conventional interpolation, while Strategy 2 incorporates both and commands along with stepover modulation to optimize tool path efficiency. Force modelling, calibrated through full-immersion slot milling on aerospace grade , accurately predicted cutting forces along curved paths, with simulation errors of less than . The experimental results confirmed that the implementation of Strategy 2 significantly mitigated the cutting load, leading to reductions of approximately in total cutting force, in maximum torque, and power consumption relative to conventional slot milling. Additionally, it shortened tool path length and machining time by relative to Strategy 1. These results demonstrate the effectiveness of the proposed strategy in achieving load-aware and supporting more intelligent and sustainable CNC machining for advanced manufacturing applications.
{"title":"A new trochoidal milling strategy for high-performance CNC machining","authors":"Mahmoud Alipour Sougavabar, Koray Kelam, Ismail Lazoglu","doi":"10.1016/j.jmapro.2025.12.033","DOIUrl":"10.1016/j.jmapro.2025.12.033","url":null,"abstract":"<div><div>This article introduces a novel adaptive trochoidal tool path strategy for high-performance CNC milling. A dynamic, parametric tool path model is developed to continuously adjust the stepover based on tool diameter, flute count, and feed rate, enabling real-time modulation of cutter engagement. This adaptive stepover approach significantly reduces force fluctuations and minimizes sudden load variations. As a key contribution, a custom G-code is developed to eliminate non-cutting tool path segments, enabling the creation of compact and efficient trajectories. Two strategies were evaluated: Strategy 1 uses conventional <span><math><mi>G</mi><mn>02</mn></math></span> interpolation, while Strategy 2 incorporates both <span><math><mi>G</mi><mn>02</mn></math></span> and <span><math><mi>G</mi><mn>03</mn></math></span> commands along with stepover modulation to optimize tool path efficiency. Force modelling, calibrated through full-immersion slot milling on aerospace grade <span><math><mi>Al</mi><mn>7050</mn></math></span>, accurately predicted cutting forces along curved paths, with simulation errors of less than <span><math><mn>6</mn><mo>%</mo></math></span>. The experimental results confirmed that the implementation of Strategy 2 significantly mitigated the cutting load, leading to reductions of approximately <span><math><mn>50</mn><mo>%</mo></math></span> in total cutting force, <span><math><mn>26</mn><mo>%</mo></math></span> in maximum torque, and power consumption relative to conventional slot milling. Additionally, it shortened tool path length and machining time by <span><math><mn>33</mn><mo>%</mo></math></span> relative to Strategy 1. These results demonstrate the effectiveness of the proposed strategy in achieving load-aware and supporting more intelligent and sustainable CNC machining for advanced manufacturing applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 747-762"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787175","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.12.019
Abhrodeep Das , Ananta Dutta , Avishek Mukherjee , Surjya K. Pal
Time-of-flight diffraction (ToFD) is a key non-destructive evaluation technique for welded structures, specifically in heavy fabrication industries. While Artificial Intelligence (AI) based methods reduce the subjectivity and time required for manual ToFD inspection, they demand large, balanced datasets, particularly with sufficient defect-class samples. Existing augmentation approaches typically target B-scan images, risking inaccurate defect sizing in downstream analysis. Therefore, the present work proposes Gen-ToFD, a generative pipeline based on Conditional Wasserstein Generative Adversarial Network with Gradient Penalty (CWGAN-GP) to generate 2D data patches consisting of A-scan collection for four distinct classes including back wall echo, lateral wave, non-defective matrix region, and defect region. Unlike prior approaches, the proposed method preserves the signal-level fidelity and spatiotemporal structure of ultrasonic data. Additionally, an adaptive inter-class patch blending strategy was used that merges synthetic signals into coherent image patches, ensuring realistic spatial relationships between different structural features. To evaluate the effectiveness of the augmented dataset, a downstream classification task was conducted, showing over 15 % improvement in accuracy when using the combined original and generated data. Furthermore, the statistical validity of this performance gain is confirmed using the McNemar test. The modular strategy of proposed method comprising of conditional signal generation, and class-aware blending is generalizable to other applications facing data scarcity.
