Additive manufacturing (AM) enables the production of complex, highly porous geometries that would be impossible to create with subtractive methods. These geometries have generated much interest in their potential applications for decreasing the weight of traditional parts as well as their potential use in orthopedic implants, such as headless compression screws. Pore size and implant porosity play an important role in the osseointegrative performance of porous implants. Ensuring that the porosity of the physical part matches that of the CAD model is thus key to implant performance. However, more work is needed to design, fabricate, and evaluate the manufacturability of AM porous implants. The threefold objectives of this study are as follows. (1) Cylindrical screw blanks with three different porosity patterns are designed in CAD. (2) The blanks are fabricated using the laser-powder bed fusion (LPBF) process, followed by manual threading. (3) The resulting porosity of each LPBF blank is characterized using optical microscopy as well as micro-CT and compared to the CAD model. It was found that the as-printed porosity did not match well with the CAD model, with the measured mean pore size about 30% larger than the theoretical. Future work involves a redesign of the blank geometry to better integrate a porous core with threaded sections as well as mechanical testing to determine feasibility of use for fixation.
{"title":"Design, hybrid manufacturing, and characterization of porous fracture fixators","authors":"Johnathan Perino , Panayiotis Kousoulas , Y.B. Guo","doi":"10.1016/j.mfglet.2025.06.099","DOIUrl":"10.1016/j.mfglet.2025.06.099","url":null,"abstract":"<div><div>Additive manufacturing (AM) enables the production of complex, highly porous geometries that would be impossible to create with subtractive methods. These geometries have generated much interest in their potential applications for decreasing the weight of traditional parts as well as their potential use in orthopedic implants, such as headless compression screws. Pore size and implant porosity play an important role in the osseointegrative performance of porous implants. Ensuring that the porosity of the physical part matches that of the CAD model is thus key to implant performance. However, more work is needed to design, fabricate, and evaluate the manufacturability of AM porous implants. The threefold objectives of this study are as follows. (1) Cylindrical screw blanks with three different porosity patterns are designed in CAD. (2) The blanks are fabricated using the laser-powder bed fusion (LPBF) process, followed by manual threading. (3) The resulting porosity of each LPBF blank is characterized using optical microscopy as well as micro-CT and compared to the CAD model. It was found that the as-printed porosity did not match well with the CAD model, with the measured mean pore size about 30% larger than the theoretical. Future work involves a redesign of the blank geometry to better integrate a porous core with threaded sections as well as mechanical testing to determine feasibility of use for fixation.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 839-846"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926656","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}
Carbon fiber reinforced plastic (CFRP) has recently been applied to aircraft structures. In milling of CFRP, the surface finish is sometimes deteriorated by delamination of polymer with uncut fibers. Because the cutting of CFRP also appears anisotropy, the surface finish depends on the fiber cutting angle, which is the cutting direction for the fiber orientation. Furthermore, in the manufacturing of aircraft parts, high machining rates are required for large removal areas. This study investigates the surface finish and the tool wear in the milling of CFRP with a 10 mm diameter PCD end mill at high feed rates up to 3000 mm/min. Delamination-free and wavy profile-free surfaces are finished at a cutting speed of 314 m/min and a feed rate of 3000 mm/min using the end mills at rake angles of 5°, 10°, and 15°. Delamination suppression is associated with the indentation load applied to the workpiece surface in the engagement of cutting edge in up-cutting. Then, the tool wear is discussed in the milling of 16-layered CFRP. An approach based on an abrasive wear model is presented to identify the wear characteristics for the fiber cutting angles. In the wear test of this study, the wear rate increases up to a fiber cutting angle of 45°; decreases to 135° (−45°); and increases again to 180° (0°). The presented approach is effective in estimation of flank wear distribution associated with the radial depth of cut
