International Journal of Lightweight Materials and Manufacture最新文献_第5页

Laser powder bed fusion of AlN and ZrN reinforced AlSi10Mg matrix composites: Effect of wettability and volume fraction on microstructure and mechanical properties AlN和ZrN增强AlSi10Mg基复合材料的激光粉末床熔接：润湿性和体积分数对组织和力学性能的影响

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-04-09 DOI: 10.1016/j.ijlmm.2025.04.002

V.S. Suvorova , L.V. Fedorenko , S.N. Zhevnenko , B.O. Zotov , V.Yu. Egorov , D.D. Zherebtsov , D.S. Suvorov , B.B. Khaydarov , K.Yu. Kotyakova , A.A. Nepapushev , I.A. Kovalev , D.O. Moskovskikh , S.V. Chernyshikhin

In this study, Laser Powder Bed Fusion (LPBF) technique was employed to obtain AlN- and ZrN-reinforced AlSi10Mg composites (De Brouckère diameter D[4,3] equals ∼2 μm). The wettability of AlN and ZrN by pure Al and AlSi10Mg melts was investigated, and the phase composition and microstructure of the bulk composites, as well as the hardness and tensile strength, were studied. The impact of wetting on the mechanical properties was also analyzed. The experimental results indicated that ZrN forms a strong interphase bond with Al as a result of reactive wetting. Due to the in-situ reaction, intermetallic inclusions of Zr(Al,Si)₃ were formed, which further strengthened the matrix. Accordingly, small amounts of ZrN (up to 1 vol%) increase the microhardness of AlSi10Mg from 108 to 126 HV_0.1 and the tensile strength from 410 to 448 MPa. In turn, insufficient inert wetting due to the short contact time of the melt during the LPBF process leads to the formation of gaps at the Al/AlN interphase boundary. This phenomenon, as well as the uneven coarsening of Si, results in a decrease in the strength of AlSi10Mg and an insignificant increase in microhardness regardless of the volume fraction of AlN. The obtained results contribute to the understanding of the role of wetting in LPBFed aluminum matrix composites, and also establish the foundation for further experimental and fundamental research in this area.

在本研究中，采用激光粉末床熔融（LPBF）技术获得了AlN-和zrn -增强AlSi10Mg复合材料（De brouck直径D[4,3] = ~ 2 μm）。研究了纯Al和AlSi10Mg熔体对AlN和ZrN的润湿性，研究了复合材料的相组成、显微组织、硬度和抗拉强度。分析了润湿对材料力学性能的影响。实验结果表明，ZrN与Al在反应性润湿作用下形成了较强的相间键。由于原位反应，形成了Zr(Al,Si)3的金属间夹杂物，进一步强化了基体。因此，少量的ZrN（高达1 vol%）使AlSi10Mg的显微硬度从108提高到126 HV0.1，抗拉强度从410提高到448 MPa。反过来，在LPBF过程中，由于熔体接触时间短，惰性润湿不足，导致Al/AlN界面边界形成间隙。无论AlN的体积分数如何，这种现象以及Si的不均匀粗化都会导致AlSi10Mg的强度下降，显微硬度的增加不显著。所得结果有助于理解润湿作用在LPBFed铝基复合材料中的作用，也为该领域的进一步实验和基础研究奠定了基础。

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引用次数: 0

3D-Printed recycled polyethylene terephthalate (PET) sandwich structures – Influence of infill design and density on tensile, dynamic mechanical, and creep response 3d打印再生聚对苯二甲酸乙二醇酯（PET）夹层结构-填充设计和密度对拉伸，动态机械和蠕变响应的影响

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-03-07 DOI: 10.1016/j.ijlmm.2025.03.001

