Advances in Industrial and Manufacturing Engineering最新文献

Enhancing edge integrity of high-strength steels by high-speed blanking to achieve improved crashworthiness 通过高速下料提高高强度钢的边缘完整性，提高耐撞性

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2026-01-30 DOI: 10.1016/j.aime.2026.100181

Olaf Schrage , Roald Lingbeek , Priidu Peetsalu , Marlon Hahn , Hamed Dardaei Joghan , Yannis P. Korkolis , A. Erman Tekkaya

The increasing use of ultra-high-strength steels (UHSS) in automotive safety components is driven by stricter crash safety requirements, vehicle weight reduction, and ecological goals in production and service. The application of UHSS requires adaptations in the manufacturing process chain, as conventional slow-speed blanking (SSB) used in mass production is challenging due to tool wear. Another aspect is crashworthiness: The interaction between material properties and blanking-induced defects—such as surface irregularities, microvoids, and microcracks—promotes crack initiation at free edges and limits edge formability. Local plastic deformation without breakage is a precondition for a stable break load of safety components, wherefore edge stretchability serves as an indicator for crashworthiness. High-speed blanking (HSB) of three steels with ultimate tensile strengths in the range of 1500 MPa—martensitic Docol 1500M, press-hardened (PH) 22MnB5, and carbon steel C60—is examined. Blanking trials are followed by central-hole tensile tests (CHTT) to assess edge stretchability. HSB produces edges with high geometric accuracy and homogeneous fracture surfaces, exhibiting roughness values comparable to wire-eroded surfaces. The shear-affected zone is confined to a narrow band of less than 2% of the sheet thickness, which is four times smaller than those observed in SSB. CHTT results show that HSB edges retain the same load-bearing capacity and edge fracture strain as wire-eroded edges, showing that edge integrity has not been compromised by HSB. In contrast, SSB triggers premature crack initiation reducing the achievable fracture strain by nearly half.

在汽车安全部件中越来越多地使用超高强度钢（UHSS），这是由更严格的碰撞安全要求、车辆重量减轻以及生产和服务中的生态目标驱动的。UHSS的应用需要在制造工艺链中进行调整，因为在批量生产中使用的传统慢速下料（SSB）由于刀具磨损而具有挑战性。另一个方面是耐撞性：材料性能和冲裁缺陷（如表面不规则、微孔和微裂纹）之间的相互作用促进了自由边缘的裂纹萌生，并限制了边缘的成形性。无断裂的局部塑性变形是安全构件获得稳定断裂载荷的前提条件，因此边缘拉伸性是安全构件耐撞性的一个指标。研究了极限抗拉强度在1500 mpa范围内的三种钢的高速落料(HSB) -马氏体Docol 1500M，压硬化（PH） 22MnB5和碳钢c60。落料试验之后是中心孔拉伸试验（CHTT），以评估边缘拉伸性。HSB产生的边缘具有高几何精度和均匀的断口表面，其粗糙度值可与金属丝侵蚀表面相媲美。剪切影响区被限制在小于板材厚度2%的窄带内，比SSB中观察到的窄带小4倍。CHTT结果表明，HSB边缘保持了与线蚀边缘相同的承载能力和边缘断裂应变，表明HSB边缘完整性没有受到损害。相反，SSB触发过早裂纹萌生，使可达到的断裂应变降低近一半。

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引用次数: 0

Towards in-process scrap reduction in aluminum extrusion: A multiscale investigation of charge-weld integrity 在铝挤压过程中减少废料：电荷焊接完整性的多尺度研究

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2026-02-06 DOI: 10.1016/j.aime.2026.100183

