2024 April - 42 articles
Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique ha...
The present study focuses on the dry and wet end milling of three distinct Aluminum 7075 alloys: A7075, A7075–Sc (with a 0.18% Sc addition), and A7075–Li–Sc (containing 2.2% Li and 0.18% Sc additions). The main objective is to explo...
This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investiga...
In the last fifteen years, several groups have investigated metal injection moulding (MIM) of NdFeB powder to produce isotropic or anisotropic rare earth magnets of greater geometric complexity than that achieved by the conventional pressing and sint...
Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study inves...
Advancements in smart manufacturing have embraced the adoption of soft robots for improved productivity, flexibility, and automation as well as safety in smart factories. Hence, soft robotics is seeing a significant surge in popularity by garnering c...
Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–therm...
Additive manufacturing (AM) is a field with both industrial and academic significance. Computer-aided optimisation has brought advances to this field over the years, but challenges and areas of improvement still remain. Design to execution inaccuraci...
Four dimensional printing enables the advanced manufacturing of smart objects that can morph and adapt shape over time in response to stimuli such as heat. This study presents a single-material 4D printing workflow which explores the residual stress...
Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, sig...
The influence of hot-top designs with different heat capacities on the distribution of positive and negative macrosegregation was investigated on a 12 metric tonne (MT) cast ingot made using Cr-Mo low-alloy steel. The three-dimensional finite element...
The monitoring of additive manufacturing processes such as powder bed fusion enables the detection of several process quantities important to the quality of the built part. In this context, radiation-based monitoring techniques have been used to obta...
The directed energy deposition (DED) parameters were determined for near-β alloy Ti-55511 by employing statistical design of experiments (DOEs) methods. Parameters resulting in fully dense freeform deposits were identified using two sequential D...
Various defects are produced during the laser powder bed fusion (L-PBF) process, which can affect the quality of the fabricated part. Previous studies have revealed that the defects formed are correlated with molten pool dimensions. Powder particles...
Laser powder bed fusion (LPBF) is widely used in metal additive manufacturing to create geometrically complex parts, where heat transfer and its affected temperature distribution significantly influence the parts’ materials’ microstructur...
Minimum quantity lubrication (MQL) technologies possess great potential for improving the sustainability of manufacturing processes, which can reduce the absolute quantity of metalworking fluid (MWF) and also enable near-dry chips that are easier to...
The conventional cutting tools used for machining titanium alloys normally experience rapid tool wear, and it is generally difficult to achieve a cutting speed over 60 m/min. In this paper, a comprehensive study on improving the machining of Ti-6Al-4...
Carbon fiber-reinforced polymer (CFRP) composites have gradually replaced metals due to their exceptional strength-to-weight ratio compared to metallic materials. However, the drilling process often reveals various defects, such as surface roughness,...
The application of computer vision and machine learning methods for semantic segmentation of the structural elements of 3D-printed products in the field of additive manufacturing (AM) can improve real-time failure analysis systems and potentially red...
This work emphasizes an innovative approach utilizing 3D imaging technology based on synchrotron radiation to assess the microstructure of second-phase iron particles and the porous structure within 3D-printed PLA/magnetic iron composites at differen...
Additively manufactured fibre-reinforced polymers are gaining traction. After the development and optimisation of a novel fibre-deposition system in a laser sintering (LS) setup, polyamide 12 specimens were produced with and without glass fibres. In...
Additive manufacturing of plastic components in medical technology enables greater freedom of design when designing patient-specific products, in particular, in production of customised medical products, such as orthoses. In the present contribution,...
This study addresses the effects of densification at varied pelletization temperatures on the novel Malaysian Khaya senegalensis wood-derived pellets biomass fuel characteristics. The lack of comprehensive understanding regarding the biomass fuel cha...
Context—Rapidly solidified aluminium alloy (RSA 443) is increasingly used in the manufacturing of optical mold inserts because of its fine nanostructure, relatively low cost, excellent thermal properties, and high hardness. However, RSA 443 is...
A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of t...
Additive Manufacturing (AM) has emerged as an innovative technology that gives designers several advantages, such as geometric freedom of design and less waste. However, the quality of the parts produced is affected by different design and manufactur...
The utilization of Al2O3 nanopowder to reinforce AA5754 aluminum alloy through blind holes employing the friction stir processing (FSP) technique to produce an aluminum matrix nanocomposite is explored in this paper. Motivated by the necessity to enh...
Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully...
In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test s...
Lap joining of an aluminum AA6082-T6 plate and a UHSS steel plate coated with an Al-Si layer was performed using Probeless Friction Stir Spot Welding (P-FSSW). The dwell time and rotational speed were controlled in the range of 10–15 s and 1000...
Copper-based materials have long been used for their outstanding thermal and electrical conductivities in various applications, such as heat exchangers, induction heat coils, cooling channels, radiators, and electronic connectors. The development of...
Long fiber thermoplastic pellets are pellets containing discontinuous reinforced fibers and a matrix, offering excellent mechanical properties, good processability, recyclability, and low cost. Typically, commercial LFTP is manufactured through the h...
This study’s novel 13Ni400 maraging steel parts are additively manufactured through a selective laser melting process. The Taguchi approach is adopted to evaluate the combined influence of process variables (energy density), viz., laser power,...
The material extrusion of plastics has matured into a lucrative and flexible alternative to conventional manufacturing. A major downside of this process is the missing quality assurance caused by the influence of process parameters on part quality. S...
In this study, the evolution of volume fractions during laser beam welding (LBW) of stainless steel, with a specific focus on incorporating the low transformation temperature (LTT) effect using the dilatometer, has been proposed. The LTT effect refer...
This experimental study probes the dynamic behaviour of a 3 mm ABS sheet during positive mould vacuum-assisted thermoforming. In this process, the sheet undergoes large and fast deformations caused by the applied vacuum and mechanical stretching by t...
The 17-4 PH stainless steel is widely used in the aerospace, petrochemical, chemical, food, and general metallurgical industries. The present study was conducted to analyze the mechanical properties of two types of 17-4 PH stainless steel—comme...
Laser beam welding as a reliable tool for high-precision joining of batteries or microelectronics is more and more the choice for achieving reproducible results in production processes. In addition to a high automation capability, the precise control...
Shape-memory alloys set high demands on the production technologies being used. During cutting, continuous heat input and mechanical stress have an undesirable influence on the shape-memory effect. Pulsed electrochemical machining (PECM), which is ba...
Laser cladding (LC) is a versatile additive manufacturing process where strands of metallic material are deposited and melted by a laser. However, there are some limitations associated with this process that may affect the performance of the final ma...
This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculati...
Accurately predicting the time-varying dynamic parameters of a workpiece during the milling of thin-walled parts is the foundation of adaptively selecting chatter-free machining parameters. Hence, a method for accurately and quickly predicting the ti...