Ans Al Rashid, Muammer Koç

Repurposing plastic waste is crucial to cope with the global population and rapid industrialization. Most plastic waste generated worldwide is mismanaged, leading to plastic pollution, landfill congestion, and microplastic contamination. Circular economy practices in the sustainable production and consumption of plastic are urgently needed to address these challenges, bringing plastics into closed-loop manufacturing and utilization. Additive manufacturing (AM) or 3D printing (3DP) have the potential to complement these efforts by facilitating on-demand, decentralized and flexible manufacturing using recycled plastics. In pursuit of circular materials for 3DP, this study investigates the influence of infill design and density on tensile and dynamic mechanical properties of 3D-printed recycled polyethylene terephthalate (rPET) sandwich structures. rPET filaments were produced using waste plastic bottles and were used for the 3DP process to produce sandwich structure coupons. In the first phase, the rPET filaments were tested for their mechanical properties revealing an average tensile strength of 111.99 MPa, failure strain of 1.20, and Young's modulus of 199.61 MPa, followed by the 3DP of tensile testing coupons with varying infill patterns (grid, tri-hexagon, octet, concentric, gyroid, and solid) and infill densities (25%, 50%, and 75%). The 3D-printed sandwich structures were evaluated for their dimensional stability and mechanical properties. All patterns demonstrated good dimensional stability, with minor variations from the CAD model. The mechanical properties of the concentric pattern at 50% infill (C50) stand out as the best among all infill types and patterns, exhibiting an average tensile strength of 34.65 MPa, failure strain of 0.067, Young's modulus of 464.32 MPa, and strength-to-weight ratio of 8.56 (S/W). In the final phase, the optimal infill pattern and density (i.e., C50) were also tested for their dynamic mechanical properties. The outcomes of this study will assist future research in developing robust 3D-printed parts using rPET, and the comprehensive approach presented in this study can be further adapted to develop novel recycled plastic waste-based composites for broader applications.

塑料垃圾的再利用对于应对全球人口和快速工业化至关重要。全球产生的大多数塑料垃圾管理不善，导致塑料污染、垃圾填埋场拥堵和微塑料污染。迫切需要在塑料的可持续生产和消费方面进行循环经济实践，以应对这些挑战，使塑料进入闭环制造和利用。增材制造（AM）或3D打印（3DP）有可能通过使用再生塑料促进按需、分散和灵活的制造来补充这些努力。为了寻找用于3d打印的圆形材料，本研究探讨了填充设计和密度对3d打印再生聚对苯二甲酸乙二醇酯（rPET）夹层结构的拉伸和动态力学性能的影响。利用废旧塑料瓶生产rPET长丝，并将其用于3d打印工艺生产三明治结构券。在第一阶段，对rPET长丝进行了力学性能测试，平均抗拉强度为111.99 MPa，破坏应变为1.20，杨氏模量为199.61 MPa，然后对不同填充模式（网格、三六边形、八边形、同心圆、旋转和实心）和填充密度（25%、50%和75%）的拉伸测试片进行了3d打印。对三维打印三明治结构的尺寸稳定性和力学性能进行了评价。所有的图案都表现出良好的尺寸稳定性，与CAD模型有微小的变化。50%填充时的同心花纹（C50）在所有填充类型和花纹中力学性能最好，平均抗拉强度为34.65 MPa，破坏应变为0.067，杨氏模量为464.32 MPa，强重比为8.56 （S/W）。在最后阶段，还测试了最佳填充模式和密度（即C50）的动态力学性能。这项研究的结果将有助于未来使用rPET开发坚固的3d打印部件的研究，并且本研究中提出的综合方法可以进一步适用于开发更广泛应用的新型再生塑料废物基复合材料。

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引用次数: 0

Deep learning-based applications in metal additive manufacturing processes: Challenges and opportunities–A review 基于深度学习的金属增材制造工艺应用：挑战与机遇综述

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-04-08 DOI: 10.1016/j.ijlmm.2025.04.001

Tuğrul Özel

In metal additive manufacturing (AM), parts often exhibit quality variations, defects, intricate surface topography, and anisotropic properties influenced by factors such as process parameters, energy and fusion interactions, and material physics. These complexities make metal-AM processes challenging to manage consistently, leading to unacceptable levels of inconsistency. To address these issues and predict quality, in-situ process sensing and monitoring as well as post-process measurements are commonly employed, aiming to enhance process understanding, control, and reliability. This review paper surveys literature on deep learning (DL) methods used in AM processes, discussing current research challenges and future directions. The ultimate objective is to develop intelligent AM systems capable of using real-time process data for automated control decisions and interventions, advancing towards more reliable defect-free manufacturing outcomes.