{"title":"Gen-ToFD: A class-aware generative framework for time-of-flight diffraction data augmentation and enhanced weld defect classification","authors":"Abhrodeep Das , Ananta Dutta , Avishek Mukherjee , Surjya K. Pal","doi":"10.1016/j.jmapro.2025.12.019","DOIUrl":"10.1016/j.jmapro.2025.12.019","url":null,"abstract":"<div><div>Time-of-flight diffraction (ToFD) is a key non-destructive evaluation technique for welded structures, specifically in heavy fabrication industries. While Artificial Intelligence (AI) based methods reduce the subjectivity and time required for manual ToFD inspection, they demand large, balanced datasets, particularly with sufficient defect-class samples. Existing augmentation approaches typically target B-scan images, risking inaccurate defect sizing in downstream analysis. Therefore, the present work proposes Gen-ToFD, a generative pipeline based on Conditional Wasserstein Generative Adversarial Network with Gradient Penalty (CWGAN-GP) to generate 2D data patches consisting of A-scan collection for four distinct classes including back wall echo, lateral wave, non-defective matrix region, and defect region. Unlike prior approaches, the proposed method preserves the signal-level fidelity and spatiotemporal structure of ultrasonic data. Additionally, an adaptive inter-class patch blending strategy was used that merges synthetic signals into coherent image patches, ensuring realistic spatial relationships between different structural features. To evaluate the effectiveness of the augmented dataset, a downstream classification task was conducted, showing over 15 % improvement in accuracy when using the combined original and generated data. Furthermore, the statistical validity of this performance gain is confirmed using the McNemar test. The modular strategy of proposed method comprising of conditional signal generation, and class-aware blending is generalizable to other applications facing data scarcity.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 670-686"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787296","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-16DOI: 10.1016/j.jmapro.2025.12.018
Qingsong Hu , Tao Zhao , Zhaoyang Yan , Jun Xiao , Xiaoyong Zhang , Fan Jiang , Kehong Wang , Jun Xiong , Shujun Chen
As an important innovation in traditional arc welding and additive manufacturing, multi-electrode arc utilizes configurations of two or more electrodes to leverage coupling effects that alter the physical characteristics of conventional single arc. This paper reviews the research progress of multi-electrode arc with a focus on exploring how they achieve in-depth decoupling control of the heat, mass, and force transfer of arc heat sources through multi-electrode configurations. Multi-electrode systems are classified into three types based on their electrical configuration and heat source connections: parallel, shunt, and division, It delves into an analysis of the coupling mechanisms, droplet transfer process and fluid flow in molten pool of parallel, shunt, and division multi-electrode arc, It highlights the high deposition efficiency of parallel multi-electrode arc, which makes them particularly suitable for High-speed and medium-to-thick plate welding, though their high heat input can compromise geometric accuracy in wire arc additive manufacturing (WAAM). In contrast, shunt and division multi-electrode arc offers superior decoupling of heat and mass transfer, making them advantageous for WAAM. However, shunt multi-electrode arc involve greater complexity and face challenges in maintaining arc stability and precise current control. Finally, by summarizing the strengths and limitations of existing multi-electrode arc, this review proposes future research directions, including intelligent manufacturing through integrated process monitoring and databases, gradient material fabrication, in-situ alloying, AI-integrated process optimization, as well as sustainability and material utilization issues.