Eren Can Sariyarlioglu, Torgeir Welo

Charge welds in ‘continuous’ billet-to-billet extrusion processes are commonly associated with substandard material properties, leading to conservative industrial scrap practices. Despite the prevalence of this problem, limited understanding exists regarding governing mechanisms in terms of microstructural and mechanical evolution across the charge-weld zone under real-world processing conditions. This study presents a comprehensive multiscale investigation of charge-weld integrity in hollow AA6082 profiles using a combined experimental and numerical approach. A large number of full-scale industrial extrusion trials were carefully conducted at varying ram speeds, followed by systematic microstructural and mechanical characterizations of the weld zone. The experimental findings reveal a gradual increase in charge-weld strength and ductility along the extruded profile. This is primarily attributed to a reduction in the density and size of oxide-induced grooves and pits at the weld interface between two succeeding billets dispersed into the extruded profile. To understand the governing mechanisms at continuum scale, a finite element model was developed using QForm-Extrusion software. The Kolpak's semi-empirical film theory-based model was incorporated to investigate how thermo-mechanical history and ‘local’ conditions influence charge-weld integrity. The numerical model effectively captured important trends of charge-weld integrity, identifying regions where weld properties progressively recovered to the levels of parent material. Our findings show that a substantial portion of the charge-weld zone provides adequate material integrity, which may call for less conservative scrap standards in industry. Overall, this work advances the fundamental understanding of charge-weld formation, offering a pathway to optimizing material yield towards more efficient manufacturing of aluminum products.

在“连续”坯料到坯料挤压过程中的充能焊接通常与不合格的材料性能有关，导致保守的工业废料做法。尽管这一问题普遍存在，但在实际加工条件下，关于电荷焊区的微观组织和力学演变的控制机制，人们的理解有限。本文采用实验与数值相结合的方法对空心AA6082型材充能焊缝完整性进行了全面的多尺度研究。在不同的冲压速度下进行了大量的全尺寸工业挤压试验，随后对焊缝区域进行了系统的显微组织和力学表征。实验结果表明，焊接强度和塑性沿挤压型材逐渐增加。这主要是由于分散在挤压型材中的两个后续坯料之间的焊接界面上的氧化诱导凹槽和坑的密度和尺寸减小。为了了解连续尺度下的控制机制，利用QForm-Extrusion软件建立了有限元模型。采用Kolpak的半经验膜理论为基础的模型来研究热机械历史和“局部”条件如何影响电荷焊完整性。数值模型有效地捕获了电荷焊缝完整性的重要趋势，确定了焊缝性能逐渐恢复到母材水平的区域。我们的研究结果表明，电荷焊区的很大一部分提供了足够的材料完整性，这可能需要在工业中不那么保守的废料标准。总的来说，这项工作促进了对电荷焊接形成的基本理解，为优化材料产量、提高铝产品的效率提供了一条途径。

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引用次数: 0

Data-driven framework for extracting steady-state deformation resistance from transient experimental data without inverse finite element analysis 从瞬态实验数据中提取稳态变形抗力的数据驱动框架，无需反有限元分析

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2025-11-28 DOI: 10.1016/j.aime.2025.100177

Eiichi Ota, Minami Fujimura, Yasumoto Sato

Accurate characterization of the steady-state deformation resistance of materials is a prerequisite for high-precision forming simulations. However, controlling the temperature and strain rate in high-temperature tensile experiments is difficult and can hinder data acquisition under ideal isothermal and constant strain-rate conditions. Although the inverse finite element method (iFEM) has been conventionally employed for this purpose, it suffers from limitations such as dependence on constitutive equations, non-uniqueness of solutions, and requirement for expert-level implementation. This study introduces a data-driven framework for extracting steady-state deformation resistance from transient experimental data without using iFEM. The proposed framework acquires transient experimental data, performs regression-based interpolation and optimal model selection, and extracts steady-state responses using regression techniques, which includes a pre-defined material model, artificial neural network, and Gaussian process regression. Two case studies with aluminum and magnesium alloys, each under distinct variable conditions, are conducted to assess validity and scalability. ANN and GPR enhance the prediction accuracy of interpolated values compared to that of the pre-defined material model. This finding validates the feasibility of accurately estimating steady-state deformation resistance through flexible model selection. The plausibility of the predicted responses is supported by visualizing the corresponding response surfaces. The proposed framework provides a flexible, scalable, and practical alternative to conventional iFEM-based approaches with promising future applicability to higher-dimensional scenarios.

