Pub Date : 2025-08-01DOI: 10.1016/j.mfglet.2025.06.011
Wei Li , Barrie R. Nault
For one-stage production, operations management faces the following three challenges to make decisions, which are inconsistencies between key performance indicators (KPIs) for production, trade-offs between the expected return and the risk in modern portfolio theory (MPT), and uncertainties in processing times. Traditionally, total completion time (TCT) and variance of completion times (VCT) are two KPIs for one-stage production scheduling, which relate to the first and second moments of completion times, respectively. We question whether the third moment of completion times is good to address the three challenges. In this paper, we introduce the skewness of completion times (SCT) in scheduling, and propose the ToB() heuristics for trade-off balancing. Through case studies with 5 levels of processing time uncertainties and compared to existing ToB() heuristics which balance trade-offs between TCT and VCT, we show that our ToB() heuristics dominate ToB() heuristics in terms of smaller expected values (E) of weighted sum of deviations from the best solutions of KPIs and smaller risks () associated with these KPI deviations. Therefore, our ToB() heuristics are more robust to balance trade-offs between the three KPIs under processing time uncertainties.
{"title":"Balancing trade-offs between first three moments of completion times for one-stage production","authors":"Wei Li , Barrie R. Nault","doi":"10.1016/j.mfglet.2025.06.011","DOIUrl":"10.1016/j.mfglet.2025.06.011","url":null,"abstract":"<div><div>For one-stage production, operations management faces the following three challenges to make decisions, which are inconsistencies between key performance indicators (KPIs) for production, trade-offs between the expected return and the risk in modern portfolio theory (MPT), and uncertainties in processing times. Traditionally, total completion time (<em>TCT</em>) and variance of completion times (<em>VCT</em>) are two KPIs for one-stage production scheduling, which relate to the first and second moments of completion times, respectively. We question whether the third moment of completion times is good to address the three challenges. In this paper, we introduce the skewness of completion times (<em>SCT</em>) in scheduling, and propose the ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics for trade-off balancing. Through case studies with 5 levels of processing time uncertainties and compared to existing ToB(<span><math><mrow><mi>α</mi></mrow></math></span>) heuristics which balance trade-offs between <em>TCT</em> and <em>VCT</em>, we show that our ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics dominate ToB(<span><math><mrow><mi>α</mi></mrow></math></span>) heuristics in terms of smaller expected values (<em>E</em>) of weighted sum of deviations from the best solutions of KPIs and smaller risks (<span><math><mrow><mi>σ</mi></mrow></math></span>) associated with these KPI deviations. Therefore, our ToB(<span><math><mrow><mi>a</mi><mo>,</mo><mi>b</mi></mrow></math></span>) heuristics are more robust to balance trade-offs between the three KPIs under processing time uncertainties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 70-79"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926662","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.2025.06.024
Fatemeh Mozaffar, Logan Smith, Beshoy Morkos
This study investigates the application of musical and voice-based auditory nudges in enhancing human-AI interactions within a manufacturing setting, utilizing nudge theory to improve worker productivity, trust, and engagement. As AI technologies become more widespread in manufacturing environments, effective methods for fostering trust and collaboration between human operators and AI are essential. The increasing demand for customized products and rapid technological advancements in Industry 4.0 (I4.0) necessitate rapid employee adaptation, with humans playing a key role as the Human Component (HC) for its success. Therefore, the relationship between artificial intelligence (AI) and humans as inseparable parts of I4.0 need to be studied. Research has been done on improving the interaction between and performance of AI and humans. The impact of different nudge methods on worker productivity has also been studied, but not as an effective communication tool in human and AI teams. This study proposes a research framework that aims to explore using music as a medium for non-verbal cues, which has been shown to influence emotional perception and enhance task performance such as task continuity and worker productivity. This study employs a mixed-methods approach, incorporating quantitative metrics such as task completion times, alongside qualitative feedback to assess the impact of varied auditory nudges—including musical elements like tempo and pitch—on worker behavior and emotional response. Results from this experimental study will help to demonstrate the viability of musical nudges in increasing trust and efficiency in human-AI collaboration, providing insights into innovative strategies for optimizing Industry 4.0 environments.
