Pub Date : 2024-10-01DOI: 10.1016/j.mfglet.2024.09.091
Stephanie B. Lawson, Milad Ghayoor, Xianzhe Fu, Ali Tabei, Andy Fan, Somayeh Pasebani
Microstructural evolution of materials under specified process conditions and parameters can be predicted by thermal modeling of additive manufacturing laser processes. The objective of this study was to develop, analyze and compare two methods for prediction: an analytical method and a numerical method for laser processing of Inconel 625 material. These methods were compared with experimental results for thermal profiling, and the effect of thermal profiles on microstructure of the experimental samples was explored. Maximum temperature and cooling rate of the numerical method were shown in good agreement, while the analytical method proved more challenging when compared to the experimental results for three laser parameters. Cooling curves were correlated with microstructure in terms of grain size, morphology, and orientation, with findings trending with parameter adjustments. This research supports the numerical modeling approach as a method for examining optimal laser processing conditions for Inconel 625 that is ideally suited for complex fluid flow analyses.
{"title":"Thermal profile modeling and microstructural evolution in laser processing of Inconel 625 plates by comparison of analytical and numerical methods","authors":"Stephanie B. Lawson, Milad Ghayoor, Xianzhe Fu, Ali Tabei, Andy Fan, Somayeh Pasebani","doi":"10.1016/j.mfglet.2024.09.091","DOIUrl":"10.1016/j.mfglet.2024.09.091","url":null,"abstract":"<div><div>Microstructural evolution of materials under specified process conditions and parameters can be predicted by thermal modeling of additive manufacturing laser processes. The objective of this study was to develop, analyze and compare two methods for prediction: an analytical method and a numerical method for laser processing of Inconel 625 material. These methods were compared with experimental results for thermal profiling, and the effect of thermal profiles on microstructure of the experimental samples was explored. Maximum temperature and cooling rate of the numerical method were shown in good agreement, while the analytical method proved more challenging when compared to the experimental results for three laser parameters. Cooling curves were correlated with microstructure in terms of grain size, morphology, and orientation, with findings trending with parameter adjustments. This research supports the numerical modeling approach as a method for examining optimal laser processing conditions for Inconel 625 that is ideally suited for complex fluid flow analyses.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 730-741"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434370","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.2024.09.014
Sean Wagner, John Agapiou
An optical non-contact inspection system was developed for measuring the slots in stator lamination stacks. To avoid passing go/no-go gage blocks through the slots, a machine vision system is instead used to measure the stator core slots and identify the presence of burrs within the slots. Utilizing telecentric optics along with an alignment monitoring system configured to monitor and orient the stator core, the core slots can be oriented relative to the imaging axis for further metrology measurements. Among these measurements, the smallest opening dimensions (slot width and depth) of each slot due to misalignment of laminations and the detection of burrs along the edges of the slots throughout the length of the lamination stack are critical for full stator assembly. Advanced image processing algorithms were developed to obtain sub-pixel accuracy which is required to measure the slots. This, used in conjunction with a robust vision calibration technique, increases the feasibility of building a device that can be implemented as a production inspection system. Experiments show the reliability of the computer vision approach and how it can be used in the inspection of slots in lamination stacks.