准确表征材料的稳态变形抗力是高精度成形模拟的先决条件。然而，在高温拉伸实验中控制温度和应变速率是困难的，并且会阻碍理想等温和恒定应变速率条件下的数据采集。尽管逆有限元法（iFEM）通常用于此目的，但它存在诸如依赖本构方程、解的非唯一性以及需要专家级实现等局限性。本文提出了一种数据驱动的框架，用于在不使用有限元法的情况下从瞬态实验数据中提取稳态变形抗力。该框架获取瞬态实验数据，进行基于回归的插值和最优模型选择，并使用包括预定义材料模型、人工神经网络和高斯过程回归在内的回归技术提取稳态响应。以铝和镁合金为例，分别在不同的变量条件下进行了两个案例研究，以评估有效性和可扩展性。与预定义的材料模型相比，人工神经网络和探地雷达提高了插值值的预测精度。这一发现验证了通过柔性模型选择精确估计稳态变形抗力的可行性。通过可视化相应的响应面来支持预测响应的合理性。提出的框架为传统的基于ifem的方法提供了一种灵活、可扩展和实用的替代方案，并有望在未来适用于高维场景。

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引用次数: 0

Parametric assessment of injection dynamics for metal and polymer rapid-tooling using in-line process measurements and modelling of micro-injection moulding 使用在线过程测量和微注射成型建模的金属和聚合物快速成型注射动力学参数评估

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2025-12-30 DOI: 10.1016/j.aime.2025.100179

Mert Gülçür , Olivia Griffiths , Adam Rich , Xiangyu Gao , Barbara Groh , James Garcia , Luis Arturo Aguirre , Gregory Gibbons , Michael Cullinan

Optimising injection dynamics in micro-injection moulding (μIM) enhances efficiency, reduces defects, and improves repeatability. The current study examines the injection dynamics of μIM using both rapid-tooling, fabricated via material jetting, and conventional aluminium metal tooling. A 20 mg micro-moulding cavity was used to assess injection behaviour, injection pressure profiles, and process variation through in-line process monitoring and computational modelling. Results reveal significant differences between rapid and metal tooling in terms of drag, pressure build-up during injection and mechanical properties of the final products. The low thermal conductivity of rapid-tooling has led to prolonged low melt viscosity retention, resulting in significantly reduced peak injection pressures and dampened pressure overshoots, improving process repeatability. Metal tooling in contrast showed increased pressure fluctuations, making the injection dynamics more complex and affecting process repeatability. Computational modelling captured the major trends and exhibited deviations in pressure profiles, particularly for rapid-tooling, where accurate heat transfer coefficient estimation remains a challenge. Mechanical property correlations with injection dynamics further highlight the data-rich nature of μIM, with shear stress effects at higher injection rates influencing part performance. This study provides new insights into μIM process dynamics, emphasising the role of thermal properties and the challenges in modelling heat transfer effects in rapid-tooling. The findings support the optimisation of μIM for improved process control, predictive modelling, and data-driven quality monitoring for both industrial and rapid prototyping settings.

在微注射成型（μIM）中优化注射动力学可提高效率，减少缺陷并提高可重复性。本研究采用材料喷射制造的快速模具和传统铝金属模具对μIM的注射动力学进行了研究。通过在线过程监测和计算建模，使用20 mg微成型腔来评估注射行为、注射压力分布和工艺变化。结果显示，在阻力、注射过程中的压力积聚和最终产品的机械性能方面，快速模具和金属模具之间存在显著差异。快速成型的低导热性使得熔体粘度保持时间更长，从而显著降低峰值注射压力，抑制压力超调，提高工艺的可重复性。相比之下，金属模具的压力波动增加，使注射动力学更加复杂，影响了过程的可重复性。计算模型捕捉了压力分布的主要趋势和偏差，特别是对于快速加工，准确的传热系数估计仍然是一个挑战。力学性能与注射动力学的相关性进一步突出了μIM数据丰富的性质，高注射速率下的剪切应力效应影响了零件的性能。这项研究为μIM过程动力学提供了新的见解，强调了热性能的作用和在快速加工中模拟传热效应的挑战。该研究结果支持μIM的优化，以改进工业和快速原型设置的过程控制，预测建模和数据驱动的质量监测。

