CIRP Journal of Manufacturing Science and Technology最新文献_第7页

Analytical modelling and experimental validation of novel surface-embedded maglev coupling for 2D valve considering the manufacturability of permanent magnet 考虑永磁体可制造性的新型二维阀面嵌入式磁浮联轴器分析建模与实验验证

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-10-27 DOI: 10.1016/j.cirpj.2025.10.004

Leidi Wang, Bin Meng, Yuzhou Huang

The manufacturability of permanent magnets (PMs) has always been a critical consideration in the design of 2D valve’s maglev couplings. The existing surface-mounted magnetic screw mechanism (SMMSM) suffers from complex manufacturing of helical PMs, resulting in poor assembly accuracy and air-gap uniformity. This paper presents a novel surface-embedded maglev coupling (SEMC), in which the surface-embedded magnetic circuit topology with standardized rectangular PMs significantly improves the manufacturability of PMs and assembly accuracy. To enable rapid and accurate prediction of output torque, an analytical model is established based on the field-circuit combined method. Sub-models for PM leakage flux, air gap reluctance, and soft magnetic component reluctance are built with the assistance of Maxwell platform. Considering the nonlinear permeability of the soft magnetic component, the permeability curve is divided into three regions to improve the modeling accuracy. The effects of key structural parameters on the output torque are investigated to guide the development of the prototype. A dedicated experimental platform is built to test the static and dynamic characteristics of SEMC. Experimental results show that the output torque is 0.625 Nm, and the step response time is 34.2 ms at a displacement of 1 mm. Then, SEMC is applied to a 2D electro-hydraulic proportional flow valve (2D-EHPFV) to verify its feasibility. Experimental results show that, at 7 MPa, the maximum no-load flow rate is 101.6 L/min, and the amplitude and phase frequency width are 48.5 Hz, and 30.6 Hz, respectively. The comparison indicates that SEMC outperforms SMMSM in manufacturability and application performance, which exhibits its potential for civil electro-hydraulic proportional control applications.

永磁体的可制造性一直是二维阀式磁悬浮联轴器设计中需要考虑的关键问题。现有的表面贴装磁螺杆机构（SMMSM）由于螺旋电机制造复杂，导致装配精度和气隙均匀性差。提出了一种新型的表面埋入式磁浮耦合（SEMC），其表面埋入式磁路拓扑结构具有标准化的矩形永磁转子，显著提高了永磁转子的可制造性和装配精度。为了快速准确地预测输出转矩，建立了基于场路组合法的解析模型。利用Maxwell平台建立了永磁漏磁、气隙磁阻和软磁元件磁阻的子模型。考虑到软磁分量的非线性磁导率，为提高建模精度，将磁导率曲线划分为3个区域。为指导样机的研制，研究了关键结构参数对输出转矩的影响。搭建了专用的实验平台，对SEMC的静态和动态特性进行了测试。实验结果表明，在位移为1 mm时，输出扭矩为0.625 Nm，阶跃响应时间为34.2 ms。然后，将SEMC应用于2D电液比例流量阀（2D- ehpfv），验证其可行性。实验结果表明，在7 MPa时，最大空载流量为101.6 L/min，幅值为48.5 Hz，相频宽为30.6 Hz。结果表明，SEMC在可制造性和应用性能上均优于SMMSM，显示出其在民用电液比例控制领域的应用潜力。

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引用次数: 0

Silver streaks dependence on processing conditions in the injection molding of post-consumer recycled polypropylene 消费后再生聚丙烯注射成型中银纹对加工条件的依赖性

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.005

Anna Bortoletto, Andrea Orfano, Marco Sorgato, Giovanni Lucchetta

The growing emphasis on sustainability in plastic waste management has driven interest in recycled polymers, including post-consumer recycled polypropylene. A critical challenge in this field is achieving satisfying aesthetic surface quality in molded components, particularly when defects such as silver streaks arise. This study explores the influence of injection molding processing parameters on the physical and chemical mechanisms underlying defect formation, with a focus on the role of volatile organic compounds released from the degradation of residual inks and binders. Results reveal that silver streaks are significantly influenced by melt temperature, shear rates, and injection speed. These findings not only improve our understanding of how silver streaks form but also suggest practical ways to improve the quality of recycled polypropylene products by adjusting process parameters.