{"title":"High feed rate milling of carbon fiber reinforced plastic with PCD tool","authors":"Sho Watanabe , Fumihiro Uchiyama , Shoichi Tamura , Takashi Matsumura","doi":"10.1016/j.mfglet.2025.06.080","DOIUrl":"10.1016/j.mfglet.2025.06.080","url":null,"abstract":"<div><div>Carbon fiber reinforced plastic (CFRP) has recently been applied to aircraft structures. In milling of CFRP, the surface finish is sometimes deteriorated by delamination of polymer with uncut fibers. Because the cutting of CFRP also appears anisotropy, the surface finish depends on the fiber cutting angle, which is the cutting direction for the fiber orientation. Furthermore, in the manufacturing of aircraft parts, high machining rates are required for large removal areas. This study investigates the surface finish and the tool wear in the milling of CFRP with a 10 mm diameter PCD end mill at high feed rates up to 3000 mm/min. Delamination-free and wavy profile-free surfaces are finished at a cutting speed of 314 m/min and a feed rate of 3000 mm/min using the end mills at rake angles of 5°, 10°, and 15°. Delamination suppression is associated with the indentation load applied to the workpiece surface in the engagement of cutting edge in up-cutting. Then, the tool wear is discussed in the milling of 16-layered CFRP. An approach based on an abrasive wear model is presented to identify the wear characteristics for the fiber cutting angles. In the wear test of this study, the wear rate increases up to a fiber cutting angle of 45°; decreases to 135° (−45°); and increases again to 180° (0°). The presented approach is effective in estimation of flank wear distribution associated with the radial depth of cut</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 687-693"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926691","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.095
Anel Zhumabekova, Asma Perveen, Didier Talamona
This work explores the use of Selective Laser Melting (SLM) to enhance the mechanical and corrosion properties of titanium-tantalum (Ti6Al4V-8Ta) alloys for biomedical applications. The study addresses the limitations of the widely used Ti6Al4V alloy, such as potential aluminum and vanadium toxicity, by incorporating tantalum (Ta), which offers superior biocompatibility and corrosion resistance. Comprehensive characterization is performed using Scanning Electron Microscopy (SEM) to analyze the chemical composition and particle morphology, while particle size distribution is measured using a Mastersizer. Mechanical testing reveals that the Ti6Al4V-8Ta alloy exhibits slightly reduced mechanical properties compared to Ti6Al4V, with an ultimate tensile strength (UTS) of 1216.73 ± 3.20 MPa, yield strength (YS) of 1058.67 ± 24.49 MPa, and elastic modulus of 99.64 ± 5.52 GPa. In comparison, Ti6Al4V has a UTS of 1222.69 ± 2.63 MPa, YS of 1063.87 ± 49.19 MPa, and elastic modulus of 106.38 ± 12.44 GPa. Microstructural analysis demonstrates a refined acicular martensitic structure, which improves toughness, while fractographic examination reveals both ductile and brittle fracture features, suggesting enhanced durability with the addition of Ta. Corrosion testing using potentiodynamic analysis and Electrochemical Impedance Spectroscopy (EIS) shows that Ti6Al4V-8Ta offers improved corrosion resistance. It exhibits a lower corrosion current density of 1.89 ± 0.38 μA/cm2 compared to 7.23 ± 1.40 μA/cm2 for Ti6Al4V, and a higher polarization resistance (Rp) of 24547.67 ± 12,157.40 Ω·cm2 compared to 6762.36 ± 3796.68 Ω·cm2 for Ti6Al4V. Additionally, the corrosion rate of Ti6Al4V-8Ta is 0.043 ± 0.023 mm/a, nearly half that of Ti6Al4V (0.093 ± 0.076 mm/a). Improved wettability is also observed, with Ti6Al4V-8Ta showing contact angles of 48.12 ± 4.36° (0° print angle) and 57.56 ± 3.03° (90° print angle), compared to 41.44 ± 1.18° and 47.61 ± 3.95° for Ti6Al4V. In conclusion, the Ti6Al4V-8Ta alloy developed using SLM achieves a favorable combination of mechanical performance and enhanced corrosion resistance. Although mechanical properties are slightly reduced, the significant improvements in corrosion resistance and hydrophobicity make Ti6Al4V-8Ta a promising candidate for long-term biomedical applications. This study highlights the potential of advanced manufacturing techniques to develop next-generation biomaterials that ensure safer and more durable implants.
