International Journal of Lightweight Materials and Manufacture最新文献

Removal notice to “Design, Analysis and Development of Prosthetic and Orthotic elements by Additive Manufacturing process” [Int. J. Lightweight Mater. Manuf. 8 (2025) 205–227] 关于“用增材制造工艺设计、分析和开发假肢和矫形元件”的删除通知[j]。轻质材料。第8号（2025）205-227]

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2026-01-01 DOI: 10.1016/j.ijlmm.2025.11.002

Piyush Patel, Piyush Gohil

引用次数: 0

Experimental study on helical milling of blind holes in Carbon Fiber Reinforced Polymer 碳纤维增强聚合物盲孔螺旋铣削试验研究

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-11-01 DOI: 10.1016/j.ijlmm.2025.07.005

Anyuan Jiao , Enyang Lu , Wanshun Zhang , Xue Li

Machining high-quality blind holes in Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges due to its anisotropic structure, abrasive fibers, and susceptibility to defects such as delamination and fiber pullout. This study explores the application of helical milling technology for CFRP blind hole fabrication, which enhances machining quality by reducing cutting forces and improving surface integrity. Kinematic analysis and simulation of the helical toolpath are conducted using MATLAB to reveal the bottom surface formation process. Finite element analysis via ABAQUS is performed to evaluate the stress, strain, and cutting force behavior during milling. A three-factor, five-level Central Composite Design (CCD) based on Response Surface Methodology (RSM) is designed to optimize key parameters, including spindle speed, axial cutting depth per revolution, and feed rate. Quality indicators such as maximum inlet tear, bottom surface roughness, and hole diameter accuracy are evaluated. The results show that helical milling combined with RSM-based parameter optimization significantly improves blind hole machining quality and precision, providing theoretical and practical references for the manufacturing of CFRP precision components in aerospace and other fields.

由于碳纤维增强聚合物（CFRP）的各向异性结构、磨损性纤维以及易受分层和纤维拔出等缺陷的影响，加工高质量的盲孔面临着巨大的挑战。本研究探讨了螺旋铣削技术在CFRP盲孔加工中的应用，通过减小切削力和提高表面完整性来提高加工质量。利用MATLAB对螺旋刀具轨迹进行了运动学分析和仿真，揭示了底表面形成过程。通过ABAQUS进行有限元分析，以评估铣削过程中的应力、应变和切削力行为。设计了一种基于响应面法（RSM）的三因素五层次中心复合设计（CCD），优化了主轴转速、每转轴向切削深度和进给速度等关键参数。质量指标，如最大进口撕裂，底部表面粗糙度和孔径精度进行评估。结果表明，螺旋铣削结合基于rsm的参数优化可显著提高盲孔加工质量和精度，为航空航天等领域CFRP精密部件的制造提供理论和实践参考。

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引用次数: 0

Investigation of dielectric properties and shore hardness of 3D-printed PLA core sandwich disc with functional ceramics surface cladding 表面包覆功能陶瓷的3d打印PLA芯夹芯盘介电性能及邵氏硬度研究

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-11-01 DOI: 10.1016/j.ijlmm.2025.06.003

Senthil Murugan S , Subhaschandra Kattimani , Nitesh Bharadwaj

Poly-lactic acid (PLA), a popular biodegradable polymer for 3D printing, has limited dielectric strength and surface hardness, restricting its use in advanced electronic and structural applications. Existing enhancement methods are often complex or yield inconsistent results. Therefore, a straightforward and scalable approach is necessary to enhance the properties of 3D-printed PLA. This study aims to explore the enhancement of the dielectric and surface hardness of printed PLA discs through surface cladding using nano-functional ceramics and graphene for next-generation multifunctional applications. PLA discs were fabricated via Fused Deposition Modelling (FDM) and subsequently cladded using hand layup with Araldite resin as a binder. Cladding materials included cobalt ferrite (CF), barium titanate (BTO), and graphene (Gr), individually and in combinations. Dielectric properties—capacitance, impedance, dielectric constant, dielectric loss, dissipation factor, and AC conductivity—were analyzed using an impedance analyzer, while surface hardness was measured using a Shore-D durometer. Results revealed that cladding led to uniform particle dispersion with effective surface bonding, improved dielectric performance, and significantly enhanced surface hardness. The CF + BTO + Gr combination exhibited superior dielectric behaviour, balancing high polarization with low energy dissipation, while BTO contributed to an enhanced dielectric constant and graphene improved charge transfer. All cladded samples showed frequency-dependent dielectric responses, with stability at higher frequencies. The highest surface hardness was achieved with CF + BTO, attributed to rigid, uniform reinforcement.