{"title":"Innovative application and trends of multi-electrode arc: State of the art review","authors":"Qingsong Hu , Tao Zhao , Zhaoyang Yan , Jun Xiao , Xiaoyong Zhang , Fan Jiang , Kehong Wang , Jun Xiong , Shujun Chen","doi":"10.1016/j.jmapro.2025.12.018","DOIUrl":"10.1016/j.jmapro.2025.12.018","url":null,"abstract":"<div><div>As an important innovation in traditional arc welding and additive manufacturing, multi-electrode arc utilizes configurations of two or more electrodes to leverage coupling effects that alter the physical characteristics of conventional single arc. This paper reviews the research progress of multi-electrode arc with a focus on exploring how they achieve in-depth decoupling control of the heat, mass, and force transfer of arc heat sources through multi-electrode configurations. Multi-electrode systems are classified into three types based on their electrical configuration and heat source connections: parallel, shunt, and division, It delves into an analysis of the coupling mechanisms, droplet transfer process and fluid flow in molten pool of parallel, shunt, and division multi-electrode arc, It highlights the high deposition efficiency of parallel multi-electrode arc, which makes them particularly suitable for High-speed and medium-to-thick plate welding, though their high heat input can compromise geometric accuracy in wire arc additive manufacturing (WAAM). In contrast, shunt and division multi-electrode arc offers superior decoupling of heat and mass transfer, making them advantageous for WAAM. However, shunt multi-electrode arc involve greater complexity and face challenges in maintaining arc stability and precise current control. Finally, by summarizing the strengths and limitations of existing multi-electrode arc, this review proposes future research directions, including intelligent manufacturing through integrated process monitoring and databases, gradient material fabrication, in-situ alloying, AI-integrated process optimization, as well as sustainability and material utilization issues.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 623-669"},"PeriodicalIF":6.8,"publicationDate":"2025-12-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787302","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-13DOI: 10.1016/j.jmapro.2025.11.084
Jie Yuan , Hong Xiao , Ye Wang , Weijun Cui , Yugang Duan , Zhibo Xin , Ben Wang
Fiber-reinforced thermoplastic composites (FRTP), characterized by their lightweight nature, high specific strength, and recyclability, are increasingly adopted as core materials for structural components in aircraft and spacecraft. They are driving its leapfrog development from structural weight reduction to functional integration. Ultrasonic welding, as an efficient, clean, and automation-friendly technique for joining method, has become a focal point attracting significant attention from researchers. This review presents a comprehensive analysis of the ultrasonic welding of FRTP from four interrelated dimensions: interfacial bonding mechanisms, welding processes, defect influencing factors, and performance regulation strategies. Although a complete ultrasonic welding process involves both frictional heating and viscoelastic heating, it can be meticulously divided into five distinct stages. Quantitative findings from recent studies are summarized: under ultrasonic spot welding process parameters (amplitude 50–85 μm, welding energy 500–1500 J, and welding time 0.3–1.5 s), lap shear strengths of 20–35 MPa have been achieved for FRTP, while innovative energy directors (EDs) can further enhance joint strength by 20–40 %. Continuous ultrasonic welding holds significant development potential. Although it can achieve a maximum welding speed of 3.6 m/min, it still faces challenges such as localized overheating and porosity, resulting in joint strength lower than that of spot welding. The review identifies that controlling interfacial melting behavior and resin flow is crucial for defect suppression and performance optimization. Strategies such as welding parameters optimization, innovative ED design, and the application of auxiliary processes are discussed as promising avenues to enhance weld integrity and reproducibility. Finally, key research directions are proposed, including continuous ultrasonic welding for curved thick plates, multiscale modeling of ultrasonic energy transmission, and intelligent process monitoring.
