Pub Date : 2024-11-01DOI: 10.1016/j.mfglet.2024.10.002
Anurag Pisupati , Axel Boivin , Alexandre Beigbeder , Roi Méndez-Rial , Ronan Le Goff
This study explores the applicability of circular economy protocols (CEP) to refurbish an old pultrusion machine in line with Industry 4.0 standards, aiming to optimize resource use, reduce waste, and extend equipment life at large scale. Incorporation of CEP seeks to revolutionize the conventional refurbishment model in manufacturing industries, creating a sustainable technological advanced framework that promotes economic viability and environmental responsibility. These protocols assure a significant reduction of investments costs (−62%) and ensure real-time monitoring and adaptive control systems to enhance operational efficiency of the machine. A significant improvement in overall equipment effectiveness by 74% and reduction in waste by 23%. Lastly, various steps of integration of CEP in the modernization of old machinery, contributing significantly to their operability and functionality in a real industrial scenario are discussed.
{"title":"Applicability of circularity protocols to extend the lifetime of a thermoplastic pultrusion line: A case study","authors":"Anurag Pisupati , Axel Boivin , Alexandre Beigbeder , Roi Méndez-Rial , Ronan Le Goff","doi":"10.1016/j.mfglet.2024.10.002","DOIUrl":"10.1016/j.mfglet.2024.10.002","url":null,"abstract":"<div><div>This study explores the applicability of circular economy protocols (CEP) to refurbish an old pultrusion machine in line with Industry 4.0 standards, aiming to optimize resource use, reduce waste, and extend equipment life at large scale. Incorporation of CEP seeks to revolutionize the conventional refurbishment model in manufacturing industries, creating a sustainable technological advanced framework that promotes economic viability and environmental responsibility. These protocols assure a significant reduction of investments costs (−62%) and ensure real-time monitoring and adaptive control systems to enhance operational efficiency of the machine. A significant improvement in overall equipment effectiveness by 74% and reduction in waste by 23%. Lastly, various steps of integration of CEP in the modernization of old machinery, contributing significantly to their operability and functionality in a real industrial scenario are discussed.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 56-60"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655676","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Bioinspired microstructure emerges as a powerful technique to enhance the surface functionalities and properties in a seizes of breakthrough areas. However, its application is limited by the scalability of fabrication methods. This study introduces a scalable fabrication technique utilizing a small wheeled robot designed to operate on a workpiece surface. Due to its unique three-point-support design, the robot maintains a stable cutting depth and exhibits high adaptability to large-scale workpieces. Motion stability is calibrated using a laser displacement sensor, achieving a maximum velocity of approximately 3.7 mm/s. Finally, the robot successfully produces microstructures with a height of 8 μm on aluminum workpieces, demonstrating its promising capacity.
{"title":"Scalable and efficient fabrication of surface microstructures using a small wheeled robot with a vibration-cutting tool","authors":"Peiyuan Ding , Jianfu Zhang , Pingfa Feng , Xiangyu Zhang , Jianjian Wang","doi":"10.1016/j.mfglet.2024.10.004","DOIUrl":"10.1016/j.mfglet.2024.10.004","url":null,"abstract":"<div><div>Bioinspired microstructure emerges as a powerful technique to enhance the surface functionalities and properties in a seizes of breakthrough areas. However, its application is limited by the scalability of fabrication methods. This study introduces a scalable fabrication technique utilizing a small wheeled robot designed to operate on a workpiece surface. Due to its unique three-point-support design, the robot maintains a stable cutting depth and exhibits high adaptability to large-scale workpieces. Motion stability is calibrated using a laser displacement sensor, achieving a maximum velocity of approximately 3.7 mm/s. Finally, the robot successfully produces microstructures with a height of 8 μm on aluminum workpieces, demonstrating its promising capacity.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 46-51"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-11-01DOI: 10.1016/j.mfglet.2024.10.007
G.H.S.F.L. Carvalho , G. Campatelli , L. Fratini
Friction stir extrusion (FSE) is a promising process capable of producing rods by recycling aluminum chips without melting them. This work studied the use of these recycled rods for GTAW deposition and additive manufacturing. The rods are suitable for single-bead depositions or applications with reduced use of filler material. For additive manufacturing multilayer depositions, the component presented a density of 77% (23% porosity), so pollutant sources must be further reduced to improve quality. The work shows that porosity significantly changes along the height, being about 10% close to the substrate, and about 45% next to the upper surface.