聚乳酸（PLA）是一种流行的用于3D打印的可生物降解聚合物，其介电强度和表面硬度有限，限制了其在先进电子和结构应用中的应用。现有的增强方法往往是复杂的或产生不一致的结果。因此，需要一种直接且可扩展的方法来增强3d打印PLA的性能。本研究旨在探索利用纳米功能陶瓷和石墨烯进行表面包覆，以增强印刷PLA光盘的介电和表面硬度，以实现下一代多功能应用。PLA圆盘是通过熔融沉积建模（FDM）制造的，随后用Araldite树脂作为粘合剂使用手工铺层进行包覆。包层材料包括钴铁氧体（CF）、钛酸钡（BTO）和石墨烯（Gr），可以单独使用，也可以组合使用。使用阻抗分析仪分析介电性能——电容、阻抗、介电常数、介电损耗、耗散因子和交流电导率，使用Shore-D硬度计测量表面硬度。结果表明，包层使颗粒均匀分散，表面结合有效，介质性能得到改善，表面硬度显著提高。CF + BTO + Gr组合表现出优异的介电性能，平衡了高极化和低能量耗散，而BTO有助于提高介电常数，石墨烯改善电荷转移。所有包覆样品均表现出频率相关的介电响应，在较高频率下具有稳定性。CF + BTO达到了最高的表面硬度，归因于刚性，均匀的强化。

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引用次数: 0

Dynamic properties of natural fiber-reinforced polymer composite plates and tubes 天然纤维增强聚合物复合板和复合管的动态特性

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-11-01 DOI: 10.1016/j.ijlmm.2024.05.008

Saeed Eyvazinejad Firouzsalari , Dmytro Dizhur , Krishnan Jayaraman , Jason Ingham

Thirty-six flax fibre-reinforced epoxy (FFRE) plates with two, three, and four fabric layers and lengths ranging from 160 mm to 270 mm and nine FFRE tubes with a diameter of 60 mm, a length of six times the tube diameter plus an overly of 50 mm with two, three, and four fabric layers were manufactured. One-hundred-eighty impulse excitation tests were conducted on FFRE plates to determine the dynamic properties of the plates in the bending mode, and 91 impulse excitation tests were conducted on the FFRE tubes to determine the dynamic properties of the tubes in the transverse, torsional, and longitudinal directions. FFRE plates showed up to six times larger specific energy capacities compared to counterpart glass fibre-reinforced polymer plates, showing significant potential for FFRE plates to replace the use of GFRP plates where considerable damping of energy is required. Additionally, the results showed that the damping ratio of the FFRE plates decreased with the increase in layers and natural frequency. For the FFRE tubes, the highest damping ratio belonged to the transverse vibration mode, followed by the torsional or longitudinal vibration modes.

生产了36个亚麻纤维增强环氧树脂（FFRE）板，有2层、3层和4层织物层，长度从160毫米到270毫米不等，9个FFRE管，直径为60毫米，长度是管径的6倍，加上50毫米的长度，有2层、3层和4层织物层。对FFRE板进行了180次脉冲激励试验，以确定板在弯曲模式下的动力特性；对FFRE管进行了91次脉冲激励试验，以确定管在横向、扭转和纵向上的动力特性。与玻璃纤维增强聚合物板相比，FFRE板显示出高达6倍的比能量容量，这表明FFRE板在需要相当大的能量阻尼的情况下取代GFRP板的巨大潜力。此外，结果表明，随着层数和固有频率的增加，FFRE板的阻尼比减小。对于FFRE管，横向振型阻尼比最高，其次是扭转振型和纵向振型。

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引用次数: 0

The fatigue damage monitoring of composite pipeline based on frequency domain analysis of electrical capacitance sensor system measurements 基于电容传感器系统测量频域分析的复合材料管道疲劳损伤监测

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-11-01 DOI: 10.1016/j.ijlmm.2025.06.002

Wael A. Altabey

In this research, a new approach for fatigue damage monitoring of composite pipelines based on checking the stability of electrical capacitance sensor (ECS) system measurements is established. The study pipeline is made of basalt fiber-reinforced polymer (BFRP) and is subjected to fatigue and thermal loading. The ECS electrodes are installed peripherally outside of pipeline. First, the capacitance between the sensor electrode pairs due to transient excitations is measured numerically using ANSYS before and after damage. Then, the capacitance data between electrode pairs was analyzed by plotting the transfer function (TF) maps, considering that the pipeline system is an “open loop system” to indicate the damage growth. To evaluate the proposed technique's reliability and applicability, a comparison between the present and experimental results available in the literature is validated. The current results are convergent with experimental results, which shows the effectiveness of the current method and the significant potential for different applications in engineering.