{"title":"Optical inspection of stator slots for electric motors","authors":"Sean Wagner, John Agapiou","doi":"10.1016/j.mfglet.2024.09.014","DOIUrl":"10.1016/j.mfglet.2024.09.014","url":null,"abstract":"<div><div>An optical non-contact inspection system was developed for measuring the slots in stator lamination stacks. To avoid passing go/no-go gage blocks through the slots, a machine vision system is instead used to measure the stator core slots and identify the presence of burrs within the slots. Utilizing telecentric optics along with an alignment monitoring system configured to monitor and orient the stator core, the core slots can be oriented relative to the imaging axis for further metrology measurements. Among these measurements, the smallest opening dimensions (slot width and depth) of each slot due to misalignment of laminations and the detection of burrs along the edges of the slots throughout the length of the lamination stack are critical for full stator assembly. Advanced image processing algorithms were developed to obtain sub-pixel accuracy which is required to measure the slots. This, used in conjunction with a robust vision calibration technique, increases the feasibility of building a device that can be implemented as a production inspection system. Experiments show the reliability of the computer vision approach and how it can be used in the inspection of slots in lamination stacks.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 103-112"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434344","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.2024.09.018
J. Patrick Spicer , Debejyo Chakraborty , Michael Wincek , Jeffrey Abell
Product technologies are changing rapidly in advanced automotive propulsion systems. These products are driving the need for new manufacturing processes and new inspection methods. To keep new propulsion systems affordable and ensure these new products are introduced with high quality, automotive manufacturers are seeking automated inspection solutions with low cost and near-zero error rates to inspect 100% of the items. In this paper, a progressive deployment strategy of a hybrid inspection system is presented and studied in the context of technology development and rapid deployment. It enabled us to begin with human inspection and gradually phase-in automated inspection technology, while almost never failing to identify a bad item. This strategy was applied successfully to inspect ultrasonic welds in lithium ion battery packs. At the time of this study, a 75% reduction in human inspection was achieved with prospects for further reduction. Actual results from the implementation of this strategy in production are presented. Recommendations are made regarding the most appropriate time to employ this strategy and how it could increase the use of advanced automated in-line inspection technologies.
{"title":"Implementation strategy for launch and performance improvement of high throughput manufacturing inspection systems","authors":"J. Patrick Spicer , Debejyo Chakraborty , Michael Wincek , Jeffrey Abell","doi":"10.1016/j.mfglet.2024.09.018","DOIUrl":"10.1016/j.mfglet.2024.09.018","url":null,"abstract":"<div><div>Product technologies are changing rapidly in advanced automotive propulsion systems. These products are driving the need for new manufacturing processes and new inspection methods. To keep new propulsion systems affordable and ensure these new products are introduced with high quality, automotive manufacturers are seeking automated inspection solutions with low cost and near-zero error rates to inspect 100% of the items. In this paper, a progressive deployment strategy of a hybrid inspection system is presented and studied in the context of technology development and rapid deployment. It enabled us to begin with human inspection and gradually phase-in automated inspection technology, while almost never failing to identify a bad item. This strategy was applied successfully to inspect ultrasonic welds in lithium ion battery packs. At the time of this study, a 75% reduction in human inspection was achieved with prospects for further reduction. Actual results from the implementation of this strategy in production are presented. Recommendations are made regarding the most appropriate time to employ this strategy and how it could increase the use of advanced automated in-line inspection technologies.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 143-152"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434348","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.2024.09.024
Liwen Hu , Baihui Chen , ElHussein Shata , Shashank Shekhar , Charif Mahmoudi , Ivan Seskar , Qingze Zou , Y.B. Guo
5G monitoring holds immense potential for revolutionizing manufacturing processes by enabling real-time data transmission, remote control, enhanced quality control, and increased efficiency. However, it also presents challenges related to 5G monitoring infrastructure. To explore 5G’s potential for process monitoring, this study introduces a novel 5G-enabled architecture designed to address the challenges, enhancing the process monitoring’s efficiency, accuracy, and reliability in the case of milling operation. To investigate the feasibility of this sophisticated 5G network for process monitoring, two testbeds, i.e., the 5G robotic milling testbed and the 5G CNC milling testbed, have been developed. An accelerometer and a laser scanner have been retrofitted with 5G communications capability to capture critical process signals in the testbeds, respectively. It has shown that the sensor data can be upstreamed to a 5G edge server for data analytics and visualization in ultra-low latency. This work highlights the transformative impact of 5G communication on process monitoring for time-critical manufacturing.