{"title":"Ultrasonic welding process and strategies for performance regulation of Fiber reinforced thermoplastic composites: A review","authors":"Jie Yuan , Hong Xiao , Ye Wang , Weijun Cui , Yugang Duan , Zhibo Xin , Ben Wang","doi":"10.1016/j.jmapro.2025.11.084","DOIUrl":"10.1016/j.jmapro.2025.11.084","url":null,"abstract":"<div><div>Fiber-reinforced thermoplastic composites (FRTP), characterized by their lightweight nature, high specific strength, and recyclability, are increasingly adopted as core materials for structural components in aircraft and spacecraft. They are driving its leapfrog development from structural weight reduction to functional integration. Ultrasonic welding, as an efficient, clean, and automation-friendly technique for joining method, has become a focal point attracting significant attention from researchers. This review presents a comprehensive analysis of the ultrasonic welding of FRTP from four interrelated dimensions: interfacial bonding mechanisms, welding processes, defect influencing factors, and performance regulation strategies. Although a complete ultrasonic welding process involves both frictional heating and viscoelastic heating, it can be meticulously divided into five distinct stages. Quantitative findings from recent studies are summarized: under ultrasonic spot welding process parameters (amplitude 50–85 μm, welding energy 500–1500 J, and welding time 0.3–1.5 s), lap shear strengths of 20–35 MPa have been achieved for FRTP, while innovative energy directors (EDs) can further enhance joint strength by 20–40 %. Continuous ultrasonic welding holds significant development potential. Although it can achieve a maximum welding speed of 3.6 m/min, it still faces challenges such as localized overheating and porosity, resulting in joint strength lower than that of spot welding. The review identifies that controlling interfacial melting behavior and resin flow is crucial for defect suppression and performance optimization. Strategies such as welding parameters optimization, innovative ED design, and the application of auxiliary processes are discussed as promising avenues to enhance weld integrity and reproducibility. Finally, key research directions are proposed, including continuous ultrasonic welding for curved thick plates, multiscale modeling of ultrasonic energy transmission, and intelligent process monitoring.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 531-553"},"PeriodicalIF":6.8,"publicationDate":"2025-12-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145734075","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-13DOI: 10.1016/j.jmapro.2025.11.076
M. Faisal Riyad , Nathan Fonseca , Neel Garde , Shams Torabnia , Mohamed A. Abbas , Pu Han , Keng Hsu
Solid-state welding (SSW) is a method for joining metals without melting, offering significant advantages over traditional fusion welding methods. These advantages include reduced thermal distortion, minimized grain growth and phase changes, and the ability to join dissimilar metals. However, existing SSW techniques exhibit several limitations, such as higher investment costs, limited joint geometry, material thickness, extensive surface preparation, high sensitivity to process control parameters, and more. In this work, we introduce a novel low-amplitude, high-frequency oscillatory-shear strain-assisted wire deposition method that enables solid-state mass transfer-based metal joining driven by acoustic softening and enhanced diffusion. To demonstrate the feasibility of the proposed method, a single V-butt weld joint was created between two aluminum 6061–T6 metal sheets by continuous and layer-by-layer deposition of a fine aluminum 6061–O wire into metal voxels. This SSW process consumes only ∼300 W of power at the machine system level, making it an excellent candidate for joining metals in extra-terrestrial environments.
{"title":"Solid state welding of metals using oscillatory-shear strain-assisted metal wire deposition","authors":"M. Faisal Riyad , Nathan Fonseca , Neel Garde , Shams Torabnia , Mohamed A. Abbas , Pu Han , Keng Hsu","doi":"10.1016/j.jmapro.2025.11.076","DOIUrl":"10.1016/j.jmapro.2025.11.076","url":null,"abstract":"<div><div>Solid-state welding (SSW) is a method for joining metals without melting, offering significant advantages over traditional fusion welding methods. These advantages include reduced thermal distortion, minimized grain growth and phase changes, and the ability to join dissimilar metals. However, existing SSW techniques exhibit several limitations, such as higher investment costs, limited joint geometry, material thickness, extensive surface preparation, high sensitivity to process control parameters, and more. In this work, we introduce a novel low-amplitude, high-frequency oscillatory-shear strain-assisted wire deposition method that enables solid-state mass transfer-based metal joining driven by acoustic softening and enhanced diffusion. To demonstrate the feasibility of the proposed method, a single V-butt weld joint was created between two aluminum 6061–T6 metal sheets by continuous and layer-by-layer deposition of a fine aluminum 6061–O wire into metal voxels. This SSW process consumes only ∼300 W of power at the machine system level, making it an excellent candidate for joining metals in extra-terrestrial environments.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"157 ","pages":"Pages 593-605"},"PeriodicalIF":6.8,"publicationDate":"2025-12-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145787295","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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