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引用次数: 0

Beyond necking - Novel characterisation method to investigate the tensile response of sheet metals at elevated temperatures and constant true strain rates 超越颈缩-新颖的表征方法，以研究在高温和恒定的真应变率下金属板的拉伸响应

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2026-02-03 DOI: 10.1016/j.aime.2026.100182

David Naumann, Marion Merklein

Characterisation of the strain hardening behaviour for metal forming simulations at elevated temperatures still poses a challenge for state of the art characterisation strategies, where often microstructural changes shall be investigated simultaneously. To do so, GLEEBLE thermo-mechanical simulators are commonly used to conduct physical testing of materials at thermal and mechanical loading at a wide range of loading rates. Such testing systems introduce a known challenge of non-uniform temperature into the specimen which leads to inhomogeneous strain distributions. This heterogeneous strain distribution consequently leads to an uncontrolled forming area together with an undesirable increase of strain rate. To address that challenge, this contribution presents and applied a novel approach to conduct locally controlled tensile tests by utilising a 3D-DIC system for a closed loop strain rate control. The titanium alloy Ti6Al4V with a thickness of 1.5 mm was investigated at temperatures between 600 °C and 900 °C and strain rates between 0.01 s⁻¹ and 0.1 s⁻¹. The novel testing method leads to a change in the analysed flow stress at 600 °C of up to 80 MPa and at 900 °C of up to 65 MPa.

高温下金属成形模拟的应变硬化行为表征仍然对最先进的表征策略提出了挑战，其中通常需要同时研究微观组织变化。为此，GLEEBLE热机械模拟器通常用于在大范围的加载速率下对热和机械加载下的材料进行物理测试。这种测试系统引入了一个已知的挑战，即试样的温度不均匀，从而导致应变分布不均匀。这种不均匀的应变分布导致了不受控制的成形区域以及不希望的应变速率增加。为了应对这一挑战，该贡献提出并应用了一种新颖的方法，通过利用3D-DIC系统进行闭环应变速率控制，进行局部控制的拉伸试验。在温度为600℃~ 900℃，应变速率为0.01 s−1 ~ 0.1 s−1的条件下，研究了厚度为1.5 mm的钛合金Ti6Al4V。新的测试方法在600°C高达80 MPa和900°C高达65 MPa时导致分析流动应力的变化。

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引用次数: 0

Joining-by-hydroforming of aluminum and poly(ether ether ketone) – A model experiment 铝与聚醚醚酮的液压成形连接。模型试验

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2025-12-30 DOI: 10.1016/j.aime.2025.100180

Florian Weber , Ulrich A. Handge , Tanmoy Rakshit , Hamed Dardaei Joghan , Marlon Hahn , Yannis P. Korkolis , A. Erman Tekkaya

Joining-by-hydroforming is a process in which components are joined through expansion under internal pressure. Depending on the required fluid pressure and application rate, this process can be technically demanding and challenging to implement on industrial equipment. To address this, a simplified experimental setup was developed to investigate the fundamental joining mechanisms. In this setup, aluminum 6061-T6 (AA6061-T6) and poly(ether ether ketone) (PEEK) rings are force-fitted using a conical punch and segmented conical expansion elements, enabling controlled radial expansion. The resulting assemblies are subsequently separated in a dedicated push-out test. Experimental results show that the required separation force increases with rising elastic strain in the polymer, attributable to an increase in contact pressure according to Coulomb's friction law. This effect diminishes once plastic deformation of the thermoplastic initiates. Furthermore, stress relaxation in PEEK causes a time-dependent decrease in joint strength, reaching a quasi-equilibrium after approximately 10⁴ s, as confirmed by relaxation experiments on PEEK coupons. To analyze thermal effects, the entire ring assembly is preheated to defined temperatures in a laboratory furnace. An inverse correlation between joining temperature and joint strength is observed, consistent with the trend identified in the dynamic-mechanical-thermal analysis (DMTA) of PEEK.

The proposed experimental method enables rapid identification of the most influential parameters for joining-by-hydroforming, without requiring dedicated hydroforming equipment or production machine time.