{"title":"Feasibility of 5G-enabled process monitoring in milling operations","authors":"Liwen Hu , Baihui Chen , ElHussein Shata , Shashank Shekhar , Charif Mahmoudi , Ivan Seskar , Qingze Zou , Y.B. Guo","doi":"10.1016/j.mfglet.2024.09.024","DOIUrl":"10.1016/j.mfglet.2024.09.024","url":null,"abstract":"<div><div>5G monitoring holds immense potential for revolutionizing manufacturing processes by enabling real-time data transmission, remote control, enhanced quality control, and increased efficiency. However, it also presents challenges related to 5G monitoring infrastructure. To explore 5G’s potential for process monitoring, this study introduces a novel 5G-enabled architecture designed to address the challenges, enhancing the process monitoring’s efficiency, accuracy, and reliability in the case of milling operation. To investigate the feasibility of this sophisticated 5G network for process monitoring, two testbeds, i.e., the 5G robotic milling testbed and the 5G CNC milling testbed, have been developed. An accelerometer and a laser scanner have been retrofitted with 5G communications capability to capture critical process signals in the testbeds, respectively. It has shown that the sensor data can be upstreamed to a 5G edge server for data analytics and visualization in ultra-low latency. This work highlights the transformative impact of 5G communication on process monitoring for time-critical manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 200-207"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434272","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.2024.09.045
Chi Wang, Yingge Zhou
Fabricating internal vascular networks within a hydrogel scaffold is essential for facilitating the supply of nutrients, oxygen, and metabolism exchange required by the encapsulated cells. The challenges in current hydrogel scaffold fabrication involve the difficulty of building adequate internal channels, poor scaffold geometry precision, and low cell viability caused by the fabrication process and polymer material properties. Stereolithography (SLA) stands out as a 3D printing technique distinguished by its superior production efficiency, advanced precision, and remarkable resolution in crafting intricate custom geometries. These attributes establish it as an innovative approach for templates in scaffold fabrication, potentially surpassing the fused deposition modeling (FDM)-based template strategy. Meanwhile, it exerts less shear stress on the cells compared to the direct bioprinting process. This novel strategy enables the fabrication of hydrogel vascular structure within the precision of 500 µm in both channel diameter and wall thickness. In this paper, various sodium alginate and collagen (SA-Col) composite hydrogels with varying collagen concentrations have been investigated to identify the optimal ratio for fabricating hydrogel scaffolds with channels.
{"title":"Stereolithography-assisted sodium alginate-collagen hydrogel scaffold with molded internal channels","authors":"Chi Wang, Yingge Zhou","doi":"10.1016/j.mfglet.2024.09.045","DOIUrl":"10.1016/j.mfglet.2024.09.045","url":null,"abstract":"<div><div>Fabricating internal vascular networks within a hydrogel scaffold is essential for facilitating the supply of nutrients, oxygen, and metabolism exchange required by the encapsulated cells. The challenges in current hydrogel scaffold fabrication involve the difficulty of building adequate internal channels, poor scaffold geometry precision, and low cell viability caused by the fabrication process and polymer material properties. Stereolithography (SLA) stands out as a 3D printing technique distinguished by its superior production efficiency, advanced precision, and remarkable resolution in crafting intricate custom geometries. These attributes establish it as an innovative approach for templates in scaffold fabrication, potentially surpassing the fused deposition modeling (FDM)-based template strategy. Meanwhile, it exerts less shear stress on the cells compared to the direct bioprinting process. This novel strategy enables the fabrication of hydrogel vascular structure within the precision of 500 µm in both channel diameter and wall thickness. In this paper, various sodium alginate and collagen (SA-Col) composite hydrogels with varying collagen concentrations have been investigated to identify the optimal ratio for fabricating hydrogel scaffolds with channels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 375-383"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434248","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.2024.09.046
Pardeep Pankaj , Pankaj Biswas , Dave Kim
The present study expanded the scientific comprehension of the friction stir welding process for dissimilar steels, namely high-strength shipbuilding grade DH36 steel and UNS G10080 steel. The effect of tool traverse speed and plunge depth on temperature history, microstructure characteristics, and mechanical properties is investigated experimentally. The metallographic characterizations were examined through an optical microscope and field emission scanning electron microscopy equipped with an energy-dispersive X-ray system. Microhardness, impact, and tensile tests were carried out on the friction-stir-welded specimens. Increasing the plunge depth and reducing the traversal speed resulted in an augmentation of the peak temperature, primarily attributable to higher heat generation. Within the range of process parameters used, the tool produced complex material movement, resulting in swirl-like and vortex-intercalated features, particularly adjacent to the stir zone/workpiece interface. These vortex-like features exhibited dynamically recrystallized fine-grained microstructures. The grain size in the stir zone and the thermo-mechanically affected zone is reduced by increasing the plunge depth and decreasing the traverse speed due to enhanced dynamic recrystallization, subsequently improving the hardness and toughness values. In the stir zone, the microstructure revealed the acicular-shaped bainite ferrite in the DH36 steel and the Widmanstatten ferrite in the UNS G10080 steel. The microhardness contours revealed the uneven hardness distribution across the weld cross-section due to the microstructural heterogeneity in the dissimilar steels. The maximum welding efficiency of 106 % and toughness of 46 J are obtained at 40 mm/min traverse speed with a plunge depth of 0.2 mm, which is attributed to sufficient heat generation and grain refinement.