日益强调塑料废物管理的可持续性，推动了对再生聚合物的兴趣，包括消费后再生聚丙烯。该领域的一个关键挑战是在成型组件中实现令人满意的美学表面质量，特别是当出现银纹等缺陷时。本研究探讨了注射成型工艺参数对缺陷形成的物理和化学机制的影响，重点研究了残留油墨和粘合剂降解释放的挥发性有机化合物的作用。结果表明，熔体温度、剪切速率和注射速度对银条有显著影响。这些发现不仅提高了我们对银纹形成的理解，而且为通过调整工艺参数来提高再生聚丙烯产品的质量提供了切实可行的方法。

引用次数: 0

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-24 DOI: 10.1016/j.cirpj.2025.09.014

Berend Denkena, Benjamin Bergmann, Henning Buhl, Miriam Handrup

Geometry and hardness fluctuations of formed blanks are challenging for process monitoring of the subsequent machining process because they lead to deviating process forces during roughing. Ordinary anomaly detection methods require the forces to be similar. In this work, a similarity-based anomaly detection method is proposed that utilizes Dynamic Time Warping to achieve robustness against blank fluctuations during roughing. It extracts the average signal shape from training signals, scales it individually for each novel process, and uses confidence limits for anomaly detection. The method is tested with multi-material shafts whose blank diameter is axially constant but varies between workpieces.

由于成形毛坯的几何形状和硬度波动会导致粗加工过程中的加工力偏差，因此对后续加工过程的过程监控具有挑战性。普通的异常检测方法要求力是相似的。在这项工作中，提出了一种基于相似性的异常检测方法，利用动态时间扭曲来实现对粗加工过程中空白波动的鲁棒性。它从训练信号中提取平均信号形状，为每个新过程单独缩放它，并使用置信限进行异常检测。该方法在多材料轴上进行了试验，这些轴的毛坯直径是轴向恒定的，但在工件之间是不同的。

引用次数: 0

Synergistic effects of ultrasonic vibration and nanofluid-MQL on surface integrity in sustainable machining of Ti-6Al-7Nb alloy 超声振动和纳米流体- mql对Ti-6Al-7Nb合金可持续加工表面完整性的协同效应

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-29 DOI: 10.1016/j.cirpj.2025.09.017

Erkin Duman , Yusuf Furkan Yapan , Alper Uysal

Recent trends in the biomedical industry emphasize improving the surface properties of materials for better biocompatibility. Consequently, various surface modification techniques, including machining, are used on titanium bioimplants. This study investigates the impact of sustainable machining on the surface integrity of the Ti-6Al-7Nb biomedical alloy under various cutting conditions including conventional dry cutting, minimum quantity lubrication (MQL), graphene nanofluid-based MQL (N-MQL), and ultrasonic vibration-assisted machining (UVA), encompassing UVA-DRY, UVA-MQL, and UVA-N-MQL. The focus is to analyze the relationship between machining performance and surface integrity. Machining experiments first evaluated cutting forces, cutting temperatures, and chip morphology. Then, surface roughness, texture, microstructural changes, microhardness, and phase transformation were examined to assess surface integrity. The findings reveal that the UVA-N-MQL significantly reduces cutting forces (by up to 6 % for main cutting force and 10.4 % for thrust force) and cutting temperatures (by up to 29 % compared to dry cutting), while enhancing chip breakability. These outcomes stem from the synergistic interaction between the ultrasonic softening effect induced by high-frequency tool oscillations and the enhanced coolant/lubricant penetration enabled by N-MQL lubrication. Additionally, surface roughness was minimized by up to 57 % with UVA-MQL, resulting in the smoothest surface finish. Microstructure analysis also indicated that dry cutting produced the deepest deformation layer (29.5 µm), while UVA-N-MQL achieved the shallowest affected zone (9.5 µm). Subsurface hardness exhibited a notable increase within a depth range of 60–80 µm, with dry cutting demonstrating the most significant work hardening (a 12 % increase), in contrast to UVA-MQL, which experienced the least. Phase transformation analysis revealed a significant increase in the β phase ratio due to machining, with conventional turning exhibiting higher transformation than UVA machining. The UVA-N-MQL method resulted in 10.4 % less phase transformation compared to conventional dry cutting.