液压成形连接是一种在内压作用下通过膨胀将零件连接起来的过程。根据所需的流体压力和应用速率，该过程在技术上要求很高，并且在工业设备上实施具有挑战性。为了解决这个问题，开发了一个简化的实验装置来研究基本的连接机制。在这种设置中，铝6061-T6 （AA6061-T6）和聚醚醚酮（PEEK）环使用锥形冲床和分段锥形膨胀元件进行强制装配，从而实现可控的径向膨胀。结果组件随后在专用的推出测试中分离。实验结果表明，根据库仑摩擦定律，随着聚合物中弹性应变的增加，所需的分离力也随之增加，这是由于接触压力的增加。一旦热塑性塑料开始塑性变形，这种效应就会减弱。此外，PEEK的应力松弛导致接头强度随时间的降低，在大约104 s后达到准平衡，这一点在PEEK的松弛实验中得到了证实。为了分析热效应，整个环组件在实验室炉中预热到规定的温度。观察到连接温度与连接强度之间呈负相关，与PEEK动态-机械-热分析（DMTA）中确定的趋势一致。所提出的实验方法能够快速识别液压成形连接最具影响的参数，而不需要专用的液压成形设备或生产机器时间。

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引用次数: 0

Experimental and numerical analysis of compaction of fine powder bed under artificial high gravity for additive manufacturing 增材制造中人工高重力下细粉床压实的实验与数值分析

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2026-05-01 Epub Date: 2025-12-17 DOI: 10.1016/j.aime.2025.100178

Zhazira Berkinova , Assem Sauirbayeva , Almaz Kenzheshov , Boris Golman , Christos Spitas

Additive manufacturing (AM) has advanced rapidly, expanding its applications across various fields. A key challenge in AM is fabricating fine, high-precision parts, which requires uniform and densely packed powder layers. While fine particles (<20 μm) hold promise for these components, their poor flowability and compactability present significant obstacles. This paper presents an experimental and numerical study on overcoming these limitations through high artificial gravity. Fine Inconel 625 particles immersed in epoxy adhesive were compacted using a lab-scale centrifuge at 1010G, 2030G, and 2810G, and a customized large-scale centrifuge at 71.7G, 101.6G, and 123G. The packing fraction of the green body increased up to 0.52 in the lab-scale centrifuge and up to 0.35 in the customized centrifuge. A validated Discrete Element Method (DEM) model simulated compaction of a fine metal powder bed without epoxy adhesive at various gravitational levels, confirming an 82.8 % improvement in packing fraction, reaching 0.53. Cross-sectional analysis of materials produced by laser melting of fine-particle powder beds without epoxy adhesive revealed substantial voids in samples fabricated under normal gravity. In contrast, samples produced under high artificial gravity (71.7G) exhibited significantly reduced void formation.

增材制造（AM）发展迅速，其应用范围遍及各个领域。增材制造的一个关键挑战是制造精细、高精度的零件，这需要均匀而密集的粉末层。虽然细颗粒（<20 μm）有望用于这些组件，但其流动性差和致密性存在重大障碍。本文介绍了利用高人工重力克服这些限制的实验和数值研究。采用1010G、2030G、2810G的实验室离心机和71.7G、101.6G、123G的定制大型离心机对浸入环氧胶粘剂中的细小Inconel 625颗粒进行压实。在实验室离心机中，绿体的填料分数增加到0.52，在定制离心机中增加到0.35。经过验证的离散元法（DEM）模型模拟了不同重力水平下无环氧胶粘剂的细金属粉末床的压实，证实了填料率提高了82.8%，达到0.53。对无环氧胶粘剂的细颗粒粉末层激光熔融制备的材料进行了截面分析，发现在正常重力下制备的样品中存在大量空隙。相比之下，在高人工重力（71.7G）下产生的样品显示出明显减少的孔隙形成。

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引用次数: 0

Characterization of sheet formability limits using a novel diagonal-cruciform test specimen 用一种新型的对角-十字形试样表征板材的成形性极限

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-11-01 Epub Date: 2025-09-11 DOI: 10.1016/j.aime.2025.100171

