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Data-driven optimization of temperature control for thick aluminum plate friction stir welding 厚铝板搅拌摩擦焊温度控制的数据驱动优化
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-12-01 DOI: 10.1016/j.mfglet.2025.11.004
Zhuo Sun, Xiaohong Lu, Banghua Yang
Temperature control in friction stir welding (FSW) of thick aluminum plates is critical for structural applications, yet direct temperature-based control targets remain undefined. Optimal temperature control targets for FSW of 18-mm-thick 2219 aluminum alloy were established through systematic analysis of 47 experimental datasets using response surface methodology and Pareto frontier analysis. An optimal temperature window (Tmax: 510.4–514.2 °C, Tmin: 419.5–423.4 °C) achieved balanced mechanical properties with ultimate tensile strength exceeding 290 MPa and elongation above 7 %. Validation experiments confirmed predictions with mean absolute percentage errors below 15 %. This framework provides direct temperature targets for industrial FSW control systems.
厚铝板搅拌摩擦焊(FSW)的温度控制是结构应用的关键,但直接基于温度的控制目标尚未明确。采用响应面法和Pareto边界分析法对47组实验数据进行了系统分析,确定了18mm厚2219铝合金FSW的最优温度控制目标。最佳温度窗(Tmax: 510.4-514.2℃,Tmin: 419.5-423.4℃)达到了平衡的力学性能,极限抗拉强度超过290 MPa,伸长率超过7%。验证实验证实了平均绝对百分比误差低于15%的预测。该框架为工业FSW控制系统提供了直接的温度目标。
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引用次数: 0
Corrigendum to “Additive manufacturing of radially oriented gyroid carbon fiber composites for low-temperature thermal absorber applications” [Manuf. Lett. 44(Supplement) (2025) 816–824] “用于低温吸热器应用的径向定向旋转碳纤维复合材料的增材制造”的勘误表[制造业公报44(补充)(2025)816-824]
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-12-01 DOI: 10.1016/j.mfglet.2025.10.019
Muhtadin Muhtadin , Semih Akin , Jung-Ting Tsai
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引用次数: 0
Temperature induced porosity in laser powder bed fusion fabricated A20X alloy 激光粉末床熔合制备A20X合金的温度致气孔
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-12-01 DOI: 10.1016/j.mfglet.2025.11.007
Heidar Karimialavijeh , Waris Nawaz Khan , Mohsen Moradi , M. Proëbstle , Etienne Martin
Temperature-induced porosity (TIP) originates from gas entrapment during laser powder bed fusion (LPBF) processing, which evolves into defects during subsequent thermal exposure. In LPBF-A20X alloy, the rapid solidification of the melt pool can trap moisture present in the powder feedstock. During post-processing heat treatment, this moisture promotes oxidation reaction forming Al2O3 and releasing H2, contributing to TIP. Severity of TIP is closely linked to LPBF processing parameters, particularly scan speed. At high scan speeds, increased solidification rate limits the escape of moisture, resulting in notable reduction in relative density (1.0–1.9%) post heat treatment. In contrast, lower scan speeds extend melt pool lifetime, facilitating H2 escape and limiting density reduction (0.2–0.8%). These findings highlight the importance of managing powder moisture and optimizing laser parameters, post-processing heat treatments to mitigate TIP.
温度诱导孔隙度(TIP)源于激光粉末床熔合(LPBF)过程中的气体夹带,在随后的热暴露过程中演变成缺陷。在LPBF-A20X合金中,熔池的快速凝固会捕获粉末原料中的水分。在后处理热处理过程中,这些水分促进氧化反应,形成Al2O3并释放H2,形成TIP。TIP的严重程度与LPBF加工参数密切相关,特别是扫描速度。在高扫描速度下,增加的凝固速率限制了水分的逸出,导致热处理后相对密度显著降低(1.0-1.9%)。相比之下,较低的扫描速度延长了熔池寿命,促进了H2的逸出,限制了密度的降低(0.2-0.8%)。这些发现强调了控制粉末水分、优化激光参数、后处理热处理以减轻TIP的重要性。
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引用次数: 0
Educational automated manufacturing cobot work cell in conjunction with machine vision 与机器视觉相结合的教育自动化制造协作机器人工作单元
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-12-01 DOI: 10.1016/j.mfglet.2025.11.001
Richard Y. Chiou , Tzu-Liang (Bill) Tseng , Md Fashiar Rahman , Yalcin Ertekin
This paper presents the design, construction, and programming of an automated collaborative robot (cobot) work cell in conjunction with machine vision, specifically tailored for educational purposes within STEM fields. The work cell integrates various manufacturing machinery on an educational level into a cohesive learning module, providing students with a practical understanding of the operations involved in a modern manufacturing work environment. The primary objective is to offer engineering students direct exposure to integrated equipment functionalities, including a conveyor belt for part transport, a machine vision system with a photoelectric sensor array for part detection and quality assurance, a 6-degree-of-freedom cobot, and a 3D printer, which is replaceable to facilitate easy transitions between different technologies. Additionally, the project is designed to be adaptable, accommodating ongoing technological advancements and thus expanding the range of topics and experiences available to students. This setup serves as a versatile educational tool, enhancing learning experience by bridging theoretical knowledge with hands-on practice in manufacturing processes.
