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

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 : 2025-09-23 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

Step-dependent machining uncertainty modeling for the process route and application in the machining of the ring-gear 工艺路线的步进不确定性建模及其在环齿加工中的应用

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-23 DOI: 10.1016/j.cirpj.2025.09.011

Yanan Zhao, Shaoming Yao

This paper proposes a step-dependent machining uncertainty modeling method for the process routes. With the between-step interaction, the process route integrity is accurately interpreted and all error sources in the production environment are involved in, including the workpiece positioning surface, machine positioning surface, cutter kinetics, workpiece kinetics, clamping force, cutting force, environmental factors, residual stress distortion, heat treatment distortion, and coating/plating variations. The machining uncertainty model shows that the machining uncertainty consists of both regenerated and inherited uncertainties. The proposed modeling method can evaluate a process route in terms of its error source impact on workpiece accuracy. A herringbone gear ring is used to demonstrate its effectiveness as a case study, where an uncertainty model is developed for the full process route, and the process route is assessed before the costly process trial. The process number is reduced from 18 to 15 without affecting the final workpiece accuracy. The experiment shows a good agreement with the uncertainty model results.

提出了一种基于步进的加工路线不确定性建模方法。通过步骤间的交互作用，可以准确地解释工艺路线的完整性，并涉及生产环境中的所有误差源，包括工件定位面、机床定位面、刀具动力学、工件动力学、夹紧力、切削力、环境因素、残余应力变形、热处理变形和涂层/电镀变化。加工不确定性模型表明，加工不确定性包括再生不确定性和继承不确定性。所提出的建模方法可以根据误差源对工件精度的影响来评估工艺路线。以人字齿环为例，建立了整个工艺路线的不确定性模型，并在昂贵的工艺试验前对工艺路线进行了评估。在不影响最终工件精度的情况下，工序数从18个减少到15个。实验结果与不确定性模型的计算结果吻合较好。

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引用次数: 0

Modelling of abrasive particle distribution for pre-mixed abrasive water jet peening surface 预混合磨料水射流喷丸表面磨料颗粒分布建模

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-22 DOI: 10.1016/j.cirpj.2025.09.010

Zhao Wang , Xiaowen Rong , Haoran Zhao , Yue Yang , Fusheng Liang , Cheng Fan

Abrasive water jet technology, as a non-traditional machining process, impinges on the workpiece surface with abrasive particles driven by the water jet beam to achieve material removal or surface modification. The abrasive particle distribution is the key factor affecting on the process quality, especially for Abrasive Water Jet Peening (AWJP) process. However, there is still limited research on the abrasive particle distribution in the AWJP process, especially regarding the distribution under variable traverse speeds and variable curvature movements of the abrasive water jet beam, which forms the basis for controlling abrasive water jet coverage, particularly on curved surfaces. In this study, an abrasive particle distribution prediction model is proposed for AWJP under different pump pressures, variable traverse speeds (accelerations), and various curvature radius by combining finite element and analytical modeling approaches. Validation experiments were conducted, and both simulation and experimental results under different parameters follow Gaussian distributions. The maximum prediction error was only 18.6 % across 24 comparisons from 15 experimental sets, confirming the feasibility and accuracy of the proposed model. Meanwhile, the influence of these three parameters on abrasive particle distribution laws is investigated respectively through comparisons between simulation and experimental results. The findings reveal that pump pressure primarily affects abrasive particle velocity and position distribution; traverse speed mainly influences abrasive particle position distribution and the percentage of particles at the central region; curvature radius predominantly affects the midline position of the abrasive particle distribution curve. This study not only provide a deep understanding of abrasive particle distribution laws under varying pump pressures, traverse speeds, and curvature radii, but the proposed model also offers valuable guidance for achieving uniform abrasive particle coverage on free-form surfaces during AWJP.