Rui F.V. Sampaio , Eduardo B.G. Dias , João M.A. Viegas , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins

This paper introduces an innovative diagonal-cruciform test specimen that significantly enhances the characterization of formability limits in sheet metal forming. The specimen's unique design features a reticular two-dimensional geometric structure, with four triangular arms connecting at the center, which effectively induce biaxial tension stress states when subjected to uniaxial loading. Furthermore, the incorporation of machined spherical cups at its center to locally reduce thickness ensures that damage accumulates in this region. Experimental strain loading paths are captured using digital image correlation (DIC) and analyzed with in-house software developed specifically for research and education on material formability. The software identifies and plots the onsets of necking and fracture in principal strain space, and results prove that the diagonal-cruciform specimen is highly effective in generating stable biaxial tension strain loading paths in C11000 copper sheets, operating under friction-independent conditions without the necessity for specialized testing equipment. The fracture limits are subsequently validated by comparing them against the strain loading paths obtained from a single-point incremental sheet-formed part up to failure. The investigation confirms the versatility and robustness of the novel diagonal-cruciform test specimen for evaluating the formability of C11000 copper sheets and provides valuable insights into its potential application across the broader field of sheet formability characterization.

本文介绍了一种创新的对角-十字形试样，显著提高了板料成形极限的表征。试件独特的设计特点是网状的二维几何结构，四个三角形臂在中心连接，在单轴加载时有效地诱导双轴拉伸应力状态。此外，在其中心加入加工球形杯以局部减少厚度，确保了该区域的损伤积累。使用数字图像相关（DIC）捕获实验应变加载路径，并使用专门用于材料成形性研究和教育的内部软件进行分析。该软件在主应变空间中识别并绘制了颈缩和断裂的起始点，结果证明，对角-十字形试样在C11000铜片中产生稳定的双轴拉伸应变加载路径是非常有效的，在不依赖摩擦的条件下运行，无需专门的测试设备。随后，通过将断裂极限与单点增量薄板成形部件直至失效的应变加载路径进行比较，验证断裂极限。该研究证实了用于评估C11000铜片可成形性的新型对角-十字形试样的通用性和稳健性，并为其在更广泛的板材可成形性表征领域的潜在应用提供了有价值的见解。

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引用次数: 0

Impact of partial rolling on structural integrity and mechanical properties of AA7075 Tailor Alloyed Blanks 局部轧制对AA7075定制合金板坯结构完整性和力学性能的影响

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-11-01 Epub Date: 2025-11-10 DOI: 10.1016/j.aime.2025.100176

Henrik Zieroth , Marcel Stephan , Michael Schmidt , Marion Merklein

This study investigates partial rolling as a post processing method to improve the microstructure and formability of Tailor Alloyed Blanks (TAB) fabricated from AA7075 via laser-induced element evaporation and filler wire alloying. While prior work demonstrated the feasibility of adapting the alloying concept to enhance ductility in targeted regions, process-induced porosity, surface irregularities and insufficient process robustness continue to limit industrial applicability. To overcome these limitations, partial rolling was applied to the modified region. A parametric study identified rolling pass as the dominant factor influencing work hardening, surface smoothing and defect closure. Applying a 0.35 mm rolling pass led to a 92 % reduction in surface irregularities, complete closure of hydrogen-related porosity and a 38 % improvement in true strain compared to the unrolled condition. The enhanced process robustness was confirmed by a significant reduction in true stress deviation, determined by upsetting tests on miniaturized specimens extracted from the adapted zone. 3-point bending tests further validated the improvement in formability, revealing a 50 % increase in bending angle compared to the unrolled TAB and double the value observed in the base material. Rolling speed had no measurable impact, whereas longitudinal rolling outperformed transverse rolling in achieving uniform strain and hardness distributions. These results establish partial rolling as an effective and scalable refinement step for TAB. It enables the translation of localized compositional tailoring into functional mechanical performance, thereby expanding the process window for high-strength aluminum alloys in forming applications.