本研究拓展了对异种钢（即高强度造船级 DH36 钢和 UNS G10080 钢）搅拌摩擦焊接工艺的科学理解。实验研究了工具移动速度和切入深度对温度历史、微观结构特征和机械性能的影响。金相特征通过光学显微镜和配备能量色散 X 射线系统的场发射扫描电子显微镜进行了检查。对摩擦搅拌焊接试样进行了显微硬度、冲击和拉伸试验。增加切入深度和降低横移速度导致峰值温度升高，这主要归因于发热量增加。在所使用的工艺参数范围内，工具产生了复杂的材料运动，形成了漩涡状和涡流交错的特征，尤其是在搅拌区/工件界面附近。这些漩涡状特征表现出动态再结晶的细粒微结构。由于动态再结晶的增强，通过增加切入深度和降低横移速度，可减小搅拌区和热机械影响区的晶粒尺寸，从而提高硬度和韧性值。在搅拌区，显微组织显示 DH36 钢中存在针状贝氏体铁素体，而 UNS G10080 钢中存在维德曼铁素体。显微硬度轮廓显示，由于异种钢的显微结构异质性，整个焊接截面的硬度分布不均匀。在横移速度为 40 mm/min、切入深度为 0.2 mm 时，焊接效率达到 106 %，韧性达到 46 J，这归功于充分的发热和晶粒细化。
{"title":"Metallurgical characteristics and mechanical properties of dissimilar friction stir welded DH36 steel and UNS G10080 steel joints","authors":"Pardeep Pankaj , Pankaj Biswas , Dave Kim","doi":"10.1016/j.mfglet.2024.09.046","DOIUrl":"10.1016/j.mfglet.2024.09.046","url":null,"abstract":"<div><div>The present study expanded the scientific comprehension of the friction stir welding process for dissimilar steels, namely high-strength shipbuilding grade DH36 steel and UNS G10080 steel. The effect of tool traverse speed and plunge depth on temperature history, microstructure characteristics, and mechanical properties is investigated experimentally. The metallographic characterizations were examined through an optical microscope and field emission scanning electron microscopy equipped with an energy-dispersive X-ray system. Microhardness, impact, and tensile tests were carried out on the friction-stir-welded specimens. Increasing the plunge depth and reducing the traversal speed resulted in an augmentation of the peak temperature, primarily attributable to higher heat generation. Within the range of process parameters used, the tool produced complex material movement, resulting in swirl-like and vortex-intercalated features, particularly adjacent to the stir zone/workpiece interface. These vortex-like features exhibited dynamically recrystallized fine-grained microstructures. The grain size in the stir zone and the thermo-mechanically affected zone is reduced by increasing the plunge depth and decreasing the traverse speed due to enhanced dynamic recrystallization, subsequently improving the hardness and toughness values. In the stir zone, the microstructure revealed the acicular-shaped bainite ferrite in the DH36 steel and the Widmanstatten ferrite in the UNS G10080 steel. The microhardness contours revealed the uneven hardness distribution across the weld cross-section due to the microstructural heterogeneity in the dissimilar steels. The maximum welding efficiency of 106 % and toughness of 46 J are obtained at 40 mm/min traverse speed with a plunge depth of 0.2 mm, which is attributed to sufficient heat generation and grain refinement.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 384-394"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434252","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.2024.09.019
Emmanuel Olorundaisi , Bukola J. Babalola , Ufoma S. Anamu , Moipone L. Teffo , Ngeleshi Michel Kibambe , Anthony O. Ogunmefun , Peter Odetola , Peter A. Olubambi
In recent years, the pursuit of cutting-edge materials has intensified, with a focus on affordability, lightweight characteristics, and exceptional performance under high-temperature conditions, to serve as alternatives to Ni-base superalloys and other conventional alloys. Potential materials suitable for high-temperature structural applications with lightweight characteristics are intermetallics such as NiAl, and TiAl, but pose numerous fabrication challenges and poor ductility behaviour at room temperature. In view of this, a novel Ni25Al25Co15Fe15 Mn8Ti7Cr5 high entropy alloy (HEA) was fabricated using spark plasma sintering (SPS). The alloy was developed at a sintering temperature of 850 °C, a heating rate of 90 °C/min, a pressure of 50 MPa, and a dwelling time of 5 min. X-ray diffraction, scanning electron microscopy, and Vickers hardness tester were used to investigate the phase formation, microstructure, and mechanical properties of the HEA, respectively. The microstructure of the sintered HEA shows a homogenous dispersion of the alloying metals. The sintered microstructures showed a mixture of simple and complex phases. The grain size analysis shows that the sintered HEA exhibited a lower grain size of 2.28 µm and a refined crystallite size of 3.159 µm. The microhardness value and relative density of the sintered HEA are 135.8 HV and 99.56 %, respectively.