{"title":"Comparison study of Selective Laser melted Ti6Al4V and Ti6Al4V-8Ta Alloys: Mechanical & corrosion properties","authors":"Anel Zhumabekova, Asma Perveen, Didier Talamona","doi":"10.1016/j.mfglet.2025.06.095","DOIUrl":"10.1016/j.mfglet.2025.06.095","url":null,"abstract":"<div><div>This work explores the use of Selective Laser Melting (SLM) to enhance the mechanical and corrosion properties of titanium-tantalum (Ti6Al4V-8Ta) alloys for biomedical applications. The study addresses the limitations of the widely used Ti6Al4V alloy, such as potential aluminum and vanadium toxicity, by incorporating tantalum (Ta), which offers superior biocompatibility and corrosion resistance. Comprehensive characterization is performed using Scanning Electron Microscopy (SEM) to analyze the chemical composition and particle morphology, while particle size distribution is measured using a Mastersizer. Mechanical testing reveals that the Ti6Al4V-8Ta alloy exhibits slightly reduced mechanical properties compared to Ti6Al4V, with an ultimate tensile strength (UTS) of 1216.73 ± 3.20 MPa, yield strength (YS) of 1058.67 ± 24.49 MPa, and elastic modulus of 99.64 ± 5.52 GPa. In comparison, Ti6Al4V has a UTS of 1222.69 ± 2.63 MPa, YS of 1063.87 ± 49.19 MPa, and elastic modulus of 106.38 ± 12.44 GPa. Microstructural analysis demonstrates a refined acicular martensitic structure, which improves toughness, while fractographic examination reveals both ductile and brittle fracture features, suggesting enhanced durability with the addition of Ta. Corrosion testing using potentiodynamic analysis and Electrochemical Impedance Spectroscopy (EIS) shows that Ti6Al4V-8Ta offers improved corrosion resistance. It exhibits a lower corrosion current density of 1.89 ± 0.38 μA/cm<sup>2</sup> compared to 7.23 ± 1.40 μA/cm<sup>2</sup> for Ti6Al4V, and a higher polarization resistance (Rp) of 24547.67 ± 12,157.40 Ω·cm<sup>2</sup> compared to 6762.36 ± 3796.68 Ω·cm<sup>2</sup> for Ti6Al4V. Additionally, the corrosion rate of Ti6Al4V-8Ta is 0.043 ± 0.023 mm/a, nearly half that of Ti6Al4V (0.093 ± 0.076 mm/a). Improved wettability is also observed, with Ti6Al4V-8Ta showing contact angles of 48.12 ± 4.36° (0° print angle) and 57.56 ± 3.03° (90° print angle), compared to 41.44 ± 1.18° and 47.61 ± 3.95° for Ti6Al4V. In conclusion, the Ti6Al4V-8Ta alloy developed using SLM achieves a favorable combination of mechanical performance and enhanced corrosion resistance. Although mechanical properties are slightly reduced, the significant improvements in corrosion resistance and hydrophobicity make Ti6Al4V-8Ta a promising candidate for long-term biomedical applications. This study highlights the potential of advanced manufacturing techniques to develop next-generation biomaterials that ensure safer and more durable implants.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 804-815"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926693","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.085
Taylor Barrett , Beth L. Armstrong , Corson L. Cramer , Brigid Mullany
The demand for high-performance lightweight optics has driven interest in silicon carbide (SiC) due to its exceptional thermal stability, hardness, and strength-to-weight ratio. This study investigates the potential of robocasting, an additive manufacturing process, as a viable method for producing lightweighted SiC components for optical applications. Four samples with varied starting powder phases (α and β) and sintering conditions were fabricated and evaluated. Post-sintering surface and form were assessed using coherence scanning interferometry (CSI) and coordinate measuring machine (CMM) techniques. A three-stage grinding process was applied to each sample, with surface roughness assessed at each stage. Results demonstrate that samples with predominantly α-phase SiC and smaller particle sizes achieved superior surface finish, particularly sample D2-α-2135 °C, which displayed the lowest post-grinding Sq value of 0.178 µm. The analysis also indicated no significant print-through effect from the lightweighting structure, or print artifacts, at this stage of grinding. However, β-phase samples showed poorer grindability, increased surface roughness, and pitting. These findings suggest that phase composition and particle size are critical for achieving the desired surface quality in robocast SiC optics. Future work will incorporate additional samples and finer grinding wheels to refine surface quality further, supporting the development of SiC for high-precision optical applications.