本文研究了采用局部轧制作为后处理方法，通过激光诱导元素蒸发和填充丝合金化，改善AA7075定制合金板坯（TAB）的组织和成形性能。虽然先前的工作证明了采用合金概念来提高目标区域延展性的可行性，但工艺引起的孔隙率、表面不规则性和工艺鲁棒性不足仍然限制了工业应用。为了克服这些局限性，对改进区域进行了局部轧制。参数化研究表明，轧制孔道是影响加工硬化、表面平滑和缺陷闭合的主要因素。采用0.35 mm轧制孔型可减少92%的表面不规则性，完全消除与氢相关的孔隙，与未轧制条件相比，真应变提高38%。通过对从适应区提取的小型化试样进行镦粗试验，证实了真实应力偏差的显著减少，从而增强了工艺稳健性。三点弯曲测试进一步验证了成形性的改善，与展开的TAB相比，弯曲角度增加了50%，是基材中观察到的值的两倍。轧制速度没有可测量的影响，而纵向轧制在获得均匀的应变和硬度分布方面优于横向轧制。这些结果表明，部分轧制是TAB的有效和可扩展的改进步骤。它能够将本地化的成分定制转化为功能性机械性能，从而扩大了成形应用中高强度铝合金的工艺窗口。

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引用次数: 0

Laser directed energy deposition of FeSi/SS 316L advanced bimetallic high-speed rotors: From material characterization to performance evaluation 激光定向能沉积FeSi/SS 316L先进双金属高速转子：从材料表征到性能评价

IF 6 Q2 ENGINEERING, INDUSTRIAL

Advances in Industrial and Manufacturing Engineering

Pub Date : 2025-11-01 Epub Date: 2025-11-06 DOI: 10.1016/j.aime.2025.100175

Chiara Gianassi , Erica Liverani , Andrea Cavagnino , Luca Zarri , Alessandro Ascari , Yulong Cui , Alessandro Fortunato

The demand for high-speed electric machinery has significantly increased, driving innovation in motor design. While permanent magnet rotors dominate due to their superior torque density and efficiency, their reliance on rare earth elements raises environmental and supply chain concerns. Synchronous Reluctance motors, which do not require permanent magnets, present a promising alternative, though their design limits rotor mechanical performance. Additive manufacturing, particularly Directed Energy Deposition (DED), addresses these challenges by enabling the production of multi-material structures.

This study investigates the potential of DED to fabricate high-speed rotors using FeSi_2.9, a soft magnetic alloy with high permeability, and the paramagnetic stainless steel AISI 316L. Single-material depositions were analyzed through microstructural and microhardness tests in both as-deposited and heat-treated conditions. Magnetic and mechanical characterization were performed on heat-treated samples. Annealing improved the magnetic properties of FeSi_2.9 without compromising the mechanical performance of AISI 316L. A bimetallic blank with alternating layers of the two materials was fabricated and characterized similarly. Subsequently, a rotor was extracted, machined, and tested.

Results demonstrated excellent printability, achieving crack-free deposits with >99 % relative densities. The fabricated SynRel rotor operated at speeds up to 100,000 rpm, underscoring the suitability of DED for producing advanced multi-material components for high-speed machinery.

对高速电机的需求显著增加，推动了电机设计的创新。虽然永磁转子因其优越的扭矩密度和效率而占据主导地位，但它们对稀土元素的依赖引发了对环境和供应链的担忧。不需要永磁体的同步磁阻电机是一个很有前途的选择，尽管它们的设计限制了转子的机械性能。增材制造，特别是定向能沉积（DED），通过实现多材料结构的生产，解决了这些挑战。本研究探讨了利用高磁导率软磁合金FeSi2.9和顺磁不锈钢AISI 316L制备高速转子的潜力。通过沉积态和热处理条件下的显微组织和显微硬度测试分析了单材料沉积。对热处理后的样品进行了磁性和力学表征。退火提高了FeSi2.9的磁性能，但不影响AISI 316L的机械性能。制备了具有两种材料交替层的双金属毛坯，并对其进行了相似的表征。随后，提取转子，加工和测试。结果证明了优异的印刷性能，实现了99%相对密度的无裂纹沉积。制造的SynRel转子运行速度高达100,000 rpm，强调了DED用于生产高速机械的先进多材料部件的适用性。

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