生物医学工业的最新趋势强调改善材料的表面特性以获得更好的生物相容性。因此，各种表面改性技术，包括机械加工，被用于钛生物植入物。本研究探讨了不同切削条件下可持续加工对Ti-6Al-7Nb生物医学合金表面完整性的影响，包括传统干切削、最小量润滑（MQL）、石墨烯纳米流体基MQL （N-MQL）和超声波振动辅助加工（UVA），包括UVA- dry、UVA-MQL和UVA-N-MQL。重点分析了加工性能与表面完整性之间的关系。加工实验首先评估切削力、切削温度和切屑形貌。然后，检测表面粗糙度、纹理、显微组织变化、显微硬度和相变以评估表面完整性。研究结果表明，UVA-N-MQL显著降低了切削力（主切削力降低了6% %，推力降低了10.4% %）和切削温度（与干切削相比降低了29% %），同时提高了切屑易碎性。这些结果源于高频工具振荡引起的超声波软化效应与N-MQL润滑增强的冷却剂/润滑剂渗透之间的协同作用。此外，UVA-MQL将表面粗糙度降低了57% %，从而实现了最光滑的表面光洁度。显微组织分析还表明，干切削产生的变形层最深（29.5 µm），而UVA-N-MQL产生的影响区最浅（9.5 µm）。在60-80 µm深度范围内，亚表面硬度显著增加，其中干切削表现出最显著的加工硬化（增加12. %），而UVA-MQL则最少。相变分析表明，加工导致β相比显著增加，常规车削比UVA加工表现出更高的相变。与传统干切削相比，UVA-N-MQL方法的相变减少了10.4% %。

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引用次数: 0

An analytical elastic-plastic contact model for process damping prediction in milling 铣削过程阻尼预测的解析弹塑性接触模型

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.004

Yan-Ru Jiang, Xiao-Jian Zhang, Ke-Yan Chen, Si-Hao Mao, Han Ding

Process damping is mainly caused by the dynamic extrusion between the flank face of the tool and the wavy machined surface of workpiece. An accurate description of process damping is critical for predicting stability and optimizing chatter-free cutting parameters. Existing process damping models neglect the extrusion deformation state in the indentation force calculation, and thus cannot reveal the dynamic deformation behavior of the extrusion. This paper presents a general analytical process damping model based on the elastic-plastic contact deformation. The proposed model analyzes three stages of contact deformation, i.e. the elastic regime, mixed elastic-plastic regime, and fully plastic regime, and calculates the indentation force separately for each stage, which avoids additional coefficient identification. Then, the equivalent viscous damping is derived from energy balance to linearize the indentation force and predict stability. The new model is validated by scratching tests and milling experiments, which can predict stability accurately and replace the traditional model.

加工阻尼主要是由刀具侧面与工件波浪形加工表面之间的动态挤压引起的。过程阻尼的准确描述对于预测稳定性和优化无颤振切削参数至关重要。现有的工艺阻尼模型在压痕力计算中忽略了挤压变形状态，无法反映挤压的动态变形行为。提出了一种基于弹塑性接触变形的通用解析过程阻尼模型。该模型分析了接触变形的三个阶段，即弹性状态、弹塑性混合状态和全塑性状态，并分别计算每个阶段的压痕力，避免了额外的系数辨识。然后，根据能量平衡导出等效粘性阻尼，对压痕力进行线性化，并对稳定性进行预测。通过刮伤试验和铣削试验验证了新模型的正确性，该模型能够准确预测工件的稳定性，取代传统模型。