近年来，人们对尖端材料的追求不断加强，重点关注材料的经济性、轻质特性以及在高温条件下的优异性能，以替代镍基超级合金和其他传统合金。适合高温结构应用且具有轻质特性的潜在材料是镍铝和钛铝等金属间化合物，但它们在制造方面存在诸多挑战，而且在室温下延展性能较差。有鉴于此，一种新型 Ni25Al25Co15Fe15 Mn8Ti7Cr5 高熵合金（HEA）采用火花等离子烧结（SPS）技术制成。该合金的烧结温度为 850 °C，加热速度为 90 °C/分钟，压力为 50 兆帕，停留时间为 5 分钟。利用 X 射线衍射、扫描电子显微镜和维氏硬度计分别研究了 HEA 的相形成、微观结构和机械性能。烧结 HEA 的微观结构显示出合金金属的均匀分散。烧结微结构显示出简单相和复杂相的混合。晶粒度分析表明，烧结 HEA 的晶粒度较低，为 2.28 µm，晶粒度较细，为 3.159 µm。烧结 HEA 的显微硬度值和相对密度分别为 135.8 HV 和 99.56 %。
{"title":"Phase formation and mechanical analysis of sintered Ni25Al25Co15Fe15Mn8Ti7Cr5 high entropy alloy","authors":"Emmanuel Olorundaisi , Bukola J. Babalola , Ufoma S. Anamu , Moipone L. Teffo , Ngeleshi Michel Kibambe , Anthony O. Ogunmefun , Peter Odetola , Peter A. Olubambi","doi":"10.1016/j.mfglet.2024.09.019","DOIUrl":"10.1016/j.mfglet.2024.09.019","url":null,"abstract":"<div><div>In recent years, the pursuit of cutting-edge materials has intensified, with a focus on affordability, lightweight characteristics, and exceptional performance under high-temperature conditions, to serve as alternatives to Ni-base superalloys and other conventional alloys. Potential materials suitable for high-temperature structural applications with lightweight characteristics are intermetallics such as NiAl, and TiAl, but pose numerous fabrication challenges and poor ductility behaviour at room temperature. In view of this, a novel Ni<sub>25</sub>Al<sub>25</sub>Co<sub>15</sub>Fe<sub>15</sub> Mn<sub>8</sub>Ti<sub>7</sub>Cr<sub>5</sub> high entropy alloy (HEA) was fabricated using spark plasma sintering (SPS). The alloy was developed at a sintering temperature of 850 °C, a heating rate of 90 °C/min, a pressure of 50 MPa, and a dwelling time of 5 min. X-ray diffraction, scanning electron microscopy, and Vickers hardness tester were used to investigate the phase formation, microstructure, and mechanical properties of the HEA, respectively. The microstructure of the sintered HEA shows a homogenous dispersion of the alloying metals. The sintered microstructures showed a mixture of simple and complex phases. The grain size analysis shows that the sintered HEA exhibited a lower grain size of 2.28 µm and a refined crystallite size of 3.159 µm. The microhardness value and relative density of the sintered HEA are 135.8 HV and 99.56 %, respectively.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 153-159"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434349","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.2024.09.020
Emmanuel Olorundaisi , Bukola J Babalola , Ufoma S. Anamu , Moipone L. Teffo , Ngeleshi M. Kibambe , Anthony O. Ogunmefun , Peter Odetola , Peter A. Olubambi
This study focuses on predicting phases and thermo-mechanical properties of NiAl-Ti-Mn-Co-Fe-Cr High Entropy Alloys (HEAs) using THERMOCALC software version 2021b with the TCHEA5 HEAs database. The thermodynamic simulation was used to investigate the phase formation and total hardness of the HEAs. The thermodynamic simulation result shows the presence of three major phases at room temperature, namely, BCC, SIGMA, and HEUSLER phases, with the BCC having a higher percentage of volume fraction of 62.4%. The activity of all components at high temperatures was studied, and the study shows Ni and Al to be stable at high temperatures, implying excellent mechanical properties are expected at high temperatures. The predicted total hardness is given as 96.2 HV.
