Journal of Manufacturing and Materials Processing

Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (T_off), and pulse-on-duration (T_off) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate (MRR) and surface roughness (SR) were selected as output measures for the study. The experiments were carried out by employing Taguchi’s L9 design at three levels. Empirical models were generated, which give the relationship between the input and output factors of the process. To check the acceptability of the model terms, analysis of variance (ANOVA) was used. The regression mode was observed to be significant for the output measures. For MRR, Toff was recorded as the highly significant factor affecting the response values with 74.95% impact, followed by Ton with 16.39%, and current with 6.56%. In the case of SR, Ton was found to be a highly significant factor with a 50.24% impact, followed by current with 43.99%, and Toff with 1.47%. Further, multi-objective optimization by using the HTS technique was performed. The effect of expanded graphite (EG) nano-powder has been studied on the output factors of MRR and SR. The use of EG nano-powder was found to improve WEDM operations as MRR was increased by 45.35%, and simultaneously, SR was reduced by 36.16%. Lastly, the surface morphology of the machined surface was investigated by employing SEM to understand the effect of EG nano-powder. The results have shown a reduction in surface defects by using EG nano-powder compared to the conventional WEDM process. Full article

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) and gas-atomized powders as a material feedstock is presented as a potential manufacturing route for the complex processing of these alloys. This research deals with the advanced material characterization of these alloys obtained by LMD and the study and understanding of their solidification paths and strengthening mechanisms. The as-built microstructure, the Vickers hardness at room temperature and at high temperatures, the nanoindentation hardness and elastic modulus of the main phases and precipitates, and the strengthening mechanisms were studied in bulk cylinders manufactured under different chemical composition grades and DED-LB/p process parameter sets (slow, normal, and fast deposition speeds), with the aim of determining the influence of the chemical composition in commercial Ni-Cr-Si-Fe-B alloys. The hardening of Ni-Cr-Si-Fe-B alloys obtained by LMD is a combination of the solid solution hardening of gamma nickel dendrites and eutectics and the contribution of the precipitation hardening of small chromium-rich carbides and hard borides evenly distributed in the as-built microstructure. Full article

Refill friction stir spot welding (RFSSW) is an emerging solid-state welding technology that demonstrates an outstanding ability to join aerospace aluminum alloys. The thermomechanical processing of RFSSW may cause variations in the workpiece in the form of distortion. This study aims to establish a metrology method for sheet metal distortion with the intent to investigate the effects of RFSSW sequences on sheet metal distortion. The approach employs a robotic metrology system and the least squares method to measure and estimate the flatness of sheet metal before RFSSW and after RFSSW. The RFSSW experimentation produces five 10-spot-weld panels with five different RFSSW sequences, whereas the RFSSW sequences are based on the common practice of making sheet metal assemblies. A panel consists of two lap-welded sheets where the top sheet, a 6013-T6 aluminum alloy, is refill friction stir spot welded onto the bottom sheet, a 2029-T8 aluminum alloy. The results suggest that RFSSW sequences do have effects on sheet metal distortion. The panel with the worst distortion has a root-mean-square error of 0.8 mm as an average deviation from the ideal flatness. Full article

Part design is the principal source of communicating design intent to manufacturing and inspection. Design data are often communicated through computer-aided design (CAD) systems. Modern analytics tools and artificial intelligence integration into manufacturing have significantly advanced machine recognition of design specification and manufacturing constraints. These algorithms require data to be uniformly structured and easily consumable; however, the design data are represented in a graphical structure and contain a nonuniform structure, which limits the use of machine learning algorithms for a variety of tasks. This paper proposes an algorithm for extracting dimensional data from three-dimensional (3D) part designs in a structured manner. The algorithm extracts face dimensions and their relationships with other faces, enabling the recognition of underlying patterns and expanding the applicability of machine learning for various tasks. The extracted part dimensions can be stored in a dimension-based numeric extensible markup language (XML) file, allowing for easy storage and use in machine-readable formats. The resulting XML file provides a dimensional representation of the part data based on their features. The proposed algorithm reads and extracts dimensions with respect to each face of the part design, preserving the dimensional and face relevance. The uniform structure of the design data facilitates the processing of data by machine learning algorithms, enabling the detection of hidden patterns and the development of pattern-based predictive algorithms. Full article