{"title":"Feasibility study of using friction stir extruded recycled aluminum rods for welding and additive manufacturing","authors":"G.H.S.F.L. Carvalho , G. Campatelli , L. Fratini","doi":"10.1016/j.mfglet.2024.10.007","DOIUrl":"10.1016/j.mfglet.2024.10.007","url":null,"abstract":"<div><div>Friction stir extrusion (FSE) is a promising process capable of producing rods by recycling aluminum chips without melting them. This work studied the use of these recycled rods for GTAW deposition and additive manufacturing. The rods are suitable for single-bead depositions or applications with reduced use of filler material. For additive manufacturing multilayer depositions, the component presented a density of 77% (23% porosity), so pollutant sources must be further reduced to improve quality. The work shows that porosity significantly changes along the height, being about 10% close to the substrate, and about 45% next to the upper surface.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 52-55"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655677","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-11-01DOI: 10.1016/j.mfglet.2024.10.006
Ruan Diego Amorim de Melo Vieira , Olga Liskevych , Déborah de Oliveira , Maksym Ziberov
Wire and Arc Additive Manufacturing is characterized for the high deposition rates, enabling the manufacturing of big, complex parts, with smaller relative production cost. However, once the part receives high heat inputs, leading to geometry variation and deformations, it is important to properly measure the part characteristics. Therefore, this work contributes with a measurement methodology for inclined walls deposited by Wire and Arc Additive Manufacturing and its application on walls deposited with different parameters. The main parameter of influence was the use of interlayer temperature control, which increased the angle in 71.0%, and the curvature in 90.3%, lower part.
{"title":"Influence of parameter variation and interlayer temperature control in wall angle, curvature and measurement methodology of ER70S-6 parts obtained by WAAM","authors":"Ruan Diego Amorim de Melo Vieira , Olga Liskevych , Déborah de Oliveira , Maksym Ziberov","doi":"10.1016/j.mfglet.2024.10.006","DOIUrl":"10.1016/j.mfglet.2024.10.006","url":null,"abstract":"<div><div>Wire and Arc Additive Manufacturing is characterized for the high deposition rates, enabling the manufacturing of big, complex parts, with smaller relative production cost. However, once the part receives high heat inputs, leading to geometry variation and deformations, it is important to properly measure the part characteristics. Therefore, this work contributes with a measurement methodology for inclined walls deposited by Wire and Arc Additive Manufacturing and its application on walls deposited with different parameters. The main parameter of influence was the use of interlayer temperature control, which increased the angle in 71.0%, and the curvature in 90.3%, lower part.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 40-45"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-11-01DOI: 10.1016/j.mfglet.2024.10.003
Mohd Aslam , Guddakesh Kumar Chandan , Brajesh Kumar Kanchan
In this study, mild steel was cladded with preplaced AISI304 stainless steel wire using a tungsten inert gas (TIG) heat source to enhance its hardness and wear resistance. The microstructure, hardness, and tribological properties of clad layer were examined. Results showed the microstructure comprised phases like dendrite, cellular, and columnar dendrite, along with austenite dendrite at the interface. Microhardness ranged from 275.61HV.5 to 334.96HV.5, while the substrate measured 176.94HV.5. The clad layer exhibited a wear rate between 57 µm and 70 µm, with substrate at 146 µm. XRD analysis revealed hard carbides and intermetallic compounds with Cr and Ni, enhancing hardness.