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引用次数: 0

Interpretable generative machine learning model based in-situ process monitoring in robotic wire arc based directed energy deposition of aluminum alloys 基于可解释生成机器学习模型的机器人电弧铝合金定向能沉积原位过程监测

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-23 DOI: 10.1016/j.cirpj.2025.08.010

Deepak Kumar, Sunil Jha

WA-DED using CMT is emerging as a high-throughput metal AM strategy, yet it remains susceptible to a variety of thermomechanical instabilities and metallurgical discontinuities. In this study, we present an advanced AE based in-situ monitoring utilizing the generative ML framework to robustly detect and characterize anomalous conditions that compromise part integrity. Specifically, we examine five critical fault scenarios which are overcurrent, high travel speed, insufficient shielding gas flow, combination of overcurrent and low shielding gas flow rate and combination of high travel speed and low shielding gas flow rate elucidate their distinct signatures in the acoustic domain. A rigorous selection of time and frequency domain descriptors is leveraged to train the variational autoencoder, enabling accurate reconstruction of normal process states and efficient outlier detection. Microstructural analyses, encompassing FESEM, Micro-CT, and XRD, validate the detrimental influence of these faults on porosity evolution, grain morphology, and mechanical properties such as UTS. The proposed VAE model demonstrated robust performance across multiple defect types, achieving peak detection accuracies of 87% for overcurrent-induced faults, 85% for high travel speed anomalies, 81% for defects caused by insufficient shielding gas flow, 87% for combined effect of overcurrent and low gas flow rate, and 84% for combined effect of high travel speed and low gas flow rate. Overcurrent anomalies induce coarse columnar grains and high porosity content, while high travel speed amplifies geometric irregularities. Low gas flow conditions foster oxidation induced porosity. The proposed approach achieves high fidelity in detection of these defects, underscoring the synergy between data driven reconstruction errors and material characterization. By integrating unsupervised generative deep learning with domain specific interpretability through feature sensitivity analysis, this acoustic monitoring paradigm provides a scalable and cost effective pathway to detect defects and ensure structural reliability in WA-DED manufactured components. The comprehensive experimental validations and multi-physics correlational insights position this framework as a robust framework for in-situ process monitoring in WA-DED.

使用CMT的WA-DED正在成为一种高通量金属AM策略，但它仍然容易受到各种热机械不稳定性和冶金不连续的影响。在这项研究中，我们提出了一种先进的基于声发射的原位监测，利用生成式ML框架来鲁棒地检测和表征损害部件完整性的异常情况。具体来说，我们研究了过流、高行程速度、保护气体流量不足、过流和低保护气体流量组合以及高行程速度和低保护气体流量组合五种临界故障场景，阐明了它们在声学领域的不同特征。一个严格的时间和频域描述符的选择被用来训练变分自编码器，使正常过程状态的准确重建和有效的离群检测。微观结构分析，包括FESEM， Micro-CT和XRD，验证了这些断层对孔隙演化，晶粒形貌和力学性能（如UTS）的不利影响。所提出的VAE模型在多种缺陷类型中表现出稳健的性能，对过流引起的故障的峰值检测准确率为87%，对高行程速度异常的峰值检测准确率为85%，对保护气体流量不足引起的缺陷的峰值检测准确率为81%，对过流和低气体流量联合作用的峰值检测准确率为87%，对高行程速度和低气体流量联合作用的峰值检测准确率为84%。过流异常导致粗柱状晶粒和高孔隙率，而高流速放大了几何不规则性。低气体流量条件促进氧化引起的孔隙度。所提出的方法在检测这些缺陷方面实现了高保真度，强调了数据驱动的重构误差和材料表征之间的协同作用。通过特征敏感性分析，将无监督生成深度学习与领域特定可解释性相结合，这种声学监测范式提供了一种可扩展且经济有效的途径来检测WA-DED制造组件的缺陷并确保结构可靠性。综合实验验证和多物理场相关见解使该框架成为WA-DED现场过程监测的强大框架。