本文介绍了与机器视觉相结合的自动化协作机器人(cobot)工作单元的设计,构建和编程,专门为STEM领域的教育目的量身定制。工作单元在教育层面上将各种制造机械集成到一个有凝聚力的学习模块中,为学生提供对现代制造工作环境中涉及的操作的实际理解。主要目标是为工程专业学生提供直接接触集成设备功能的机会,包括用于部件运输的传送带,用于部件检测和质量保证的带有光电传感器阵列的机器视觉系统,6自由度协作机器人和3D打印机,这些都是可更换的,以便于不同技术之间的轻松转换。此外,该项目被设计为适应性强,适应不断发展的技术进步,从而扩大了学生可获得的主题和经验的范围。这种设置作为一种多功能的教育工具,通过将理论知识与制造过程中的实践联系起来,增强学习经验。
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引用次数: 0
Electropulsing-enhanced interfacial recrystallization in ultrasonic consolidation of Cu/Al heterogeneous lamellar structure 超声固结Cu/Al非均相片层结构中电脉冲增强界面再结晶
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-12-01 DOI: 10.1016/j.mfglet.2025.11.005
Yanyuan Zhou , Zhenqiang Wang , Su Zhao , Fengchun Jiang
Electropulsing was employed to assist the ultrasonic consolidation of Cu/Al heterogeneous lamellar structures, which effectively optimizes the microstructure by reducing dislocation density and facilitating recrystallization and recovery, particularly within the Al layer. Due to the relatively high electrical resistivity of aluminum and the skin effect associated with electropulsing, electrical energy was preferentially concentrated near the Al interface, thereby promoting significant grain recrystallization and enhancing the interfacial bonding strength of the Cu/Al structure.
利用电脉冲辅助Cu/Al非均相片层结构的超声固结,通过降低位错密度,促进再结晶和恢复,有效地优化了微观结构,特别是在Al层内。由于铝相对较高的电阻率和电脉冲相关的趋肤效应,电能优先集中在Al界面附近,从而促进了显著的晶粒再结晶,增强了Cu/Al结构的界面结合强度。
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引用次数: 0
Microwave-Assisted compression moulding of Flax/Bio-PBS composites using an Innovative Spring-Loaded fixture for sustainable manufacturing 微波辅助压缩成型亚麻/生物pbs复合材料使用创新的弹簧加载夹具可持续制造
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-11-22 DOI: 10.1016/j.mfglet.2025.11.006
Adil Irshad , Sunny Zafar , Himanshu Pathak , Rajneesh Sharma
This study presents a novel spring-loaded fixture for microwave-assisted compression moulding (MACM) of sustainable flax fiber-reinforced bio-based Polybutylene Succinate (bio-PBS) composites. Unlike conventional screw fixtures, the spring system ensures continuous, uniform pressure during rapid microwave curing, preventing relaxation and enhancing fiber–matrix bonding. As a result, composites exhibited superior densification and void reduction (19.50 % to 2.69 % (7.25 times)), confirmed by X-ray micro-CT. The improved consolidation yielded significantly improved mechanical properties. The optimum composite at 0.5 MPa achieved tensile strength of 76 MPa, tensile modulus of 5.75 GPa, flexural strength of 109.5 MPa, and flexural modulus of 15 GPa, improvements of 4.4, 3.3, 2.6, and 3.2 times, respectively, over conventional samples. Overall, the spring-loaded fixture offers a scalable, energy-efficient approach to producing high-performance, low-void fiber reinforced composites, advancing MACM for sustainable manufacturing.