在金属增材制造（AM）中，零件经常表现出质量变化、缺陷、复杂的表面形貌和各向异性特性，这些特性受到工艺参数、能量和熔合相互作用以及材料物理等因素的影响。这些复杂性使得金属增材制造过程的一致性管理具有挑战性，导致不可接受的不一致性水平。为了解决这些问题并预测质量，通常采用原位过程传感和监测以及过程后测量，旨在增强过程理解，控制和可靠性。本文综述了在增材制造过程中使用的深度学习方法的文献，讨论了当前的研究挑战和未来的方向。最终目标是开发智能增材制造系统，能够使用实时过程数据进行自动控制决策和干预，朝着更可靠的无缺陷制造结果迈进。

引用次数: 0

Enhanced performance of epoxy composites: A study on Walikukun-glass fiber hybrid reinforcement for automotive applications 环氧复合材料性能的增强：汽车用玻璃纤维混合增强材料的研究

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-03-07 DOI: 10.1016/j.ijlmm.2025.03.003

Andoko Andoko , Femiana Gapsari , Afifah Harmayanti , Abdul M. Sulaiman , Riduwan Prasetya , Nursyahbani Putri , Mohammad Sukri Mustapa

The increasing demand for sustainable, lightweight, and high-performance materials in the automotive industry necessitates innovative hybrid composite solutions. This study addresses the limitations of natural fibers like Walikukun (WF) in achieving high mechanical and thermal properties by hybridizing them with glass fibers (GF) in epoxy composites. Using a hot press technique, hybrid composites with varying WF and GF ratios were fabricated and evaluated for density, tensile strength, flexural properties, and thermal stability. The results revealed that the hybrid composite with 20 % WF and 10 % GF (W20G10) configuration achieved superior performance, with the highest flexural strength (96.11 ± 22.79 MPa), notable tensile strength (132.81 ± 30.73 MPa), and excellent thermal stability at 248.07 °C initial degradation temperature. Morphological analysis further confirmed improved fiber-matrix adhesion and effective stress distribution in W20G10 composites. This research contributes to the development of hybrid composites, offering valuable insights into optimizing material properties for advanced automotive applications.

汽车行业对可持续、轻量化和高性能材料的需求不断增长，需要创新的混合复合材料解决方案。该研究解决了Walikukun （WF）等天然纤维在环氧复合材料中与玻璃纤维（GF）杂交以获得高机械和热性能方面的局限性。利用热压技术，制备了不同WF和GF比例的混合复合材料，并对其密度、拉伸强度、弯曲性能和热稳定性进行了评估。结果表明：W20G10复合材料在初始降解温度为248.07℃时，具有较高的抗弯强度（96.11±22.79 MPa）和显著的抗拉强度（132.81±30.73 MPa），且具有良好的热稳定性。形态分析进一步证实W20G10复合材料改善了纤维-基体的粘附性和有效应力分布。这项研究有助于混合复合材料的发展，为优化先进汽车应用的材料性能提供了有价值的见解。

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引用次数: 0

Additively manufactured injection mould tooling incorporating gradient density lattice structures for mass and energy reduction 采用梯度密度晶格结构的增材制造注射模具，以减少质量和能量

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-03-26 DOI: 10.1016/j.ijlmm.2025.03.007

Rokas Šakalys , Christopher O'Hara , Mandana Kariminejad , Albert Weinert , Mohammadreza Kadivar , Bruno Zluhan , Karl Costello , Marion McAfee , Gerard McGranaghan , Ramesh Raghavendra , David Tormey

The benefits of reducing the mass of injection moulding (IM) tooling include opportunities to also reduce material and energy consumption of the Additive Manufacturing L-PBF (Laser Powder Bed Fusion) processes, leading to lower overall costs for the IM setup. This provides a competitive advantage and reduces the environmental impact of the tool-making process in comparison to manufacturing heavier IM tooling. Mass reduction of tooling by using complex internal geometries like lattice structures, which are impossible to achieve using subtractive fabrication approaches, can be easily implemented through additive manufacturing (AM). Therefore, this research exploits the combination of lattice structure design and AM to make functional IM tooling. A tooling design with solid infill was initially modified with a lattice structure of uniform strut thickness, and then Finite Element (FE) Structural Analysis was performed to estimate the stress field typical of an injection mould cycle. Based on these results, a field-driven approach was further applied to alter the lattice structure into a variable gradient strut thickness lattice, aiming for an additional mass reduction. The tooling was additively manufactured using L-PBF technology and successfully applied in the IM process. Mass reductions of 21.86 and 23.95 % were achieved for moving and fixed halves respectively; this corresponds to laser energy savings of 11.06 and 13.44 %. The tooling demonstrated complete functionality during the industrial IM process producing parts within the design specification.