{"title":"Assessment of the grindability of robocast silicon carbide","authors":"Taylor Barrett , Beth L. Armstrong , Corson L. Cramer , Brigid Mullany","doi":"10.1016/j.mfglet.2025.06.085","DOIUrl":"10.1016/j.mfglet.2025.06.085","url":null,"abstract":"<div><div>The demand for high-performance lightweight optics has driven interest in silicon carbide (SiC) due to its exceptional thermal stability, hardness, and strength-to-weight ratio. This study investigates the potential of robocasting, an additive manufacturing process, as a viable method for producing lightweighted SiC components for optical applications. Four samples with varied starting powder phases (α and β) and sintering conditions were fabricated and evaluated. Post-sintering surface and form were assessed using coherence scanning interferometry (CSI) and coordinate measuring machine (CMM) techniques. A three-stage grinding process was applied to each sample, with surface roughness assessed at each stage. Results demonstrate that samples with predominantly α-phase SiC and smaller particle sizes achieved superior surface finish, particularly sample D2-α-2135 °C, which displayed the lowest post-grinding <em>Sq</em> value of 0.178 µm. The analysis also indicated no significant print-through effect from the lightweighting structure, or print artifacts, at this stage of grinding. However, β-phase samples showed poorer grindability, increased surface roughness, and pitting. These findings suggest that phase composition and particle size are critical for achieving the desired surface quality in robocast SiC optics. Future work will incorporate additional samples and finer grinding wheels to refine surface quality further, supporting the development of SiC for high-precision optical applications.</div><div>Click here to enter text.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 726-733"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926832","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.067
H. Yagishita
Ti6Al4V, which is one of difficult-to-cut metals, is widely used in an aircraft structure, parts of a gas turbine and medical equipment so that a hole making operation of Ti6Al4V is indispensable to fasten the parts. When a highspeed drilling by a conventional twist drill is applied to hole making of Ti6Al4V, it is very difficult to obtain highly accurate hole diameter in the depth of hole, also roundness and inlet–outlet edge quality due to a rise of cutting temperature caused by its small heat conductivity. Moreover, it is well-known that Ti6Al4V causes transiently phase transformation from α phase (close-packed hexagonal lattice) to β phase (body-centered cubic lattice) as soon as it reaches the phase transformation temperature of about 883 °C (1621 °F). Since cooling effect by coolant upon inner surface of hole being drilled would be considerably different between conventional drilling and orbital drilling, to make clear highly accurate hole making technology in the depth direction of Ti6Al4V a lot of hole making tests of φ15 mm × 258 mm depth were executed supplying coolant by conventional drilling of φ15 mm twist drill and by orbital drilling of φ11 mm endmill having 6 blades. In order to elucidate the process for hole diameter in the depth direction to be determined, both cutting speeds of conventional drilling and orbital drilling were set to nearly equal and they were varied at 12 values in the range from 23 m/min to 85 m/min. Hole diameter and roundness measured simultaneously at six positions in the depth direction of hole were drawn in relation to depth of hole and hole diameter in the depth direction was compared and considered deeply between the two drilling methods. Consequently, it is ascertained that although the hole diameter drilled by conventional drilling becomes smaller from top to bottom in the depth direction of hole, the hole diameter drilled by orbital drilling becomes slightly larger in the depth direction of hole since the temperature at the area neighboring inner wall of hole being drilled would be maintained under phase transformation temperature of Ti6Al4V over a drilling operation except the exit area of hole.