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引用次数: 0

Towards digital twin-enhanced control policies: A knowledge-based classification of release and dispatching policies in manufacturing systems 面向数字孪生增强控制策略：制造系统中放行和调度策略的基于知识的分类

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-10-10 DOI: 10.1016/j.cirpj.2025.08.006

Marcello Urgo , Walter Terkaj , Lei Liu

The management of modern discrete manufacturing systems is challenged by high levels of complexity arising from intricate interdependencies among processes and the need to adapt to frequent internal and external disruptions. In this context, control policies play a pivotal role in managing manufacturing operations, guiding decisions for governing systems and optimising their performance. This study investigates the design and classification of release and dispatching policies based on the type and structure of information they require, with particular emphasis on supporting real-time and adaptive decision-making. This analysis takes advantage of the concept of Digital Twin (DT), tightly integrated with the physical manufacturing system via IIoT technologies, enabling continuous monitoring of operations in a factory, but also forward-looking simulation of system behaviour. The proposed classification leverages an ontology-based data model that formalises the structure of manufacturing knowledge and facilitates the systematic identification of the information required by control policies. The classification scheme incorporates both the informational requirements and the potential role of the DT in supporting their execution and the results provide a structured perspective on how control strategies can be aligned with available data and digital infrastructure to enhance the management of manufacturing systems.

现代离散制造系统的管理是由过程之间错综复杂的相互依赖关系和需要适应频繁的内部和外部中断而产生的高度复杂性所挑战的。在这种情况下，控制策略在管理制造操作、指导管理系统的决策和优化其性能方面发挥着关键作用。本文研究了基于信息类型和结构的放行和调度策略的设计和分类，特别强调支持实时和自适应决策。该分析利用了数字孪生（DT）的概念，通过工业物联网技术与物理制造系统紧密集成，实现了对工厂运营的持续监控，以及对系统行为的前瞻性模拟。提出的分类利用了基于本体的数据模型，该模型形式化了制造知识的结构，并促进了控制策略所需信息的系统识别。分类方案结合了信息需求和DT在支持其执行方面的潜在作用，结果提供了一个结构化的视角，说明如何将控制策略与可用数据和数字基础设施相结合，以增强制造系统的管理。

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引用次数: 0

Development and validation of theoretical model for nanofluid minimal quantity lubrication selection in aviation difficult-to-machine materials 航空难加工材料纳米流体最小量润滑选择理论模型的建立与验证

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-11 DOI: 10.1016/j.cirpj.2025.09.003

Ben Wang , Qi Zhang , Chang Song , Hao Wang , Tianlong Zhu

Difficult-to-machine aeronautical materials like ceramic matrix composites exhibit high strength and complex machinability, leading to high cutting forces, temperatures, and poor surface quality. Nanofluid minimum quantity lubrication (NMQL) offers excellent friction-reduction and heat-transfer performance, but nanofluid parameter selection remains empirical, lacking theoretical support, which limits its broader engineering application. Accordingly, a theoretical model for nanofluid selection was established by comprehensively considering tribological characteristics, thermophysical properties, dispersion stability, particle concentration, and material compatibility, and was solved using a multi-objective particle swarm optimization algorithm. The input parameters of the model include the physical properties and interfacial behavior characteristics of various base oils and nanoparticles, while the output is the optimal NMQL combination scheme. Results showed that, when applied to 2.5D SiC_f/SiC composites, the optimal solution determined and experimentally validated was palm oil-carbon nanotubes (CNTs)-vol. 2 %. In terms of machining performance, compared with dry grinding (DG), the grinding force under NMQL-CNTs-2 % condition decreased by up to 75.2 %, and the surface roughness decreased by 41.81 %. Meanwhile, the number of rough fracture surfaces was minimized, and fiber wear was minimal, indicating the high accuracy of the optimal solution. In addition, validation was performed using experimental data from existing studies on Ti6Al4V titanium alloy, GH4169 alloy, carbon fiber reinforced polymer (CFRP) composites, and quartz fiber reinforced polyimide (QFRP) composites. The predicted results from the model were consistent with the experimental findings, further demonstrating its applicability and generalizability. The study effectively guides nanofluid selection while providing theoretical support for high-efficiency, precision machining of aeronautical difficult-to-machine materials.