{"title":"Hard and wear resistant AISI304 stainless steel clad layer deposited on mild steel substrate by TIG cladding","authors":"Mohd Aslam , Guddakesh Kumar Chandan , Brajesh Kumar Kanchan","doi":"10.1016/j.mfglet.2024.10.003","DOIUrl":"10.1016/j.mfglet.2024.10.003","url":null,"abstract":"<div><div>In this study, mild steel was cladded with preplaced AISI304 stainless steel wire using a tungsten inert gas (TIG) heat source to enhance its hardness and wear resistance. The microstructure, hardness, and tribological properties of clad layer were examined. Results showed the microstructure comprised phases like dendrite, cellular, and columnar dendrite, along with austenite dendrite at the interface. Microhardness ranged from 275.61HV<sub>.5</sub> to 334.96HV<sub>.5</sub>, while the substrate measured 176.94HV<sub>.5</sub>. The clad layer exhibited a wear rate between 57 µm and 70 µm, with substrate at 146 µm. XRD analysis revealed hard carbides and intermetallic compounds with Cr and Ni, enhancing hardness.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 34-39"},"PeriodicalIF":1.9,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142655680","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-09DOI: 10.1016/j.mfglet.2024.09.201
Pratishtha Sharma , Dheerendra Kumar Dwivedi
An approach is proposed to enhance the mechanical properties (ductility and impact toughness) of dissimilar martensitic steel-austenitic stainless steel joint by ‘A-TIG welding with induction post-heating (A-TIG(I) welding)’. The A-TIG(I) welding mitigates the martensite formation and promotes the ferrite formation within the weld zone (WZ) by retarding the cooling rate (from 9.83 °C/s to 0.8 °C/s). Microstructural transformations enabled in achieving the improved ductility (44.9 %) without significant loss of strength (665.75 MPa). Overmatched impact toughness (103 ± 2) J of WZ was also obtained.
{"title":"Enhancing mechanical properties of dissimilar steel A-TIG weld joint by in-situ induction post-heating","authors":"Pratishtha Sharma , Dheerendra Kumar Dwivedi","doi":"10.1016/j.mfglet.2024.09.201","DOIUrl":"10.1016/j.mfglet.2024.09.201","url":null,"abstract":"<div><div>An approach is proposed to enhance the mechanical properties (ductility and impact toughness) of dissimilar martensitic steel-austenitic stainless steel joint by ‘A-TIG welding with induction post-heating (A-TIG<sub>(I)</sub> welding)’. The A-TIG<sub>(I)</sub> welding mitigates the martensite formation and promotes the ferrite formation within the weld zone (WZ) by retarding the cooling rate (from 9.83 °C/s to 0.8 °C/s). Microstructural transformations enabled in achieving the improved ductility (44.9 %) without significant loss of strength (665.75 MPa). Overmatched impact toughness (103 ± 2) J of WZ was also obtained.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"42 ","pages":"Pages 30-33"},"PeriodicalIF":1.9,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142417378","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-01DOI: 10.1016/j.mfglet.2024.09.074
Hyeong Gu Kim , Tae Hwa Hong , Dave Kim , Seong Hyeon Kim
This study investigates the effect of the cutting process parameters on the cutting forces and the quality parameters of a woven carbon fiber preform during robotic ultrasonic-knife cutting. An ultrasonic cutting device, with a power of 1200 W, a frequency of 24 kHz, and an amplitude of 60 µm, mounted on the end effector of a six-axis degree of freedom industrial robot to make linear cuts. A three-level factorial experimental design was used to examine the effect of the feed rate (1 m/min to 5 m/min) and the knife’s attack angle (45° to 75°) on the cutting forces, the dimensional accuracy of the machined preform coupons, and the damage on the machined preform edges. The cutting force analysis results show that the increasing feed rate resulted in increasing feed force and thrust force. However, the increase of the attack angle increases the feed force but decreases the thrust force. The average width and damage of the ultrasonic knife cut preform coupons are highly related to the process conditions. The combination of the low feed rate, 1 m/min, and the low attack angle, 45°, resulted in dimensional errors ranging from 253 μm to 365 μm oversized from the programmed 15.0 mm width with no damage. When the feed became 3 m/min and 5 m/min at the attack angle of 75°, the preform coupons’ dimensional accuracy and damage formation worsened. In these conditions, the ultrasonic knife attached to the industrial robot arm could not cut the preform plate effectively, so the tows on the preform were unevenly cut or dislodged.