Ti6Al4V是一种难以切割的金属，广泛应用于飞机结构、燃气轮机部件和医疗设备中，因此为了紧固零件，Ti6Al4V的打孔操作是必不可少的。传统麻花钻高速钻孔加工Ti6Al4V时，由于其导热系数小，导致切削温度升高，很难在孔深上获得高精度的孔径、圆度和进出口边缘质量。此外，众所周知，Ti6Al4V在相变温度达到883 °C（1621°F）左右时，从α相（密集的六方晶格）转变为β相（体心立方晶格）。由于常规钻削和轨道钻削对孔内表面的冷却效果有较大差异，为明确Ti6Al4V深度方向的高精度制孔工艺，采用φ15 mm常规钻削和φ11 mm 6刃立铣刀轨道钻削提供冷却剂，进行了φ15 mm × 258 mm深度的大量制孔试验。为了阐明待确定深度方向孔径的变化过程，将常规钻削和轨道钻削的切削速度设置为接近相等，并在23 m/min ~ 85 m/min范围内变化12个值。绘制了孔深方向上6个位置同时测量的孔径和圆度与孔深的关系，并对两种钻孔方法在孔深方向上的孔径进行了比较和深入考虑。由此可以确定，虽然常规钻孔在孔深方向上从上到下钻孔直径变小，但轨道钻孔在孔深方向上钻孔直径变大，因为在一次钻孔过程中，Ti6Al4V相变温度下，除孔出口区域外，邻近钻孔内壁区域的温度是保持不变的。
{"title":"Highly accurate hole making technology of Ti6Al4V experimental elucidation of process for hole diameter in the depth direction to be determined","authors":"H. Yagishita","doi":"10.1016/j.mfglet.2025.06.067","DOIUrl":"10.1016/j.mfglet.2025.06.067","url":null,"abstract":"<div><div>Ti6Al4V, which is one of difficult-to-cut metals, is widely used in an aircraft structure, parts of a gas turbine and medical equipment so that a hole making operation of Ti6Al4V is indispensable to fasten the parts. When a highspeed drilling by a conventional twist drill is applied to hole making of Ti6Al4V, it is very difficult to obtain highly accurate hole diameter in the depth of hole, also roundness and inlet–outlet edge quality due to a rise of cutting temperature caused by its small heat conductivity. Moreover, it is well-known that Ti6Al4V causes transiently phase transformation from α phase (close-packed hexagonal lattice) to β phase (body-centered cubic lattice) as soon as it reaches the phase transformation temperature of about 883 °C (1621 °F). Since cooling effect by coolant upon inner surface of hole being drilled would be considerably different between conventional drilling and orbital drilling, to make clear highly accurate hole making technology in the depth direction of Ti6Al4V a lot of hole making tests of φ15 mm × 258 mm depth were executed supplying coolant by conventional drilling of φ15 mm twist drill and by orbital drilling of φ11 mm endmill having 6 blades. In order to elucidate the process for hole diameter in the depth direction to be determined, both cutting speeds of conventional drilling and orbital drilling were set to nearly equal and they were varied at 12 values in the range from 23 m/min to 85 m/min. Hole diameter and roundness measured simultaneously at six positions in the depth direction of hole were drawn in relation to depth of hole and hole diameter in the depth direction was compared and considered deeply between the two drilling methods. Consequently, it is ascertained that although the hole diameter drilled by conventional drilling becomes smaller from top to bottom in the depth direction of hole, the hole diameter drilled by orbital drilling becomes slightly larger in the depth direction of hole since the temperature at the area neighboring inner wall of hole being drilled would be maintained under phase transformation temperature of Ti6Al4V over a drilling operation except the exit area of hole.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 566-575"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926543","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.020
Ufoma Silas Anamu , Odetola Peter Ifeolu , Peter Apata Olubambi