难以加工的航空材料，如陶瓷基复合材料，具有高强度和复杂的可加工性，导致高切削力、高温度和低表面质量。纳米流体最小量润滑（NMQL）具有优异的减摩和换热性能，但纳米流体的参数选择仍然是经验的，缺乏理论支持，限制了其在工程上的广泛应用。基于此，综合考虑摩擦学特性、热物性、分散稳定性、颗粒浓度和材料相容性等因素，建立了纳米流体选择的理论模型，并采用多目标粒子群优化算法进行求解。模型的输入参数包括各种基础油和纳米颗粒的物理性质和界面行为特征，输出为最优的NMQL组合方案。结果表明，当应用于2.5D SiCf/SiC复合材料时，确定并实验验证的最佳溶液为棕榈油-碳纳米管(CNTs)-vol。2 %。在加工性能方面，与干式磨削（DG）相比，NMQL-CNTs-2 %条件下的磨削力降低了75.2% %，表面粗糙度降低了41.81 %。同时，粗断口数量最小，纤维磨损最小，表明最优解具有较高的精度。此外，利用Ti6Al4V钛合金、GH4169合金、碳纤维增强聚合物（CFRP）复合材料和石英纤维增强聚酰亚胺（QFRP）复合材料的现有研究实验数据进行验证。模型的预测结果与实验结果一致，进一步证明了模型的适用性和推广性。该研究有效地指导了纳米流体的选择，同时为航空难加工材料的高效、精密加工提供了理论支持。

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引用次数: 0

Multi-material laser powder bed fusion additive manufacturing of a bimodal laminate heterostructure with Cu-base and Ni-base alloys 多材料激光粉末床熔合增材制造铜基和镍基合金双峰层状异质结构

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-13 DOI: 10.1016/j.cirpj.2025.09.009

Liming Yan , Bo Li , Jianrui Zhang , Fuzhen Xuan

A bimodal laminate heterostructure consisting of alternating copper-base (CuCrZr) and nickel-base (Hastelloy X) alloy layers was carefully fabricated via multi-material laser powder bed fusion (MM-LPBF) additive manufacturing approach, employing a custom-designed multi-powder delivery device system and proprietary process-control software. The heterostructure shows a hierarchical architecture with periodically alternating coarse-grained (predominantly Hastelloy X) and fine-grained (primarily CuCrZr) layers, interconnected by transition zones containing mixed grain morphologies. The heterostructural material demonstrates exceptional mechanical performance under building-direction loading, achieving a yield strength of 674.2 MPa, ultimate tensile strength of 756.4 MPa (∼92 % of monolithic LPBF-processed Hastelloy X), and elongation of 19.9 %. Crystal plasticity simulations elucidate deformation coordination and strength-ductility synergy mechanisms, while microstructural characterization confirms the bimodal grain structure originates from the LPBF-laser-induced melt pool dynamics and heterogeneous nucleation during the rapid solidification. This study establishes MM-LPBF as a viable approach for manufacturing high-performance, architecturally graded multi-material systems.