本研究提出了一种用于可持续亚麻纤维增强生物基聚丁二酸丁酯(bio-PBS)复合材料微波辅助压缩成型(MACM)的新型弹簧加载夹具。与传统的螺丝固定装置不同,弹簧系统确保在快速微波固化过程中连续,均匀的压力,防止松弛并增强纤维基质粘合。结果,复合材料表现出优异的致密性和孔隙减少(19.50 %至2.69 %(7.25倍)),x射线显微ct证实了这一点。强化后的材料力学性能显著提高。在0.5 MPa下,最佳复合材料的抗拉强度为76 MPa,抗拉模量为5.75 GPa,抗弯强度为109.5 MPa,抗弯模量为15 GPa,分别比常规样品提高4.4倍、3.3倍、2.6倍和3.2倍。总的来说,弹簧加载夹具提供了一种可扩展的、节能的方法来生产高性能、低空隙纤维增强复合材料,推进MACM的可持续制造。
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引用次数: 0
Collaborative virtual learning factory for advanced manufacturing: investigating user experience and team dynamics 面向先进制造业的协作式虚拟学习工厂:研究用户体验和团队动态
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-11-08 DOI: 10.1016/j.mfglet.2025.11.002
Rumena Begum , Nour Hamado , Faisal Aqlan , Richard Zhao , Hui Yang , Jason Saleem , Marci DeCaro , Karen Murphy
The rapid evolution of manufacturing technologies and the demand for a skilled workforce highlight the need for innovative training methods. Traditional approaches often lack flexibility for virtual training, especially during disruptions like pandemics, and do not effectively integrate sensor-based tracking for studying problem-solving. To address these gaps, this study developed a collaborative virtual learning factory to advance manufacturing education and analyze both human–human teaming and human–machine interaction. The virtual factory simulates the physical assembly of toy cars in a virtual reality environment, reflecting manufacturing paradigms such as craft production, mass production, mass customization, and personalized production. It offers an immersive, interactive space where learners gain hands-on experience, collaborate, and build problem-solving skills. Collaborative features include a voice system for communication, team-based performance requirements, and interdependencies along the production line, fostering teamwork and communication. While the broader goal of the virtual learning factory is to support modern manufacturing training, this paper focuses specifically on evaluating usability, workload, and team collaboration as critical foundations for educational impact. A study involving 30 participants engaged them in assembly tasks within the virtual factory, while their interactions and collaboration were recorded. Data collected included physiological signals (e.g., heart rate, electrodermal activity) and performance measures such as perceived workload and system usability. Analysis revealed that higher physiological synchrony among group members was linked to better task performance, underscoring the importance of physiological alignment in team effectiveness. Additionally, a significant negative correlation (r = –.60, p < 0.05) was found between workload and system usability. Overall, this study demonstrates the potential of virtual learning factories to improve user experience by enhancing system usability and reducing cognitive workload, offering promising avenues for modern manufacturing training.
制造技术的快速发展和对熟练劳动力的需求突出了对创新培训方法的需求。传统方法通常缺乏虚拟培训的灵活性,特别是在流行病等中断期间,并且不能有效地集成基于传感器的跟踪来研究问题解决。为了解决这些差距,本研究开发了一个协作式虚拟学习工厂,以推进制造业教育,并分析人与人之间的团队合作和人机交互。虚拟工厂在虚拟现实环境中模拟玩具汽车的物理组装,反映了工艺生产、批量生产、大规模定制、个性化生产等制造范式。它提供了一个身临其境的互动空间,让学习者获得实践经验,合作,并建立解决问题的能力。协作特性包括用于通信的语音系统,基于团队的性能需求,以及沿着生产线的相互依赖性,促进团队合作和通信。虽然虚拟学习工厂更广泛的目标是支持现代制造业培训,但本文特别关注评估可用性、工作量和团队协作,将其作为教育影响的关键基础。一项涉及30名参与者的研究让他们在虚拟工厂内完成组装任务,同时记录他们的互动和协作。收集的数据包括生理信号(如心率、皮电活动)和性能指标,如感知工作量和系统可用性。分析显示,团队成员之间较高的生理同步性与更好的任务绩效有关,强调了生理一致性对团队效率的重要性。此外,显著负相关(r = -。60, p < 0.05)。总体而言,本研究证明了虚拟学习型工厂通过提高系统可用性和减少认知工作量来改善用户体验的潜力,为现代制造业培训提供了有前途的途径。
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引用次数: 0
Innovations in manufacturing education 制造业教育创新
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-11-07 DOI: 10.1016/j.mfglet.2025.11.003
John Liu (Executive Guest Editor)
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引用次数: 0
Experimental insights into aerosol jet printing on 3D curved surfaces: line morphology and resistivity 在3D曲面上的气溶胶喷射打印的实验见解:线形态和电阻率
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-11-05 DOI: 10.1016/j.mfglet.2025.10.020
Reihane Arabpoor, Azadeh Haghighi
Aerosol Jet Printing (AJP) is a versatile, non-contact technique for fabricating fine-feature electronics on various substrates, yet its application to complex 3D geometries remains underexplored. Here, we investigate how substrate curvature affects line morphology and electrical performance in AJP-printed lines. By printing on concave and convex surfaces with systematically varied slope magnitudes, and characterizing line width, thickness, overspray, and resistivity, we reveal trends in these parameters. Our findings provide one of the first quantitative insights into conformal AJP deposition, laying the groundwork for process optimization on non-planar surfaces and opening new avenues for directly integrating printed electronics on 3D parts.