磨料水射流技术是一种非传统的加工工艺，在水射流光束的驱动下，使磨料颗粒撞击工件表面，达到去除材料或表面改性的目的。磨料颗粒分布是影响工艺质量的关键因素，特别是磨料水喷丸工艺。然而，对AWJP过程中磨料颗粒分布的研究仍然有限，特别是对磨料水射流束在变横移速度和变曲率运动下的分布，这是控制磨料水射流覆盖范围的基础，特别是在曲面上。本文采用有限元和解析建模相结合的方法，建立了不同泵压力、变横移速度（加速度）和不同曲率半径条件下AWJP的磨粒分布预测模型。进行了验证实验，不同参数下的仿真和实验结果均服从高斯分布。在15个实验集的24个对比中，最大预测误差仅为18.6 %，证实了所提出模型的可行性和准确性。同时，通过仿真结果与实验结果的对比，研究了这三个参数对磨粒分布规律的影响。结果表明：泵压力主要影响磨粒速度和位置分布；横移速度主要影响磨料颗粒的位置分布和颗粒在中心区域的百分比；曲率半径主要影响磨粒分布曲线的中线位置。这项研究不仅提供了对不同泵压力、穿越速度和曲率半径下磨粒分布规律的深入理解，而且所提出的模型也为在AWJP过程中实现自由曲面上均匀覆盖磨粒提供了有价值的指导。

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引用次数: 0

Research on the deformation mechanism for current-assisted splitting spinning forming of small-module gear-shaped parts with extreme diameter-to-module ratios 极径模比小模数齿轮件电流辅助劈裂旋压成形变形机理研究

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-18 DOI: 10.1016/j.cirpj.2025.08.012

Qinxiang Xia , Haoyang Zhou , Gangfeng Xiao , Sizhu Cheng , Junhao Zhang

Small-module gear-shaped parts (SMGSPs, module m < 1) with extreme diameter-to-module ratios (D/m>100) are critical components in miniature precision systems for spatial transmission and lightweight structural applications. However, it exhibits restricted fatigue strength and excessive material wastage when manufactured by conventional machining processes. A novel current-assisted splitting spinning forming (CASSF) method combining the precision of spinning technology with the electroplastic effects of pulsed current synergistically was proposed to realize the high-performance near-net shape forming of SMGSPs. A finite element model coupled with the electroplasticity effect is constructed. Finite element model (FEM) simulations and experimental studies systematically investigated the distribution of the electric field, temperature field, the equivalent stress and strain, and the dynamic material flow of small module gears during CASSF. The results revealed that the current density of the SMGSP is concentrated near the contact area of the roller, so the softening region, due to the electroplasticity effect, highly overlaps with the deformation region of the SMGSP. The gear profile deformation exhibits a non-uniform stress-strain distribution, with peak stress concentrations localized at the exit-side tooth root arc. The application of pulsed current effectively reduced equivalent stress and enhanced material deformability, achieving saturation thresholds at 17.5 A/mm² current density (J_p) and 40 % duty ratio (d). Five distinct material flow orientations develop during CASSF, forming four flow division surfaces between them. The uneven tooth height defect originates from asymmetric material flow between the entry and exit sides, whereas tooth underfilling stems from insufficient axial material flow. A forward-reversed forming strategy with intensified pulsed current eliminated tooth height discrepancies and improved tooth saturation (γ) to 97.8 %, demonstrating the potential of CASSF potential for forming extreme ratio SMGSPs.

具有极径模比（D/m>100）的小模块齿轮形零件（smgsp，模块m <； 1）是用于空间传动和轻量化结构应用的微型精密系统的关键部件。然而，当用传统的加工工艺制造时，它表现出有限的疲劳强度和过度的材料浪费。为了实现smgsp的高性能近净成形，提出了一种将旋压技术的精度与脉冲电流的电塑性效应协同结合的电流辅助分裂旋压成形方法。建立了考虑电塑性效应的有限元模型。通过有限元模型仿真和实验研究，系统地研究了小模数齿轮在CASSF过程中的电场、温度场、等效应力和应变分布以及动态物质流动。结果表明：SMGSP的电流密度集中在滚子接触区附近，因此由于电塑性效应，SMGSP的软化区与变形区高度重叠；齿形变形呈现非均匀应力应变分布，应力峰值集中在齿根弧出口处。脉冲电流的应用有效地降低了等效应力，增强了材料的变形能力，达到了17.5 A/mm²电流密度（Jp）和40 %占空比(d)的饱和阈值。在CASSF过程中，形成了五种不同的物质流动方向，在它们之间形成了四个流动划分面。齿高不均匀缺陷是由于进、出口侧物料流动不对称造成的，而齿深充填是由于轴向物料流动不足造成的。脉冲电流增强的正反向成形策略消除了齿高差异，并将齿饱和度（γ）提高到97.8% %，证明了CASSF潜力形成极端比smgsp的潜力。