In this study, four optimized septenary high entropy alloys (HEAs): Ti14.286Al14.286Cr14.286Nb14.286Ni14.286Cu14.286Co14.286 (A), Ti20Al20Cr5Nb5Ni19Cu12Co19 (B), Ti20Al20Cr5Nb5Ni18Cu14Co18 (C) and Ti20Al20Cr5Nb5Ni17Cu16Co17 (D) were designed theoretically by thermo-physical calculations and CALPHAD-based tool (ThermoCalc) to predict the phase diagram, stable phases formed, thermodynamic and mechanical properties of the HEAs prior to the experimentation process. The elemental feedstocks for the HEAs were mechanically alloyed at 10 hrs milling time in a wet environment before being consolidated via pulse electric sintering technique at a sintering temperature of 900 °C, heating rate of 100 °C/min, pressure of 50 MPa, and a dwelling time of 10 min. Nanoindentation testing was conducted to evaluate the nano-mechanical characteristics of the fabricated HEAs. 5 stable phases were identified- BCC_B2, FCC_L12, Sigma, Heusler and C15_Laves at varying fractions across all four HEAs. Simulation from the Property Model Calculator (PMC) module of the ThermoCalc software indicated intrinsic hardness values of 126.116 HV, 144.096 HV, 138.283 HV and 132.972 HV for alloys A, B, C and D respectively. Under 100 mN load, with a loading and unloading rate of 600 mN/min and a holding period of 2 secs, the nanoindentation results revealed that alloy B exhibited the highest nanohardness (15.185 GPa), the least penetration depth (427.822 nm) and highest elastic modulus (246.92 GPa) among the properties. Notably, increasing the composition of Cu at the expense of Ni and Co led to a BCC-FCC phase transformation, resulting in a significant decrease in nanohardness from alloy B to D. A comparative analysis of the hardness results simulated from the PMC module and the experimental nano-hardness results obtained exhibited a consistent trend, confirming the reliability of the predictive model.
{"title":"Investigation of the nano-mechanical properties of pulse electric sintered TiAl-based high entropy alloys by CALPHAD-based simulation and experimental studies","authors":"Ufoma Silas Anamu , Odetola Peter Ifeolu , Peter Apata Olubambi","doi":"10.1016/j.mfglet.2025.06.020","DOIUrl":"10.1016/j.mfglet.2025.06.020","url":null,"abstract":"<div><div>In this study, four optimized septenary high entropy alloys (HEAs): Ti<sub>14.286</sub>Al<sub>14.286</sub>Cr<sub>14.286</sub>Nb<sub>14.286</sub>Ni<sub>14.286</sub>Cu<sub>14.286</sub>Co<sub>14.286</sub> (<strong><em>A</em></strong>), Ti<sub>20</sub>Al<sub>20</sub>Cr<sub>5</sub>Nb<sub>5</sub>Ni<sub>19</sub>Cu<sub>12</sub>Co<sub>19</sub> (<strong><em>B</em></strong>), Ti<sub>20</sub>Al<sub>20</sub>Cr<sub>5</sub>Nb<sub>5</sub>Ni<sub>18</sub>Cu<sub>14</sub>Co<sub>18</sub> (<strong><em>C</em></strong>) and Ti<sub>20</sub>Al<sub>20</sub>Cr<sub>5</sub>Nb<sub>5</sub>Ni<sub>17</sub>Cu<sub>16</sub>Co<sub>17</sub> (<strong><em>D</em></strong>) were designed theoretically by thermo-physical calculations and CALPHAD-based tool (ThermoCalc) to predict the phase diagram, stable phases formed, thermodynamic and mechanical properties of the HEAs prior to the experimentation process. The elemental feedstocks for the HEAs were mechanically alloyed at 10 hrs milling time in a wet environment before being consolidated via pulse electric sintering technique at a sintering temperature of 900 °C, heating rate of 100 °C/min, pressure of 50 MPa, and a dwelling time of 10 min. Nanoindentation testing