{"title":"Tunes of trust: A framework for auditory nudges in human-ai manufacturing collaboration","authors":"Fatemeh Mozaffar, Logan Smith, Beshoy Morkos","doi":"10.1016/j.mfglet.2025.06.024","DOIUrl":"10.1016/j.mfglet.2025.06.024","url":null,"abstract":"<div><div>This study investigates the application of musical and voice-based auditory nudges in enhancing human-AI interactions within a manufacturing setting, utilizing nudge theory to improve worker productivity, trust, and engagement. As AI technologies become more widespread in manufacturing environments, effective methods for fostering trust and collaboration between human operators and AI are essential. The increasing demand for customized products and rapid technological advancements in Industry 4.0 (I4.0) necessitate rapid employee adaptation, with humans playing a key role as the Human Component (HC) for its success. Therefore, the relationship between artificial intelligence (AI) and humans as inseparable parts of I4.0 need to be studied. Research has been done on improving the interaction between and performance of AI and humans. The impact of different nudge methods on worker productivity has also been studied, but not as an effective communication tool in human and AI teams. This study proposes a research framework that aims to explore using music as a medium for non-verbal cues, which has been shown to influence emotional perception and enhance task performance such as task continuity and worker productivity. This study employs a mixed-methods approach, incorporating quantitative metrics such as task completion times, alongside qualitative feedback to assess the impact of varied auditory nudges—including musical elements like tempo and pitch—on worker behavior and emotional response. Results from this experimental study will help to demonstrate the viability of musical nudges in increasing trust and efficiency in human-AI collaboration, providing insights into innovative strategies for optimizing Industry 4.0 environments.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 195-204"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926722","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.2025.06.087
Chenyang Zhu , Rui Huang , Nian X. Sun , Xin Zhao
Silicon wafer processing is crucial in the semiconductor industry, especially in applications requiring precision through-trench fabrication. This study investigates the impact of various laser fluence, scan counts, and focal point dynamics on the trench width for both the entrance (top) and exit (bottom) surfaces using ultrafast laser machining on silicon wafers. Experiments revealed that while the trench width at the entrance remains nearly constant, the width at the exit increases with higher laser fluence and scan counts, stabilizing once a complete through-drill state is reached. Additionally, dynamic focal point strategy (step processing) experiments at laser fluences of 20 and 30 J/cm2, and total scan counts of 300 and 600 were conducted. It was found that when the scan count was below the through-drill threshold, increasing the number of steps led to a wider trench bottom. However, when the scan count exceeded the threshold, the trench width at the bottom reached its maximum at two steps and then decreased with additional steps. Furthermore, the effect of polarization direction on machining quality was assessed, showing improved trench uniformity when the polarization was perpendicular to the trench direction. These findings suggest that a 2-step processing approach, with each step meeting the through-drill scan threshold and maintaining perpendicular polarization to the trench, optimizes micro-machining quality and minimizes taper.