本文提出了一种基于电容传感器（ECS）系统测量稳定性校验的复合材料管道疲劳损伤监测新方法。研究管道由玄武岩纤维增强聚合物（BFRP）制成，承受疲劳和热载荷。ECS电极安装在管道外围。首先，利用ANSYS对传感器电极对之间的瞬态激励电容进行了损伤前后的数值测量。然后，考虑管道系统是一个“开环系统”，通过绘制传递函数（TF）图来分析电极对之间的电容数据，以表示损伤的增长。为了评估所提出的技术的可靠性和适用性，将现有的结果与文献中的实验结果进行了比较。计算结果与实验结果有较好的收敛性，表明了现有方法的有效性和在不同工程应用中的巨大潜力。

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引用次数: 0

Characterization of stress serrations in AlMg alloys AlMg合金中应力锯齿的表征

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-11-01 DOI: 10.1016/j.ijlmm.2025.05.001

Dóra Harangozó, Imre Czinege

A set of parameters was developed to characterize the stress serrations produced by the Portevin-Le-Chatelier (PLC) effect, including the stress amplitudes and their frequency and time functions. In addition to the traditional Fast Fourier Transform (FFT), the Short Time Fourier Transform (STFT), which can simultaneously display the amplitude as function of time and frequency, proved to be very illustrative. This made it possible to identify type A and type B serrations, as well as their appearance in the spectrum. Based on this evaluation method, six different cold rolling and annealing variants of an AlMg3 alloy were analyzed. It was found that in the cold-formed and annealed versions of sheets an FFT amplitude peak uniformly appears at 4–10 Hz, which can be attributed to the PLC serration of type A. This peak continuously decreases in the case of the annealed sheets, while cold-formed sheet shows a new peak at approximately 18–20 Hz before the uniform strain, which indicates the appearance of type B serrations. The amplitude of stress serrations decreases with increasing yield strength, tensile strength and normal anisotropy, and increases with uniform and fracture strains and hardening exponent.

建立了一组参数来表征由Portevin-Le-Chatelier （PLC）效应产生的应力锯齿，包括应力幅值及其频率和时间函数。除了传统的快速傅里叶变换（FFT）之外，短时傅里叶变换（STFT）可以同时显示振幅作为时间和频率的函数，被证明是很有说明意义的。这使得识别A型和B型锯齿以及它们在光谱中的外观成为可能。基于该评价方法，对一种AlMg3合金的6种不同冷轧和退火工艺进行了分析。结果发现，在冷弯和退火版本中，板的FFT振幅峰值在4-10 Hz均匀出现，这可归因于a型PLC锯齿。在退火情况下，峰值持续下降，而冷弯板在均匀应变前约18-20 Hz出现新的峰值，这表明B型锯齿的出现。应力锯齿的振幅随屈服强度、抗拉强度和正向各向异性的增大而减小，随均匀应变和断裂应变及硬化指数的增大而增大。

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引用次数: 0

Fabrication of an isotropic Ti–3Al–8V–6Cr–4Mo–4Zr alloy with a combination of high strength and good ductility 制备具有高强度和良好延展性的各向同性Ti-3Al-8V-6Cr-4Mo-4Zr合金

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-08-29 DOI: 10.1016/j.ijlmm.2025.08.005

Wensheng Li , Yinxiang Chai , Zhongliang Lin , Yue Qi , Jie Zheng , Yan Liu , Dunwen Zuo , Wenbin Zheng , Tong Liu , Hongye Sun , Xiaoling Zhang , Shuo Zhao

A method on fabricating the Ti-3.09Al-6.66V-5.62Cr-4.54Zr-4.93Mo (Ti-38644) fasteners with high strength and good ductility was reported in this study, whose tensile property evades the strength–ductility trade-off dilemma in Ti-38644 alloys. The microstructure in present Ti-38644 alloy is mainly composed of equiaxial β grains with tiny α particles embedded in them. The microstructure is homogeneous without obvious textures, leading to an isotropic mechanical property. The present method to process Ti-38644 fastener is both cost-effective and readily scalable. The process discovered here is readily scalable at a low cost and might be conducive to industrial production and to be applicable to other Ti alloys fasteners.