was conducted to evaluate the nano-mechanical characteristics of the fabricated HEAs. 5 stable phases were identified- BCC_B2, FCC_L1<sub>2</sub>, Sigma, Heusler and C15_Laves at varying fractions across all four HEAs. Simulation from the Property Model Calculator (PMC) module of the ThermoCalc software indicated intrinsic hardness values of 126.116 HV, 144.096 HV, 138.283 HV and 132.972 HV for alloys <strong><em>A</em></strong>, <strong><em>B</em></strong>, <strong><em>C</em></strong> and <strong><em>D</em></strong> respectively. Under 100 mN load, with a loading and unloading rate of 600 mN/min and a holding period of 2 secs, the nanoindentation results revealed that alloy <strong><em>B</em></strong> exhibited the highest nanohardness (15.185 GPa), the least penetration depth (427.822 nm) and highest elastic modulus (246.92 GPa) among the properties. Notably, increasing the composition of Cu at the expense of Ni and Co led to a BCC-FCC phase transformation, resulting in a significant decrease in nanohardness from alloy <strong><em>B</em></strong> to <strong><em>D</em></strong>. A comparative analysis of the hardness results simulated from the PMC module and the experimental nano-hardness results obtained exhibited a consistent trend, confirming the reliability of the predictive model.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 157-166"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926617","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}
This study presents the design, fabrication, and assembly of a microfluidic chip with embedded electrical traces, produced through injection molding, to enable electrochemical diagnostics in small liquid volumes. Traditional PCB-based electronic devices face limitations in compactness and sealing reliability, particularly for lab-on-a-chip applications where fluids must interact with sensors without compromising electrical components. To address this, we employed in-mold electronics (IME) technology to integrate electrical traces directly within the microfluidic structure, eliminating the need for a separate PCB and enhancing design flexibility and durability.
The microfluidic chip comprises microchannels, fluidic ports, and embedded electrical traces that transmit signals from a sensor pad through a mechanical interconnection facilitated by L-shaped cantilever structures. The microchannels, designed to prevent leakage, guide the sample to the reaction site. Electrical traces were fabricated using a blanking process and assembled into an injection mold where they were encapsulated within the polycarbonate microfluidic plate. The design of the L-shaped cantilever structure ensures reliable electrical contact through mechanical pressure, without the need for soldering, while a double-sided adhesive film seals the microfluidic channels to the sensor pad plate.
Experimental tests confirmed that the microfluidic chip achieves both effective channel sealing and secure electrical interconnection, suitable for applications requiring electrochemical or impedance-based biomarker detection. This work demonstrates the feasibility of injection-molded, electrical trace-embedded microfluidic chips as diagnostic platforms for biochip and lab-on-a-chip applications, offering a promising approach for compact, reliable electrochemical diagnostics.