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引用次数: 0

Gaussian process-based surrogate framework for efficient prediction of geometrical inaccuracy in Wire Electrical Discharge Machining of thin-wall miniature components 基于高斯过程的薄壁微细零件线切割加工几何误差预测替代框架

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-17 DOI: 10.1016/j.cirpj.2025.09.006

Aswin P., Rakesh G. Mote

High aspect ratio, thin-walled miniature structures are critical in applications such as microfluidics and micromechanical cooling. Wire Electrical Discharge Machining (Wire EDM) presents a commercially viable alternative to specialized micromachining setups for fabricating such features. However, as part size decreases, conventional Wire EDM faces challenges in achieving accurate profiles due to intensified thermal effects and reduced part stiffness, leading to increased geometrical errors. To address this, a reduced-order surrogate framework based on Gaussian Process Regression (GPR) is developed to predict key geometrical deviations specifically, reduced wall thickness and wall deformation as functions of process parameters. The framework integrates four GPR models trained on hybrid datasets combining experimental data and physics-based numerical results. A discrepancy model further refines numerical predictions by accounting for deviations from experimental data. The final GPR models achieve mean absolute errors of 3.39

μ

m and 6.08

μ

m for wall thickness and deformation, with

R^{2}

values of 0.96 and 0.99. K-fold cross-validation and validation experiments confirm model reliability, with prediction errors around 14.3

μ

m and 12.1

μ

m. The discrepancy model reduces the deviation of numerical predictions from actual values by 55%. Process parameter optimization is performed to fabricate thin walls with targeted deformation levels, achieving reasonable accuracy within 22.3

μ

m. Furthermore, sensitivity analysis is conducted to quantify both individual and interactive influences of major process parameters on geometrical errors.

高宽高比、薄壁微型结构在微流体和微机械冷却等应用中至关重要。线材电火花加工（线材EDM）提供了一种商业上可行的替代专门的微加工装置来制造这些特征。然而，随着零件尺寸的减小，由于热效应加剧和零件刚度降低，传统的线切割在实现精确轮廓方面面临挑战，从而导致几何误差增加。为了解决这一问题，开发了基于高斯过程回归（GPR）的降阶代理框架，以预测关键几何偏差，减少壁厚和壁变形作为工艺参数的函数。该框架集成了四种基于混合数据集训练的探地雷达模型，这些混合数据集结合了实验数据和基于物理的数值结果。差异模型通过考虑与实验数据的偏差进一步改进数值预测。最终GPR模型对壁厚和变形的平均绝对误差分别为3.39 μm和6.08 μm， R2分别为0.96和0.99。K-fold交叉验证和验证实验验证了模型的可靠性，预测误差分别为14.3 μm和12.1 μm。差异模型将数值预测与实际值的偏差减少了55%。通过优化工艺参数，实现了薄壁的目标变形水平，实现了22.3 μm以内的合理精度。此外，还进行了灵敏度分析，以量化主要工艺参数对几何误差的单独和相互影响。

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引用次数: 0

Characterization of the friction behavior of wrought and hot isostatic pressed laser powder bed fusion Ti6Al4V alloys 变形和热等静压激光粉末床熔合Ti6Al4V合金摩擦行为的表征

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-16 DOI: 10.1016/j.cirpj.2025.09.007