减少注射成型（IM）模具质量的好处包括有机会减少增材制造L-PBF（激光粉末床融合）工艺的材料和能源消耗，从而降低IM设置的总体成本。与制造较重的IM工具相比，这提供了竞争优势，并减少了工具制造过程对环境的影响。通过使用晶格结构等复杂的内部几何形状来减少工具的质量，这是使用减法制造方法无法实现的，可以通过增材制造（AM）轻松实现。因此，本研究利用点阵结构设计与增材制造相结合的方法来制作功能性的增材制造工具。首先将固体填充的模具设计修改为均匀支撑厚度的点阵结构，然后进行有限元结构分析以估计注塑模周期的典型应力场。基于这些结果，进一步应用场驱动方法将晶格结构改变为可变梯度支撑厚度晶格，旨在进一步减少质量。采用L-PBF技术对模具进行增材制造，并成功应用于IM工艺。移动半段和固定半段的质量分别减少21.86%和23.95%；这相当于激光节能11.6%和13.44%。该工具在工业IM过程中展示了在设计规范内生产零件的完整功能。

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引用次数: 0

Finite element analysis and experimental whiffletree testing of a small UAV composite wing 某小型无人机复合材料机翼有限元分析及实验whifftretree测试

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-03-20 DOI: 10.1016/j.ijlmm.2025.03.004

Aryandi Marta , Fajar Ari Wandono , Abian Nurrohmad , Riki Ardiansyah , Ilham Bagus Wiranto , Iqbal Reza Alfikri , Aditya Rio Prabowo , Gesang Nugroho

This study presents a comprehensive investigation of the structural performance of a small unmanned aerial vehicle (UAV) composite wing, integrating finite element analysis (FEA) and experimental whiffletree testing. The study focuses on a pusher-type UAV with a 2.9-m wingspan and 21 kg maximum takeoff weight. The distributed load from the Schrenk's method was converted into multiple point loads for whiffletree load by using the cantilever beam approach. When subjected to load within the limit load, the observed failure at the upper skin wing near the wing-body joint also complied with the failure results according to the finite element analysis with the Tsai-Wu failure index of 1. Conversely, the deflection comparison between the finite element analysis using whiffletree loads and the actual whiffletree testing showed good agreement, with maximum deflection values of 122 mm and 120 mm, respectively. With a difference of 1.67 % in maximum deflection, the study validates the wing's structural integrity up to the design limit load and identifies failure modes within this limit. This aircraft structure can withstand load factor up to 2.8, making it safe for standard maneuvers during flight operations.

采用有限元分析和实验whiffletree测试相结合的方法，对小型无人机（UAV）复合材料机翼的结构性能进行了综合研究。该研究的重点是一种翼展2.9米、最大起飞重量21公斤的推式无人机。采用悬臂梁法将Schrenk法得到的分布荷载转化为多点荷载，得到whiffletree荷载。当载荷在极限载荷范围内时，近翼身结合处的上蒙皮翼观察到的破坏也符合有限元分析的破坏结果，破坏指数Tsai-Wu为1。相反，使用whiffletree荷载的有限元分析与实际whiffletree试验之间的挠度比较显示出良好的一致性，最大挠度值分别为122 mm和120 mm。在最大挠度差异为1.67%的情况下，该研究验证了机翼在设计极限载荷下的结构完整性，并确定了该极限内的失效模式。这种飞机结构可以承受高达2.8的负载系数，使其在飞行操作期间的标准机动安全。

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引用次数: 0

Electrical discharge machining: Recent advances and future trends in modeling, optimization, and sustainability 电火花加工：建模、优化和可持续性的最新进展和未来趋势

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-04-01 DOI: 10.1016/j.ijlmm.2025.03.006

Muhamad Taufik Ulhakim , Sukarman , Khoirudin , Dodi Mulyadi , Hendri Susilo , Rohman , Muji Setiyo

Electrical Discharge Machining (EDM) has experienced significant advancements in modeling, optimization, and sustainability, reflecting the growing demand for intelligent and environmentally friendly manufacturing practices. Advanced modeling techniques, such as finite element analysis (FEA) and artificial intelligence (AI)-driven simulations, have improved the accuracy of process predictions, enabling real-time adjustments and precise control of machining parameters. Optimization approaches, including machine learning-based algorithms, multi-objective optimization, and hybrid methods, have enhanced key performance indicators, such as material removal rate (MRR), surface quality, and tool wear, thereby increasing process efficiency and reducing machining time. The incorporation of AI and machine learning is crucial for addressing EDM challenges and driving future development. Moreover, sustainability has become a key area of emphasis in EDM research, with recent advancements focusing on energy-saving discharge techniques, eco-friendly dielectric fluids, and sustainable waste management practices. The progress made is in line with the Sustainable Development Goals (SDGs), ensuring that EDM contributes to advanced manufacturing while minimizing environmental impact. Future studies should focus on the effects of AI-driven approaches on environmentally friendly EDM practices by prioritizing green dielectrics, energy-efficient machining, and waste reduction strategies. This review highlights the interconnected roles of modeling, optimization, and sustainability in advancing EDM and outlines key research directions to address the remaining challenges.