{"title":"Design and injection-molding of microfluidic chip with embedded electrical traces","authors":"Yeong-Eun Yoo , Sang-Won Woo , Jae-Ho Jin , Doo-Sun Choi , Kyeong-Sik Shin","doi":"10.1016/j.mfglet.2025.06.021","DOIUrl":"10.1016/j.mfglet.2025.06.021","url":null,"abstract":"<div><div>This study presents the design, fabrication, and assembly of a microfluidic chip with embedded electrical traces, produced through injection molding, to enable electrochemical diagnostics in small liquid volumes. Traditional PCB-based electronic devices face limitations in compactness and sealing reliability, particularly for lab-on-a-chip applications where fluids must interact with sensors without compromising electrical components. To address this, we employed in-mold electronics (IME) technology to integrate electrical traces directly within the microfluidic structure, eliminating the need for a separate PCB and enhancing design flexibility and durability.</div><div>The microfluidic chip comprises microchannels, fluidic ports, and embedded electrical traces that transmit signals from a sensor pad through a mechanical interconnection facilitated by L-shaped cantilever structures. The microchannels, designed to prevent leakage, guide the sample to the reaction site. Electrical traces were fabricated using a blanking process and assembled into an injection mold where they were encapsulated within the polycarbonate microfluidic plate. The design of the L-shaped cantilever structure ensures reliable electrical contact through mechanical pressure, without the need for soldering, while a double-sided adhesive film seals the microfluidic channels to the sensor pad plate.</div><div>Experimental tests confirmed that the microfluidic chip achieves both effective channel sealing and secure electrical interconnection, suitable for applications requiring electrochemical or impedance-based biomarker detection. This work demonstrates the feasibility of injection-molded, electrical trace-embedded microfluidic chips as diagnostic platforms for biochip and lab-on-a-chip applications, offering a promising approach for compact, reliable electrochemical diagnostics.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 167-171"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926620","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.003
Xun Xu , Stefania Bruschi , Robert X. Gao
{"title":"NAMRC 53 Fast-Tracked research papers to Journal of Manufacturing Systems and Journal of Manufacturing Processes","authors":"Xun Xu , Stefania Bruschi , Robert X. Gao","doi":"10.1016/j.mfglet.2025.06.003","DOIUrl":"10.1016/j.mfglet.2025.06.003","url":null,"abstract":"","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 6-7"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926641","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 : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.034
Xinan Zhou , Jing Zou , Hangyu Li , Donghai Wang , Sun Jin
This manuscript proposes a deviation analysis method based on the Jacobian-Torsor model for the rigid-flexible hybrid deviations in serial assembly. The method establishes the Torsor model to represent the linear and angular deviations induced by the flexible deformation of the hyperelastic aerogel-based thermal insulation pads. Meanwhile, the Jacobian model is constructed to accurately predict the assembly deviations resulting from the combined effects of rigid and flexible deviations. The position deviations of the intermediate plate and the battery side faces are evaluated and utilized to address specific assembly issues in battery stack assembly. The simulation results of the assembly deviations based on this approach align with the production process measurement data, which demonstrates the effectiveness of the proposed method. In addition, the method can be further used to refine the tolerance representation models for various interactions between rigid and flexible components in parallel assembly scenarios.
{"title":"Rigid-flexible hybrid deviation analysis of battery stack assembly based on the Jacobian-Torsor model","authors":"Xinan Zhou , Jing Zou , Hangyu Li , Donghai Wang , Sun Jin","doi":"10.1016/j.mfglet.2025.06.034","DOIUrl":"10.1016/j.mfglet.2025.06.034","url":null,"abstract":"<div><div>This manuscript proposes a deviation analysis method based on the Jacobian-Torsor model for the rigid-flexible hybrid deviations in serial assembly. The method establishes the Torsor model to represent the linear and angular deviations induced by the flexible deformation of the hyperelastic aerogel-based thermal insulation pads. Meanwhile, the Jacobian model is constructed to accurately predict the assembly deviations resulting from the combined effects of rigid and flexible deviations. The position deviations of the intermediate plate and the battery side faces are evaluated and utilized to address specific assembly issues in battery stack assembly. The simulation results of the assembly deviations based on this approach align with the production process measurement data, which demonstrates the effectiveness of the proposed method. In addition, the method can be further used to refine the tolerance representation models for various interactions between rigid and flexible components in parallel assembly scenarios.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 279-286"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926672","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}
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