{"title":"Thermo-mechanical and phase prediction of Ni25Al25Co14Fe14Ti9Mn8Cr5 high entropy alloys system using THERMO-CALC","authors":"Emmanuel Olorundaisi , Bukola J Babalola , Ufoma S. Anamu , Moipone L. Teffo , Ngeleshi M. Kibambe , Anthony O. Ogunmefun , Peter Odetola , Peter A. Olubambi","doi":"10.1016/j.mfglet.2024.09.020","DOIUrl":"10.1016/j.mfglet.2024.09.020","url":null,"abstract":"<div><div>This study focuses on predicting phases and thermo-mechanical properties of NiAl-Ti-Mn-Co-Fe-Cr High Entropy Alloys (HEAs) using THERMOCALC software version 2021b with the TCHEA5 HEAs database. The thermodynamic simulation was used to investigate the phase formation and total hardness of the HEAs. The thermodynamic simulation result shows the presence of three major phases at room temperature, namely, BCC, SIGMA, and HEUSLER phases, with the BCC having a higher percentage of volume fraction of 62.4%. The activity of all components at high temperatures was studied, and the study shows Ni and Al to be stable at high temperatures, implying excellent mechanical properties are expected at high temperatures. The predicted total hardness is given as 96.2 HV.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 160-169"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434350","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}
Additive manufacturing (AM), such as directed energy deposition (DED), enables fabrication of complex geometries for critical parts at near-net shape, but creates a need for post-processing to achieve desired geometry and performance. In particular, parts made using DED are sometimes printed with a high initial surface roughness, requiring post-processing to meet application-dependent requirements. Magnetic field-assisted finishing (MAF), in which a magnetic polishing tool is manipulated by magnetic force and generates relative motion against a target surface, has been applied to smooth AM parts. An advantage of MAF is that the magnetically manipulated polishing tools can finish both external part surfaces and part interiors. In this paper, an oscillating magnetic polishing tool is proposed to smooth the inner surfaces of rectangular NASA HR-1 alloy channels made using DED. Because effective tool motion allows reduction of surface roughness and waviness, parameters that control polishing-tool motion are of great interest. This paper describes three parameters that control polishing-tool motion: number of polishing tools, magnetic field, and abrasive slurry. The effects of tool motion on the polishing characteristics are demonstrated, showing that the roughness of the interior channel surface can be reduced from several tens of micron to a sub-micron level.