电火花加工（EDM）在建模、优化和可持续性方面取得了重大进展，反映了对智能和环保制造实践日益增长的需求。先进的建模技术，如有限元分析（FEA）和人工智能（AI）驱动的仿真，提高了过程预测的准确性，实现了加工参数的实时调整和精确控制。优化方法，包括基于机器学习的算法、多目标优化和混合方法，提高了关键性能指标，如材料去除率（MRR）、表面质量和刀具磨损，从而提高了工艺效率并缩短了加工时间。人工智能和机器学习的结合对于解决EDM挑战和推动未来发展至关重要。此外，可持续发展已成为电火花加工研究的重点领域，最近的进展集中在节能放电技术、环保介质流体和可持续废物管理实践方面。所取得的进展符合可持续发展目标（sdg），确保EDM为先进制造业做出贡献，同时最大限度地减少对环境的影响。未来的研究应侧重于人工智能驱动的方法对环境友好型电火花加工实践的影响，优先考虑绿色电介质、节能加工和减少废物的策略。这篇综述强调了建模、优化和可持续性在推进电火花加工中的相互关联的作用，并概述了解决剩余挑战的关键研究方向。

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引用次数: 0

Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape 采用独特的工具形状搅拌摩擦焊接，提高了Inconel 700合金的机械性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-02-12 DOI: 10.1016/j.ijlmm.2025.02.005

Ibrahim Sabry , Omar Awayssa , Abdel-Hamid I. Mourad , Majid Naseri , Ahmed Hewidy

For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.

本文首次采用响应面法（RSM）对Inconel 700搅拌摩擦焊接过程中刀具几何形状的影响进行了系统研究。该工具设计实现了两种不同的针探头几何形状：具有三个间歇平面的螺纹针（D1）和全螺纹圆柱形针（D2）。本研究主要考察了这些不同的销形对Inconel 700接头FSW性能的影响。此外，还进行了实验分析，即维氏硬度值（VHN）、极限抗拉强度（UTS）和表面粗糙度（SR），以评估关键力学性能。响应面法（RSM）被评价为确定焊缝性能的合适方法，D1和D2工具配置的数学模型分别达到93%和98%的置信度。与此同时，与D2结构相比，D1销形结构产生了卓越的机械性能，即UTS从630到662 MPa， VHN从93到110 HV，并且表面光洁度得到改善，突出了该设计在提高FSW连接质量方面的有效性。

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引用次数: 0

Enhancing physical-thermal-mechanical properties of biobased ceramic composite utilizing natural beta-tricalcium phosphate, glass, and tricalcium silicate 利用天然β-磷酸三钙、玻璃和硅酸三钙增强生物基陶瓷复合材料的物理-热-机械性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2024-05-18 DOI: 10.1016/j.ijlmm.2024.05.006

Prichaya Waibanthao, Wanfah Pophet, Nuchnapa Tangboriboon

Eggshells, a sustainable raw material, accumulate in millions of tons daily after consumption and are utilized across various industries including food, pharmaceuticals, agriculture, and cosmetics. Composed mainly of calcium carbonate (CaCO₃) with a purity exceeding 98 wt%, eggshells serve as raw material for producing beta tricalcium phosphate (β-Ca₃(PO₄)₂). The addition of tricalcium silicate cement (C₃S) enhances thickening, ductility, and setting properties, facilitating polymerization and solidification through curing and hydration processes. Incorporating soda lime glass powder at varying concentrations (0, 10, 20, 30, 40, and 50 wt%) improves the mechanical and thermal properties of biobased ceramic composite. Higher concentrations of embedded soda lime glass powder have demonstrated increased compressive strength, reduced water absorption, decreased thermal expansion coefficient, and lowered firing temperature. This renders it a promising alternative for replacing and repairing materials in medical applications such as bone grafts and splints.