气溶胶喷射打印(AJP)是一种多用途的非接触式技术,用于在各种基材上制造精细电子产品,但其在复杂3D几何形状上的应用仍未得到充分探索。在这里,我们研究了衬底曲率如何影响ajp印刷线的线形态和电性能。通过在具有系统变化坡度的凹面和凸面上打印,并表征线宽,厚度,过喷和电阻率,我们揭示了这些参数的趋势。我们的研究结果为保形AJP沉积提供了首批定量见解之一,为非平面表面的工艺优化奠定了基础,并为直接将印刷电子元件集成到3D部件上开辟了新的途径。
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引用次数: 0
Collaborative problem-solving in mixed reality manufacturing environments 混合现实制造环境中的协同解决问题
IF 2 Q3 ENGINEERING, MANUFACTURING Pub Date : 2025-10-30 DOI: 10.1016/j.mfglet.2025.10.018
Israa Azzam , Khalid Bello , Farid El Breidi , Faisal Aqlan
Extended Reality (XR) technology has shown promise in enhancing manufacturing training by providing realistic simulations in safe and controlled environments. Although many XR tools focus on single-user experiences to build individual skills, collaborative training plays a role in promoting teamwork and reinforcing production outcomes. Multi-user XR systems facilitate training on collaborative tasks and support the development of teamwork and communication skills. This study explores the use of a multi-user Mixed Reality (MR) training module in manufacturing education. The proposed MR module supports a multi-user experience, allowing trainees to work collaboratively in a shared virtual environment. The goal of this research is to assess how collaboration in MR-based training affects learning, particularly regarding how quickly tasks are completed and how effectively problems are solved. The study included 103 participants who experienced the collaborative MR module to design and assemble a hydraulic bike. The shared MR setup connected multiple HoloLens 2 headsets, allowing users to interact in the same virtual workspace and complete assigned tasks. To evaluate teamwork and problem-solving abilities, a survey focusing on team dynamics and collaboration was utilized. Participants’ experiences were also assessed using the System Usability Scale (SUS) and the Simulation Task Load Index (SIM-TLX) to understand the system usability and the mental and physical effort required during the training activity.
扩展现实(XR)技术通过在安全和受控的环境中提供逼真的模拟,在加强制造培训方面显示出了希望。尽管许多XR工具侧重于单个用户体验来培养个人技能,但协作培训在促进团队合作和加强生产成果方面发挥着重要作用。多用户XR系统促进了协作任务的培训,并支持团队合作和沟通技巧的发展。本研究探讨了多用户混合现实(MR)培训模块在制造业教育中的应用。提议的MR模块支持多用户体验,允许学员在共享的虚拟环境中协同工作。本研究的目的是评估基于核磁共振的培训中的协作如何影响学习,特别是如何快速完成任务和如何有效地解决问题。这项研究包括103名参与者,他们经历了协同磁共振模块来设计和组装液压自行车。共享的MR设置连接了多个HoloLens 2头显,允许用户在同一个虚拟工作区中交互并完成分配的任务。为了评估团队合作和解决问题的能力,我们利用了一项关于团队动力和协作的调查。参与者的体验也使用系统可用性量表(SUS)和模拟任务负荷指数(SIM-TLX)进行评估,以了解系统可用性和训练活动期间所需的精神和体力努力。
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引用次数: 0
期刊
Manufacturing Letters
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