Necati Uçak , Kubilay Aslantas , Adem Çiçek , José Outeiro

This paper presents determination of the friction coefficients and an analysis of the frictional behavior of wrought and hot isostatic pressed Laser Powder Bed Fusion (LPBF) Ti6Al4V alloys against uncoated cemented carbide (WC-Co) under conditions that simulate those encountered in metal cutting. For this purpose, a series of pin-on-bar tribological tests were performed in an open tribometer configuration at a high average contact pressure (∼1.5 GPa) and different sliding speeds (9.58–38.3 m/min) under dry conditions. The tests permitted to determine sliding speed dependent apparent friction coefficients (μ_app) between WC-Co pins and wrought/LPBF Ti6Al4V bars. A 3D model of the tribological test was developed for the purpose of obtaining the adhesive friction coefficients (μ_adh) through the post-processing of the test data of μ_app. The tribological behavior was evaluated in terms of the friction coefficient, the build-up material (adhesion) to the pin, surface topography, and subsurface microstructure. The test results showed that wrought and LPBF Ti6Al4V alloys have a different tribological behavior. The μ_app exhibited a range of values for the wrought Ti6Al4V alloy spanning from 0.458 to 0.327, while the LPBF Ti6Al4V alloy demonstrated a slightly different range, from 0.499 to 0.251, depending on the sliding speed. At high sliding speeds, the wrought material exhibited higher adhesion volumes on the pins, as well as higher friction coefficients and a greater deformation zone thickness in comparison to the LPBF Ti6Al4V alloy. The μ_adh values obtained for both the wrought and LPBF Ti6Al4V alloys can be employed in the modelling and simulation of metal cutting operations.

本文在模拟金属切削过程中遇到的摩擦条件下，测定了变形和热等静压激光粉末床熔合（LPBF） Ti6Al4V合金与未涂层硬质合金（WC-Co）的摩擦系数，并分析了摩擦行为。为此，在干燥条件下，在高平均接触压力（~ 1.5 GPa）和不同滑动速度（9.58-38.3 m/min）下，在开放式摩擦计配置中进行了一系列针杆摩擦学测试。试验允许测定WC-Co销与变形/LPBF Ti6Al4V杆之间随滑动速度变化的表观摩擦系数（μapp）。通过对μapp测试数据的后处理，建立了摩擦试验的三维模型，得到了黏着摩擦系数（μadh）。摩擦学性能是根据摩擦系数、与销钉的积累材料（附着力）、表面形貌和地下微观结构来评估的。试验结果表明，变形Ti6Al4V合金与LPBF Ti6Al4V合金具有不同的摩擦学性能。变形Ti6Al4V合金μapp的取值范围为0.458 ~ 0.327，而LPBF Ti6Al4V合金μapp的取值范围为0.499 ~ 0.251，这与滑动速度有关。在高滑动速度下，与LPBF Ti6Al4V合金相比，变形材料在销上表现出更高的粘附体积、更高的摩擦系数和更大的变形区厚度。得到的变形Ti6Al4V合金和LPBF Ti6Al4V合金的μadh值可用于金属切削过程的建模和仿真。

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引用次数: 0

Bottom-up segmentation of composite structures for cost-efficient manufacturing 自下而上的复合材料结构分割，以实现成本效益制造

IF 5.4 2区工程技术 Q2 ENGINEERING, MANUFACTURING

CIRP Journal of Manufacturing Science and Technology

Pub Date : 2025-09-16 DOI: 10.1016/j.cirpj.2025.08.011

Ádám Ipkovich , Alex Kummer , Balázs Fodor , Gergely Erdős , László Takács , János Abonyi

This work focuses on optimizing manufacturing processes for composite products with complex geometry. The goal is to efficiently partition the 3D surface mesh so that parts can be manufactured with specific technologies while minimizing costs. For this purpose, the proposed algorithm merges the elementary units iteratively by selecting the two elements that reduce the total cost through a bottom-up hierarchical clustering algorithm. The applicability of the method is demonstrated in a case study of bus manufacturing. The results illustrate how the costs of tools, adhesives, and materials vary when a complex structure is segmented.

这项工作的重点是优化复杂几何形状的复合材料产品的制造工艺。目标是有效地划分3D表面网格，以便零件可以用特定的技术制造，同时最大限度地降低成本。为此，该算法通过自底向上的分层聚类算法，选择两个降低总成本的元素，迭代合并基本单元。以客车制造为例，验证了该方法的适用性。结果表明，当复杂结构被分割时，工具、粘合剂和材料的成本是如何变化的。

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 : 2025-09-13 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 : 2025-09-13 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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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 : 2025-09-11 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