蛋壳是一种可持续的原材料，每天在消费后积累数百万吨，用于食品，制药，农业和化妆品等各个行业。蛋壳主要由碳酸钙（CaCO3）组成，纯度超过98%，是生产β-磷酸三钙（β-Ca3(PO4)2）的原料。硅酸三钙水泥（C3S）的加入增强了水泥的增稠性、延展性和凝结性，促进了水泥在固化和水化过程中的聚合和固化。掺入不同浓度（0、10、20、30、40和50% wt%）的钠石灰玻璃粉可改善生物基陶瓷复合材料的机械和热性能。较高浓度的钠石灰玻璃粉包埋后，抗压强度增加，吸水率降低，热膨胀系数降低，烧成温度降低。这使得它在诸如骨移植和夹板等医疗应用中成为替代和修复材料的有希望的替代品。

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引用次数: 0

Investigation and optimization of machining parameters in Micro-WEDM of SMA to enhance performance SMA微细线切割加工参数的研究与优化，提高加工性能

Q1 Engineering

International Journal of Lightweight Materials and Manufacture

Pub Date : 2025-07-01 Epub Date: 2025-03-07 DOI: 10.1016/j.ijlmm.2025.03.002

Rakesh R. Kolhapure , Duradundi S. Badkar

Ti–Ni Shape Memory Alloys (SMAs) are extensively used in biomedical applications due to their superior biocompatibility and mechanical properties over traditional biomaterial SS316L and Ti alloys. However, achieving high precision and surface integrity during machining remains a significant challenge. This study focuses on optimizing the Micro-Wire Electric Discharge Machining (μ-WEDM) parameters to enhance the machining efficiency and surface quality of Ti–Ni SMAs. An L27 orthogonal array (OA) and Grey Relational Analysis (GRA) were applied to optimize multiple machining responses, including Material Removal Rate (MRR), Surface Roughness (SR), Dimensional Deviation (DD), and Kerf Width (KW) by using Voltage (V), Capacitance (C), and Wire feed (WF) as process parameters. Analysis of Variance (ANOVA) was conducted to evaluate the contribution of each parameter. The results indicate that ‘C’ significantly influences MRR (78.40 %), DD (50.98 %), and KW (36.64 %), while ‘V’ has the highest impact on SR (57.62 %). The optimal parameter combination (105 V, 6 nF, 1 mm/min) improved machining efficiency by 2.79 % (GRG) increased from 0.6898 to 0.7091, minimized surface defects, and enhanced dimensional accuracy. Scanning Electron Microscope (SEM) analysis confirmed that optimized μ-WEDM parameters minimized surface defects, refined textures, and reduced micro-cracks, enhancing surface integrity also minimizing recast layer results in dimensional accuracy. Energy Dispersive Spectroscopy (EDS) analysis verified minimal contamination, ensuring biocompatibility, making μ-WEDM ideal for high-precision biomedical applications. Furthermore, the study emphasizes the environmental sustainability of μ-WEDM, highlighting its reduced material waste and lower energy consumption compared to traditional machining methods. By integrating robust statistical analysis and process control, the study offers new insights into achieving good surface quality and performance in medical field.

Ti - ni形状记忆合金（sma）由于其优于传统生物材料SS316L和钛合金的生物相容性和机械性能而广泛应用于生物医学领域。然而，在加工过程中实现高精度和表面完整性仍然是一个重大挑战。为了提高Ti-Ni sma的加工效率和表面质量，对微线切割加工参数进行了优化研究。以电压(V)、电容(C)和进给丝（WF）为工艺参数，采用L27正交阵列（OA）和灰色关联分析（GRA）对材料去除率（MRR）、表面粗糙度（SR）、尺寸偏差（DD）和切口宽度（KW）等多个加工响应进行优化。进行方差分析（ANOVA）来评估每个参数的贡献。结果表明，“C”显著影响MRR（78.40%）、DD（50.98%）和KW(36.64%)，而“V”对SR的影响最大（57.62%）。最佳参数组合（105 V, 6 nF, 1 mm/min）使加工效率提高2.79% (GRG)，从0.6898提高到0.7091，表面缺陷最小化，尺寸精度提高。扫描电镜（SEM）分析证实，优化后的μ-WEDM参数最大限度地减少了表面缺陷，改善了织构，减少了微裂纹，提高了表面完整性，最大限度地减少了重铸层，提高了尺寸精度。能量色散光谱（EDS）分析验证了最小的污染，确保了生物相容性，使μ-WEDM成为高精度生物医学应用的理想选择。此外，该研究强调μ-电火花线切割的环境可持续性，强调与传统加工方法相比，μ-电火花线切割减少了材料浪费和降低了能耗。通过整合稳健的统计分析和过程控制，该研究为医疗领域实现良好的表面质量和性能提供了新的见解。

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引用次数: 0