本文报道了一种制备高强度、高延展性的Ti-3.09Al-6.66V-5.62Cr-4.54Zr-4.93Mo （Ti-38644）紧固件的方法，该紧固件的拉伸性能解决了Ti-38644合金的强度-延性权衡问题。现有Ti-38644合金的显微组织主要由等轴β晶粒组成，其中嵌有细小的α颗粒。组织均匀，无明显织构，具有各向同性的力学性能。目前加工Ti-38644紧固件的方法既具有成本效益，又易于扩展。这里发现的工艺很容易以低成本扩展，可能有利于工业生产，并适用于其他钛合金紧固件。

引用次数: 0

Resistance spot welding of DH1200 using short pulses and high currents: Effects on nugget size, microstructure, hardness, liquid metal embrittlement, and tensile shear strength 短脉冲大电流DH1200电阻点焊：对熔核尺寸、显微组织、硬度、液态金属脆化和抗拉剪切强度的影响

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-08-25 DOI: 10.1016/j.ijlmm.2025.08.003

Saeed Shiri , Holger Schubert , Benjamin Hilpert , Luke N. Brewer

This study investigates short-pulse high-current resistance spot welding (RSW) of DH1200, a third-generation advanced high-strength steel (AHSS) critical to lightweight automotive structures. Six RSW scenarios were designed by varying weld time and current in both single- and double-pulse schedules, targeting a rarely explored regime with durations as short as ∼100 ms and currents up to 15 kA. Key weld attributes, including nugget size, microstructure, hardness, liquid metal embrittlement (LME) cracking, and tensile shear strength (TSS), were systematically analyzed. Contrary to conventional understanding, increased heat input did not necessarily generate larger nuggets or greater LME severity. Instead, weld current was found to be the dominant controller of nugget size, LME cracks, and TSS. Microhardness near the weld centerline was governed primarily by microstructure and remained largely insensitive to process parameters. Short-time, high-current conditions in double-pulse RSW produced large nugget sizes, exceeding even the

6 \sqrt{sheet thickness}

criterion, and enhanced both TSS peak load and energy absorption. Furthermore, reducing weld time at constant current significantly mitigated LME, which caused substantial strength degradation in two severe cracking cases. These findings offer new insights into the development of short-pulse RSW schedules beyond conventional practice, enabling cycle-time reduction in automotive production.

本研究研究了DH1200的短脉冲大电流电阻点焊（RSW）， DH1200是第三代先进高强度钢（AHSS），对汽车轻量化结构至关重要。通过在单脉冲和双脉冲计划下改变焊接时间和电流，设计了6种RSW方案，目标是一个很少探索的持续时间短至~ 100 ms，电流高达15 kA的区域。对熔核尺寸、显微组织、硬度、液态金属脆化（LME）开裂、抗拉剪切强度（TSS）等关键焊缝属性进行了系统分析。与传统的理解相反，增加的热量输入不一定会产生更大的掘金或更严重的LME。相反，发现焊缝电流是控制熔核尺寸、LME裂纹和TSS的主要因素。焊缝中心线附近的显微硬度主要由显微组织决定，对工艺参数基本不敏感。在短时间、大电流条件下，双脉冲RSW产生了大的金块尺寸，甚至超过了6薄片的厚度标准，并增强了TSS的峰值负载和能量吸收。此外，减少恒流下的焊接时间可以显著减轻LME，在两种严重的开裂情况下，LME会导致强度大幅下降。这些发现为开发超越传统做法的短脉冲RSW时间表提供了新的见解，从而缩短了汽车生产的周期时间。

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引用次数: 0

Rapid prototyping assisted optimization and experimental three point bending evaluation of spreader bar structure 快速成型辅助下的吊具杆结构优化及三点弯曲试验评定

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-08-22 DOI: 10.1016/j.ijlmm.2025.08.004

Abian Nurrohmad , Fajar Ari Wandono , Awang Rahmadi Nuranto , M Hafid , Try Kusuma Wardana , Kosim Abdurohman , Ristiyanto Adiputra , Agus Bayu Utama , Didi Budhyarso , Pramudita Satria Palar