增材制造（AM），如定向能沉积（DED），能以接近净形的方式制造复杂几何形状的关键零件，但需要进行后处理，以实现所需的几何形状和性能。特别是，使用定向能沉积技术制造的零件有时会打印出较高的初始表面粗糙度，这就需要进行后处理，以满足与应用相关的要求。磁场辅助精加工（MAF）是通过磁力操纵磁性抛光工具，使其产生与目标表面的相对运动，已被应用于光滑的 AM 零件。磁场辅助抛光的优点是磁力操纵的抛光工具既能抛光零件外表面，也能抛光零件内部。本文提出了一种摆动磁性抛光工具，用于平滑使用 DED 制作的矩形 NASA HR-1 合金通道的内表面。由于有效的工具运动可以减少表面粗糙度和波纹，因此控制抛光工具运动的参数非常重要。本文介绍了控制抛光工具运动的三个参数：抛光工具数量、磁场和研磨浆。结果表明，抛光工具运动对抛光特性的影响可以将通道内表面的粗糙度从几十微米降低到亚微米级。
{"title":"Characterization of oscillatory magnetic field-assisted finishing of directed energy deposition NASA HR-1 integral channels","authors":"Kateland Hutt , Justin Rietberg , Paul Gradl , Hitomi Yamaguchi","doi":"10.1016/j.mfglet.2024.09.085","DOIUrl":"10.1016/j.mfglet.2024.09.085","url":null,"abstract":"<div><div>Additive manufacturing (AM), such as directed energy deposition (DED), enables fabrication of complex geometries for critical parts at near-net shape, but creates a need for post-processing to achieve desired geometry and performance. In particular, parts made using DED are sometimes printed with a high initial surface roughness, requiring post-processing to meet application-dependent requirements. Magnetic field-assisted finishing (MAF), in which a magnetic polishing tool is manipulated by magnetic force and generates relative motion against a target surface, has been applied to smooth AM parts. An advantage of MAF is that the magnetically manipulated polishing tools can finish both external part surfaces and part interiors. In this paper, an oscillating magnetic polishing tool is proposed to smooth the inner surfaces of rectangular NASA HR-1 alloy channels made using DED. Because effective tool motion allows reduction of surface roughness and waviness, parameters that control polishing-tool motion are of great interest. This paper describes three parameters that control polishing-tool motion: number of polishing tools, magnetic field, and abrasive slurry. The effects of tool motion on the polishing characteristics are demonstrated, showing that the roughness of the interior channel surface can be reduced from several tens of micron to a sub-micron level.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 670-678"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434357","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.2024.09.029
Xuepeng Jiang, Pengyu Zhang, Hantang Qin
Electrohydrodynamic inkjet printing enables high-resolution patterning for nano features. In-flight dynamics of EHD inkjet printing play an essential role in the quality control of printing results. We applied a laser diffraction/scattering in-situ analyzing setup for the EHD inkjet printing system to replace the zoom lens and high-speed camera imaging system. In contrast to conventional imaging systems, the laser diffraction/scattering system is based on analyzing the diffraction pattern and scattering intensity, respectively, which provided higher resolution for micro-scale jetting measurement and enabled sub-micron level jetting correlation between the voltage applied to the electrode and printing results. Furthermore, Taylor cone information from the nozzle head could also be analyzed in real-time to make adjustments to the printing process. In this work, we successfully validated the feasibility of laser diffraction analysis in-situ monitoring for EHD inkjet printing at micron and sub-micron levels.
{"title":"A qualitative validation of an in-situ monitoring system for EHD inkjet printing via laser diffraction","authors":"Xuepeng Jiang, Pengyu Zhang, Hantang Qin","doi":"10.1016/j.mfglet.2024.09.029","DOIUrl":"10.1016/j.mfglet.2024.09.029","url":null,"abstract":"<div><div>Electrohydrodynamic inkjet printing enables high-resolution patterning for nano features. In-flight dynamics of EHD inkjet printing play an essential role in the quality control of printing results. We applied a laser diffraction/scattering in-situ analyzing setup for the EHD inkjet printing system to replace the zoom lens and high-speed camera imaging system. In contrast to conventional imaging systems, the laser diffraction/scattering system is based on analyzing the diffraction pattern and scattering intensity, respectively, which provided higher resolution for micro-scale jetting measurement and enabled sub-micron level jetting correlation between the voltage applied to the electrode and printing results. Furthermore, Taylor cone information from the nozzle head could also be analyzed in real-time to make adjustments to the printing process. In this work, we successfully validated the feasibility of laser diffraction analysis in-situ monitoring for EHD inkjet printing at micron and sub-micron levels.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"41 ","pages":"Pages 248-252"},"PeriodicalIF":1.9,"publicationDate":"2024-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434277","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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