采用多材料激光粉末床熔合（MM-LPBF）增材制造方法，采用定制设计的多粉末输送装置系统和专有的过程控制软件，精心制备了由铜基（CuCrZr）和镍基（Hastelloy X）合金交替层组成的双峰层状异质结构。异质结构呈现出周期性交替的粗晶层（主要是哈氏合金X）和细晶层（主要是CuCrZr）的分层结构，由包含混合晶粒形态的过渡区相互连接。异质结构材料在建筑方向载荷下表现出优异的力学性能，屈服强度为674.2 MPa，极限抗拉强度为756.4 MPa（约为单片lpbf加工的哈氏合金X的92 %），伸长率为19.9 %。晶体塑性模拟阐明了变形协调和强度-延性协同机制，而显微组织表征证实了快速凝固过程中lpbf激光诱导熔池动力学和非均相形核导致的双峰型晶粒结构。本研究确立了MM-LPBF作为制造高性能、结构分级的多材料系统的可行方法。

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引用次数: 0

Influence of non-planar orientations on solidification microstructure during robot-assisted laser-wire directed energy deposition 机器人辅助激光丝定向能沉积过程中非平面取向对凝固组织的影响

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-12-01 Epub Date: 2025-09-13 DOI: 10.1016/j.cirpj.2025.09.002

Sumitkumar Rathor , Dhruva Kumar Goyal , Ravi Kant , Ekta Singla

This work investigates the effect of temperature gradient on the solidification morphology during the non-planar laser-wire directed energy deposition (LWDED) process, abbreviated as DED-LB/w according to ISO/ASTM 52900:2021 standard. The LWDED abbreviation is used further in this work. The novelty of this study lies in the independent variation of substrate tilt angle (STA) and wire feed angle (WFA), which presents a comprehensive understanding of non-planar depositions. The temperature distribution and solidification parameters were computed using a customized 3D transient heat transfer model. This numerical model was introduced considering the pulsed laser beam, laser spot shape and size change due to different non-planar orientations. Solidification time, microstructural changes, and heat-affected zone (HAZ) morphology were discussed by correlating the stainless steel 316 L temperature distributions. A numerical and experimental analysis was presented for single-layer deposits. The STA and WFA significantly influence the cooling rates during solidification, affecting the microstructure of the beads. Lower STA (0°-15°) and WFA (10°-20°) result in higher cooling rates. The change in the laser beam spot size affects the solidification rate in the tilt direction due to the lower heating concentration. Smaller WFA (10°-20°) enables the wire to be positioned closer to the molten pool. It results in better energy absorption and efficient melting by increasing temperature. It increased the initial temperature difference and cooling rate. The fraction of equiaxed solidification morphology from the centre to the tilt direction increased with a reduced thermal gradient. The main outcome of this work is the validated solidification map for non-planar LWDED for optimizing deposition strategies in supportless additive manufacturing. The present approach will help suggest the deposition orientations to achieve consistent quality and reliability in deposited parts at non-planar orientations. This work is required to decide deposition strategies for supportless additive manufacturing.

根据ISO/ASTM 52900:2021标准，研究了温度梯度对非平面激光丝定向能沉积（LWDED）过程中凝固形态的影响。LWDED缩写在本工作中进一步使用。本研究的新颖之处在于基材倾斜角度（STA）和送丝角度（WFA）的独立变化，从而对非平面沉积有了全面的了解。使用定制的三维瞬态传热模型计算温度分布和凝固参数。该数值模型考虑了脉冲激光束、光斑形状和尺寸因不同的非平面取向而发生的变化。通过对比316不锈钢 L温度分布，讨论了凝固时间、显微组织变化和热影响区（HAZ）形貌。对单层沉积进行了数值和实验分析。STA和WFA显著影响凝固过程中的冷却速率，从而影响珠的微观组织。较低的STA（0°-15°）和WFA（10°-20°）导致较高的冷却速率。由于加热浓度较低，激光束光斑尺寸的变化影响了倾斜方向的凝固速率。较小的WFA（10°-20°）使焊丝更靠近熔池。通过提高温度，可以更好地吸收能量，提高熔炼效率。增大了初始温差和冷却速率。随着热梯度的减小，从中心到倾斜方向的等轴凝固形貌的比例增加。这项工作的主要成果是验证了非平面LWDED的凝固图，用于优化无支撑增材制造中的沉积策略。本方法将有助于建议沉积方向，以实现非平面取向沉积零件的一致质量和可靠性。这项工作需要确定无支撑增材制造的沉积策略。

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