{"title":"An experimental study of ultrasonic-knife cutting for a woven carbon fiber preform by an industrial robot","authors":"Hyeong Gu Kim , Tae Hwa Hong , Dave Kim , Seong Hyeon Kim","doi":"10.1016/j.mfglet.2024.09.074","DOIUrl":"10.1016/j.mfglet.2024.09.074","url":null,"abstract":"<div><div>This study investigates the effect of the cutting process parameters on the cutting forces and the quality parameters of a woven carbon fiber preform during robotic ultrasonic-knife cutting. An ultrasonic cutting device, with a power of 1200 W, a frequency of 24 kHz, and an amplitude of 60 µm, mounted on the end effector of a six-axis degree of freedom industrial robot to make linear cuts. A three-level factorial experimental design was used to examine the effect of the feed rate (1 m/min to 5 m/min) and the knife’s attack angle (45° to 75°) on the cutting forces, the dimensional accuracy of the machined preform coupons, and the damage on the machined preform edges. The cutting force analysis results show that the increasing feed rate resulted in increasing feed force and thrust force. However, the increase of the attack angle increases the feed force but decreases the thrust force. The average width and damage of the ultrasonic knife cut preform coupons are highly related to the process conditions. The combination of the low feed rate, 1 m/min, and the low attack angle, 45°, resulted in dimensional errors ranging from 253 μm to 365 μm oversized from the programmed 15.0 mm width with no damage. When the feed became 3 m/min and 5 m/min at the attack angle of 75°, the preform coupons’ dimensional accuracy and damage formation worsened. In these conditions, the ultrasonic knife attached to the industrial robot arm could not cut the preform plate effectively, so the tows on the preform were unevenly cut or dislodged.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 581-587"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434405","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-01DOI: 10.1016/j.mfglet.2024.09.092
Kandice S.B. Ribeiro , Ana C. Reghini , Reginaldo T. Coelho
Additive manufacturing of metal alloys via laser Directed Energy Deposition (L-DED) has been gaining popularity due to its potential to repair and create new features/components, enabling new applications for built parts. The success of L-DED operations hinges on the precise control of printing parameters, including laser power, scanning speed, and powder feed rate. These parameters significantly influence heat distribution during printing, directly impacting the quality of the resulting parts. Thus, defining an efficient methodology to find a good correlation between these parameters for the printing process is crucial to boost part production, as it reduces the time-consuming trial-and-error parameter tuning process. In this context, our study introduces an analytical model that predicts printing parameters based on the deposited material volume along track lines. Deposition was carried in stainless steel 316L with different values for laser power (ranging from 500 to with increments), scanning speed (from 400 to with increments), and powder feed rate ( and ). The experimental data verified the effectiveness of the proposed model, demonstrating its potential to standardize the first step of printing process and expedite the initial search for optimal printing parameters in L-DED. The model provided accurate initial estimates of laser power, with a maximum relative error of , particularly for the optimum mass flow rate () of . Beyond its benefits to the L-DED process, this analytical solution contributes to experimental practices by offering an efficient method for predicting material deposition volume during printing. Thus, our work underscores the significance of optimizing printing parameters to achieve high-quality parts and provides a valuable reference for future research and studies in the field of L-DED.