{"title":"Ultrafast laser micromachining of through-drill trenches in silicon wafers","authors":"Chenyang Zhu , Rui Huang , Nian X. Sun , Xin Zhao","doi":"10.1016/j.mfglet.2025.06.087","DOIUrl":"10.1016/j.mfglet.2025.06.087","url":null,"abstract":"<div><div>Silicon wafer processing is crucial in the semiconductor industry, especially in applications requiring precision through-trench fabrication. This study investigates the impact of various laser fluence, scan counts, and focal point dynamics on the trench width for both the entrance (top) and exit (bottom) surfaces using ultrafast laser machining on silicon wafers. Experiments revealed that while the trench width at the entrance remains nearly constant, the width at the exit increases with higher laser fluence and scan counts, stabilizing once a complete through-drill state is reached. Additionally, dynamic focal point strategy (step processing) experiments at laser fluences of 20 and 30 J/cm<sup>2</sup>, and total scan counts of 300 and 600 were conducted. It was found that when the scan count was below the through-drill threshold, increasing the number of steps led to a wider trench bottom. However, when the scan count exceeded the threshold, the trench width at the bottom reached its maximum at two steps and then decreased with additional steps. Furthermore, the effect of polarization direction on machining quality was assessed, showing improved trench uniformity when the polarization was perpendicular to the trench direction. These findings suggest that a 2-step processing approach, with each step meeting the through-drill scan threshold and maintaining perpendicular polarization to the trench, optimizes micro-machining quality and minimizes taper.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 746-751"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926749","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.2025.06.047
Aqib Mashood Khan, Salman Pervaiz, Muhammad Jamil, Wei Zhao, Longhui Meng
The low-temperature properties of the titanium alloy Ti17 affect the milling process. In order to better understand the various physical phenomena in the cryogenic cutting process, cryogenic impact tests and tensile tests of titanium alloy Ti17 were undertaken in this study. Based on the cryogenic performance of the material, experiments on dry milling and cryogenic milling with a liquid nitrogen jet were conducted. It was found that the strength was increased, and the toughness was decreased under cryogenic conditions. The milling force shows an increasing trend with the increase of cutting speed and feed rate under both cooling conditions. The milling forces of cryogenic conditions were higher than that of dry cutting, and the surface roughness under cryogenic conditions was also improved compared to dry cutting. This study highlights how cryogenic milling of Titanium Alloy Ti17 can improve surface roughness and mechanical strength, leading to extended tool life and reduced material waste, which contributes to sustainable manufacturing. Additionally, using cryogenic cooling minimizes the need for conventional cutting fluids, reducing environmental impact and enhancing process sustainability.
{"title":"New Investigations on the performance Enhancement of Cryogenic-LN2 assisted sustainable milling of titanium alloy","authors":"Aqib Mashood Khan, Salman Pervaiz, Muhammad Jamil, Wei Zhao, Longhui Meng","doi":"10.1016/j.mfglet.2025.06.047","DOIUrl":"10.1016/j.mfglet.2025.06.047","url":null,"abstract":"<div><div>The low-temperature properties of the titanium alloy Ti17 affect the milling process. In order to better understand the various physical phenomena in the cryogenic cutting process, cryogenic impact tests and tensile tests of titanium alloy Ti17 were undertaken in this study. Based on the cryogenic performance of the material, experiments on dry milling and cryogenic milling with a liquid nitrogen jet were conducted. It was found that the strength was increased, and the toughness was decreased under cryogenic conditions. The milling force shows an increasing trend with the increase of cutting speed and feed rate under both cooling conditions. The milling forces of cryogenic conditions were higher than that of dry cutting, and the surface roughness under cryogenic conditions was also improved compared to dry cutting. This study highlights how cryogenic milling of Titanium Alloy Ti17 can improve surface roughness and mechanical strength, leading to extended tool life and reduced material waste, which contributes to sustainable manufacturing. Additionally, using cryogenic cooling minimizes the need for conventional cutting fluids, reducing environmental impact and enhancing process sustainability.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 396-404"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926605","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.2025.06.049
Nithya Srimurugan , Sathyan Subbiah
In-situ resource utilization is important to ensure sustainability of exploration missions such as establishing a habitable extra-terrestrial base on the moon. Resources available on the lunar surface such as the regolith must be tapped to build structures and manufacture products on moon. This requires raw materials like metals, metal alloys and ceramics to be extracted from the regolith. Regolith contains silicon as an abundant element next to oxygen, and hence synthesis of silicon and its compounds seems pragmatic. Therefore, the objective of this study is to extract silicon carbide (SiC) from lunar regolith which has a wide range of applications in producing abrasives, electronics and ceramic components. The methodology involves heating the regolith to a high temperature so that volatile species such as Na, K, Fe, SiO are liberated and subsequently, the evolved SiO gases are reduced to SiC by using methane. This resulted in the formation of SiC whiskers which are verified by X-ray diffraction and Raman spectroscopy. Electron microscopy images reveal that the majority of the SiC whiskers are formed by vapor–liquid-solid mechanisms with diameters ranging from 0.3 to 2 µm. Detailed electron diffraction and microscopy studies reveal that the whiskers formed are single crystals having a core–shell structure containing SiC and SiOx respectively. This study provides a foundation for the direct manufacturing of SiC whiskers from lunar regolith which can be used for fabricating electronic devices, construction materials, radiation shields and habitats on the surface of moon.