This paper investigates the advantages of optimization and rapid prototyping technology to aid in the improvement process of a spreader bar for an amphibious commuter aircraft, intended to withstand critical loads by combining topology and size optimization. The initial spreader bar, although lightweight, fails when subjected to a critical load. The geometrical parameters of the spreader bar's cross-section serve as the design variables for optimization. Topology optimization was performed first to minimize compliance under the fraction mass constraint, using a solid elliptical structure as a starting point. Following that, size optimization was conducted to reduce mass with the maximum stress constraint applied. The two-step topology and size optimization process resulted in a hollow ellipse cross-section with a spar in the middle as the optimized design. This optimized design turned the margin of safety from −0.37 to 0, which met the safety requirements. The initial and optimized designs were then scaled down and 3D printed using Polylactic Acid (PLA) material at a ratio of 1:5. Next, a three-point bending evaluation was carried out to compare the mechanical strength of the two designs. The experimental investigation revealed that the optimized design was considerably superior and more efficient than the initial design. The new parameter proposed in this research, maximum load efficiency, the optimized design was 7.16 N/g while the baseline design was about 1.94 N/g. The specific energy absorption of the spreader bar was improved from 6.32 J/g to 119 J/g. The findings of this study indicate that the combination of rapid prototyping and sequential topology–size optimization can be applied to real-world cases, taking into account design constraints from multiple aspects.

本文研究了优化和快速成型技术的优势，以帮助水陆两栖通勤飞机吊具杆的改进过程，通过拓扑优化和尺寸优化相结合，旨在承受临界载荷。最初的吊具杆虽然很轻，但在承受临界载荷时就会失效。以吊具横截面的几何参数作为优化设计变量。首先以固体椭圆结构为出发点，在分数质量约束下进行拓扑优化，使柔度最小化。然后进行尺寸优化，在施加最大应力约束的情况下减小质量。通过两步拓扑和尺寸优化，得到了中空椭圆截面，中间有一根梁作为优化设计。优化后的安全裕度由- 0.37变为0，满足了安全要求。然后按比例缩小初始设计和优化设计，并使用聚乳酸（PLA）材料按1:5的比例进行3D打印。接下来，进行三点弯曲评估，以比较两种设计的机械强度。实验研究表明，优化后的设计比初始设计更优越，效率更高。优化设计的最大负载效率为7.16 N/g，基线设计为1.94 N/g。布料棒的比能吸收由6.32 J/g提高到119 J/g。研究结果表明，快速成型和顺序拓扑尺寸优化相结合的方法可以应用于现实案例，并从多个方面考虑设计约束。

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引用次数: 0

Experimental investigation of degradation in the marine environment of FDM-based 3D printed specimens 基于fdm的3D打印样品在海洋环境中的降解实验研究

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-08-19 DOI: 10.1016/j.ijlmm.2025.08.002

Singaravel B , Niranjan T , Laxmireddy P , Srinivasulu K , Chakradhar B , Poojitha G

Additive manufacturing technology, commonly known as 3D printing, is used to create three-dimensional objects. In 3D printing, Fused Deposition Modeling (FDM) is a solid-based additive manufacturing technique. For FDM-printed parts used in environments with humidity or marine exposure, understanding polymer degradation is essential to ensure long-term performance. In this work, degradation was investigated in terms of tensile strength reduction using two different environments. The study also focused on how different raw materials and FDM process parameters influence the tensile strength of 3D-printed parts. Two different environments were considered: an artificial seawater environment (simulated) and a natural seawater environment (marine). The materials used in this study are Nylon, Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), and Polylactic Acid (PLA). The samples were stored for 30 days in both environments to examine changes in tensile strength. The experimental results revealed a decrease in tensile strength due to degradation, with reductions of 31–44 % in Nylon, 15–25 % in ABS, 17–28 % in PETG, and 26–35 % in PLA. It is understood that degradation resistance and mechanical retention are crucial for optimizing the performance and reliability of 3D-printed components in marine and offshore environments. The degradation of polymer molecules in artificial seawater is primarily influenced by hydrolytic reactions.

增材制造技术，通常被称为3D打印，用于创建三维物体。在3D打印中，熔融沉积建模（FDM）是一种基于固体的增材制造技术。对于在潮湿或海洋环境中使用的fdm打印部件，了解聚合物降解对于确保长期性能至关重要。在这项工作中，降解研究了在两种不同环境下的抗拉强度降低。研究还关注了不同原材料和FDM工艺参数对3d打印部件抗拉强度的影响。考虑了两种不同的环境：人工海水环境（模拟）和自然海水环境（海洋）。本研究使用的材料有尼龙、丙烯腈-丁二烯-苯乙烯（ABS）、聚对苯二甲酸乙二醇酯（PETG）和聚乳酸（PLA）。样品在两种环境中保存30天，以检查抗拉强度的变化。实验结果显示，由于降解导致拉伸强度下降，尼龙降低31 - 44%，ABS降低15 - 25%，PETG降低17 - 28%，PLA降低26 - 35%。据了解，抗降解性和机械保持性对于优化海洋和近海环境中3d打印部件的性能和可靠性至关重要。聚合物分子在人工海水中的降解主要受水解反应的影响。

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引用次数: 0