{"title":"An analytical model for estimating process parameters input in L-DED based on bead geometry","authors":"Kandice S.B. Ribeiro , Ana C. Reghini , Reginaldo T. Coelho","doi":"10.1016/j.mfglet.2024.09.092","DOIUrl":"10.1016/j.mfglet.2024.09.092","url":null,"abstract":"<div><div>Additive manufacturing of metal alloys via laser Directed Energy Deposition (L-DED) has been gaining popularity due to its potential to repair and create new features/components, enabling new applications for built parts. The success of L-DED operations hinges on the precise control of printing parameters, including laser power, scanning speed, and powder feed rate. These parameters significantly influence heat distribution during printing, directly impacting the quality of the resulting parts. Thus, defining an efficient methodology to find a good correlation between these parameters for the printing process is crucial to boost part production, as it reduces the time-consuming trial-and-error parameter tuning process. In this context, our study introduces an analytical model that predicts printing parameters based on the deposited material volume along track lines. Deposition was carried in stainless steel 316L with different values for laser power (ranging from 500 to <span><math><mrow><mn>750</mn><mspace></mspace><mtext>W</mtext></mrow></math></span> with <span><math><mrow><mn>50</mn><mspace></mspace><mtext>W</mtext></mrow></math></span> increments), scanning speed (from 400 to <span><math><mrow><mn>700</mn><mspace></mspace><mtext>mm</mtext><mo>/</mo><mtext>min</mtext></mrow></math></span> with <span><math><mrow><mn>100</mn><mspace></mspace><mi>mm</mi><mo>/</mo><mi>min</mi></mrow></math></span> increments), and powder feed rate (<span><math><mrow><mn>6.4</mn><mo>,</mo><mn>8.0</mn></mrow></math></span> and <span><math><mrow><mn>10.0</mn><mspace></mspace><mtext>g</mtext><mo>/</mo><mtext>min</mtext></mrow></math></span>). The experimental data verified the effectiveness of the proposed model, demonstrating its potential to standardize the first step of printing process and expedite the initial search for optimal printing parameters in L-DED. The model provided accurate initial estimates of laser power, with a maximum relative error of <span><math><mrow><mn>12</mn><mo>%</mo></mrow></math></span>, particularly for the optimum mass flow rate (<span><math><mrow><mover><mrow><mi>m</mi></mrow><mrow><mo>̇</mo></mrow></mover></mrow></math></span>) of <span><math><mrow><mn>8.0</mn><mspace></mspace><mtext>g</mtext><mo>/</mo><mtext>min</mtext></mrow></math></span>. Beyond its benefits to the L-DED process, this analytical solution contributes to experimental practices by offering an efficient method for predicting material deposition volume during printing. Thus, our work underscores the significance of optimizing printing parameters to achieve high-quality parts and provides a valuable reference for future research and studies in the field of L-DED.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 742-752"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434403","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-01DOI: 10.1016/j.mfglet.2024.09.060
Patrick Chernjavsky , Rohit Dey , Jack Shanks , Yinggang Tian , Yihao Zheng
Controllable, adaptable internal polishing is critical to metal additive manufactured (MAM) complex channels. Conventional fluid-based internal polishing methods are challenging to control the material removal, resulting in varied surface roughness (Sa) depending on channel length, aspect ratio (AR), and complexity. HydroFlex is an internal polishing method which drives a fixed-abrasive grinding wheel via a flexible spindle to navigate complex, high AR channels controllably and predictably removing material. Key to HydroFlex performance is the orbital motion of the grinding wheel governed by the hydrodynamic and cutting forces to achieve uniform polishing. Effect of grit size on orbital motion, and corresponding performance was experimentally evaluated. 46 µm, 76 µm, and 91 µm grit sizes were tested at a rotational speed of 50,000 rpm and a channel to wheel (C/W) ratio of 0.54 and orbital frequency and consistency, grinding force, Sa, material removal rate (MRR), and wheel wear were compared. Orbital frequency was found to directly correlate with increasing grit size and consistency of orbit shown to be highest at moderate grinding forces. Sa and MRR were inversely proportional with sub-micron roughness achieved at 0.15 g/min and 0.34 g/min corresponding to 2.2 µm Sa. Wheel wear was effected by grain pullout, attrition, and capping with all grit sizes experiencing similar wear. These findings suggest that orbital motion can be controlled through manipulation of wheel kinetics enabling precise control of grinding dynamics essential to adaptable performance in complex, non-uniform MAM channels.