{"title":"Carbo-thermal reduction of lunar highland regolith simulant for in-situ manufacturing of SiC","authors":"Nithya Srimurugan , Sathyan Subbiah","doi":"10.1016/j.mfglet.2025.06.049","DOIUrl":"10.1016/j.mfglet.2025.06.049","url":null,"abstract":"<div><div>In-situ resource utilization is important to ensure sustainability of exploration missions such as establishing a habitable extra-terrestrial base on the moon. Resources available on the lunar surface such as the regolith must be tapped to build structures and manufacture products on moon. This requires raw materials like metals, metal alloys and ceramics to be extracted from the regolith. Regolith contains silicon as an abundant element next to oxygen, and hence synthesis of silicon and its compounds seems pragmatic. Therefore, the objective of this study is to extract silicon carbide (SiC) from lunar regolith which has a wide range of applications in producing abrasives, electronics and ceramic components. The methodology involves heating the regolith to a high temperature so that volatile species such as Na, K, Fe, SiO are liberated and subsequently, the evolved SiO gases are reduced to SiC by using methane. This resulted in the formation of SiC whiskers which are verified by X-ray diffraction and Raman spectroscopy. Electron microscopy images reveal that the majority of the SiC whiskers are formed by vapor–liquid-solid mechanisms with diameters ranging from 0.3 to 2 µm. Detailed electron diffraction and microscopy studies reveal that the whiskers formed are single crystals having a core–shell structure containing SiC and SiO<sub>x</sub> respectively. This study provides a foundation for the direct manufacturing of SiC whiskers from lunar regolith which can be used for fabricating electronic devices, construction materials, radiation shields and habitats on the surface of moon.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 416-423"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926607","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.2025.06.051
Jake Dvorak, Tony Schmitz
Metrology grade structured light scanning has been established as an effective non-contact measurement method for dimensional analysis of complex components at standard temperatures. Initial efforts have demonstrated the use of custom structured light systems for measurements of forgings and at elevated temperature environments. However, little work has been done to evaluate the performance of metrology grade structured light systems at elevated temperatures. This paper provides a performance baseline for a commercially available ZEISS ATOS Q structured light system using a calibrated gage block at elevated temperatures. Results show that the measured length of the gage block matches that of simulated lengths using a temperature-dependent coefficient of thermal expansion taken from handbook data. These results motivate the use of structured light scanning for measurements in forging and other elevated temperature manufacturing applications.
{"title":"Elevated temperature structured light scanning for in situ monitoring of forging dies","authors":"Jake Dvorak, Tony Schmitz","doi":"10.1016/j.mfglet.2025.06.051","DOIUrl":"10.1016/j.mfglet.2025.06.051","url":null,"abstract":"<div><div>Metrology grade structured light scanning has been established as an effective non-contact measurement method for dimensional analysis of complex components at standard temperatures. Initial efforts have demonstrated the use of custom structured light systems for measurements of forgings and at elevated temperature environments. However, little work has been done to evaluate the performance of metrology grade structured light systems at elevated temperatures. This paper provides a performance baseline for a commercially available ZEISS ATOS Q structured light system using a calibrated gage block at elevated temperatures. Results show that the measured length of the gage block matches that of simulated lengths using a temperature-dependent coefficient of thermal expansion taken from handbook data. These results motivate the use of structured light scanning for measurements in forging and other elevated temperature manufacturing applications.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 430-433"},"PeriodicalIF":2.0,"publicationDate":"2025-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144926609","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}
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}
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