{"title":"Grit size effect on HydroFlex polishing dynamics and performance","authors":"Patrick Chernjavsky , Rohit Dey , Jack Shanks , Yinggang Tian , Yihao Zheng","doi":"10.1016/j.mfglet.2024.09.060","DOIUrl":"10.1016/j.mfglet.2024.09.060","url":null,"abstract":"<div><div>Controllable, adaptable internal polishing is critical to metal additive manufactured (MAM) complex channels. Conventional fluid-based internal polishing methods are challenging to control the material removal, resulting in varied surface roughness (Sa) depending on channel length, aspect ratio (AR), and complexity. HydroFlex is an internal polishing method which drives a fixed-abrasive grinding wheel via a flexible spindle to navigate complex, high AR channels controllably and predictably removing material. Key to HydroFlex performance is the orbital motion of the grinding wheel governed by the hydrodynamic and cutting forces to achieve uniform polishing. Effect of grit size on orbital motion, and corresponding performance was experimentally evaluated. 46 µm, 76 µm, and 91 µm grit sizes were tested at a rotational speed of 50,000 rpm and a channel to wheel (C/W) ratio of 0.54 and orbital frequency and consistency, grinding force, Sa, material removal rate (MRR), and wheel wear were compared. Orbital frequency was found to directly correlate with increasing grit size and consistency of orbit shown to be highest at moderate grinding forces. Sa and MRR were inversely proportional with sub-micron roughness achieved at 0.15 g/min and 0.34 g/min corresponding to 2.2 µm Sa. Wheel wear was effected by grain pullout, attrition, and capping with all grit sizes experiencing similar wear. These findings suggest that orbital motion can be controlled through manipulation of wheel kinetics enabling precise control of grinding dynamics essential to adaptable performance in complex, non-uniform MAM channels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 494-503"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434153","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-01DOI: 10.1016/j.mfglet.2024.09.095
Changyu Ma , Tianqi Zheng , Yu-Keng Lin , Philip Mallory , Xiaochun Li , Y. Morris Wang , Bruce Kang , Bingbing Li
Oxide dispersion strengthened (ODS) SS316L is a promising candidate for the nuclear industry for its enhanced irradiation resistance and high temperature strength. Additionally, additive manufacturing enables the design flexibility of components. Achieving a uniform distribution of oxides in ODS SS316L is one of the remaining challenges in additive manufacturing. In this paper, we investigated the effects of printing parameters on the microstructure and mechanical properties of ODS SS316L (SS316L + 0.5 wt% Y2O3) through laser powder bed fusion (L-PBF) additive manufacturing. The results showed that plate-like Y-Si-rich oxides (∼50 μm) were observed along the molten pool boundary in the ODS SS316L printed with nominal parameters (48.5 J/mm3) for pure SS 316L, resulting from inadequate heat input in molten pool due to the reduced laser absorption rate of powder feedstock. Through higher volumetric energy density (76.2 J/mm3) and remelting, a bimodal distribution of oxides, including nanoparticles and fine spherical oxide (∼2.5 μm), was achieved. Consequently, this contributed to increased ultimate tensile strength (UTS) and strain of ODS SS316L from 685.2.6 ± 31.4 MPa and 27.8 ± 6.2 % to 706.6 ± 36.2 MPa and 33.0 ± 6.1 %, respectively. The exploration of parameters optimization provides valuable insights into the additive manufacturing of ODS alloys with uniformly distributed nanoparticles.
{"title":"Achieving uniform distribution of nanoparticles in oxide dispersion strengthened (ODS) SS316L through laser powder bed fusion (L-PBF)","authors":"Changyu Ma , Tianqi Zheng , Yu-Keng Lin , Philip Mallory , Xiaochun Li , Y. Morris Wang , Bruce Kang , Bingbing Li","doi":"10.1016/j.mfglet.2024.09.095","DOIUrl":"10.1016/j.mfglet.2024.09.095","url":null,"abstract":"<div><div>Oxide dispersion strengthened (ODS) SS316L is a promising candidate for the nuclear industry for its enhanced irradiation resistance and high temperature strength. Additionally, additive manufacturing enables the design flexibility of components. Achieving a uniform distribution of oxides in ODS SS316L is one of the remaining challenges in additive manufacturing. In this paper, we investigated the effects of printing parameters on the microstructure and mechanical properties of ODS SS316L (SS316L + 0.5 wt% Y<sub>2</sub>O<sub>3</sub>) through laser powder bed fusion (L-PBF) additive manufacturing. The results showed that plate-like Y-Si-rich oxides (∼50 μm) were observed along the molten pool boundary in the ODS SS316L printed with nominal parameters (48.5 J/mm<sup>3</sup>) for pure SS 316L, resulting from inadequate heat input in molten pool due to the reduced laser absorption rate of powder feedstock. Through higher volumetric energy density (76.2 J/mm<sup>3</sup>) and remelting, a bimodal distribution of oxides, including nanoparticles and fine spherical oxide (∼2.5 μm), was achieved. Consequently, this contributed to increased ultimate tensile strength (UTS) and strain of ODS SS316L from 685.2.6 ± 31.4 MPa and 27.8 ± 6.2 % to 706.6 ± 36.2 MPa and 33.0 ± 6.1 %, respectively. The exploration of parameters optimization provides valuable insights into the additive manufacturing of ODS alloys with uniformly distributed nanoparticles.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 766-771"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434287","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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