This paper introduces a new formability test based on double-action radial extrusion to characterize material formability in the three-dimensional to plane-stress material flow transitions that are found in bulk metal-formed parts. The presentation draws from a multidirectional tool, which was designed to convert the vertical press stroke into horizontal movement of the compression punches towards each other, aspects of experimental strain determination, fractography, and finite element analysis. Results show that three-dimensional to plane-stress material flow transitions at the radially extruded flanges lead to different modes of fracture (by tension and by shear) that may or may not be preceded by necking, such as in sheet metal forming. The new formability test also reveals adequate characteristics to characterize the failure limits of very ductile wrought and additively manufactured metallic materials, which cannot be easily determined by conventional upset compression tests, and to facilitate the identification of the instant of cracking and of the corresponding fracture strains by combination of the force vs. time evolutions with the in-plane strains obtained from digital image correlation. Full article

An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control on the joints’ mechanical performance. To this end, a series of welds with a fixed 3° tilt angle, a travel speed of 120 mm/min, and 600 RPM of rotational speed was carried out. The analysis encompassed the mechanical strength of the fabricated joints and the mechanical energy input throughout the joining processes, the resulting cross-sectional interfaces, both on macro and micro scales, and the observed defects. The quasi-static shear tensile tests resulted in average tensile strengths varying between 5.5 and 26.1 MPa, representing joint efficiencies ranging from 10.1% to 47.4%, respectively. The joints that exhibited the lowest mechanical performance were fabricated with the highest level of tool penetration (higher pin length) with the process being position-controlled, while the best performance was recorded in joints welded with the lowest tool penetration and a force-controlled process. Nonetheless, the joint welded with a 2 mm long pin and position-controlled process exhibited a mechanical strength comparable with the highest one with a significantly lower standard deviation, a promising attribute for technological industrialization. In this way, it was found that the tool penetration, controlled by adjusting the pin length, played a significant role in the development of the joints’ morphology and, consequently, mechanical performance, whereas the process control exhibited a minor influence on the mechanical performance of the joints, but a considerable effect on process repeatability. Full article

In order to capitalize on the cost-effectiveness of additive manufacturing (AM), it is critical to understand how to build components with consistency and high quality. Directed energy deposition (DED) is an AM method for creating parts layer by layer through the use of a moving heat source and powder material inserted into the melt pool generated on the substrate. DED, like most AM processes, is highly complex due to the rapid thermal gradients experienced during processing. These thermal gradients are determined by a variety of processing parameters, which include laser power, powder feed rate, travel speed, layer height hatch spacing, etc. A lot of effort has been carried out in the additive manufacturing community to understand what these critical parameters are and how they influence the thermal gradients. Despite all these efforts, AM industries rely on a trial-and-error-based approach to find the right set of parameters to produce a quality part. This is time-consuming and not a cost-effective use of AM technology. The aim of our research is to reduce the amount of experimental data in combination with numerical analysis to optimize this relationship. Physics-based two-dimensional melt-pool modeling and experimental results from an OPTOMEC 850M LENS will be utilized to investigate the effects of processing parameters on melt-pool geometry, and the results from this study will provide key processing guidelines to achieve desirable clad geometry and powder efficiency for the DED method. Full article

A precise prediction of the rolling force is critical to ensure the quality of the final product, especially in the cold rolling of thin strips. Based on this, a new mathematical model is developed to work out the rolling force when considering the roll crossing angle and work roll shifting values at speed ratios of 1.1, 1.2 and 1.3. An iterative method was used to indicate the contact area shape, from which the rolling force was automatically calculated using the Matlab™ code for the cases of work roll cross angles of 0.5° and 1°. Experimental measurements and analysis were carried out to validate the theoretical calculations. The result shows that the theoretical analysis and experimental results are in good agreement, which indicates that the developed theoretical model can predict the rolling force well with a consideration of roll crossing during the cold rolling process. Full article

Component porosity is a quality attribute in additive manufacturing (AM). One possibility for the non-destructive three-dimensional determination of porosity or pore shape is X-ray computed tomography (CT), which enables an investigation of the influence of AM process parameters on the appearance and characteristics of the pores. Since there is no porosity standard for CT, a traceable determination of the measurement uncertainty is not possible. Using a digital twin of the CT system, an estimation of the CT measurement uncertainty is in principle possible. In this contribution, experimental CT analyses of powder bed fusion samples made of Ti64 and PA12 are compared with CT simulations. The results show a size-dependent influence on the shape and detectability of the pores. Using the CT model, a simulated shape- and material-dependent probability of detection (POD) is calculated. Full article

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization of an intelligent welding system (IWS) for feedback controlling the welding process. In this study, the GMAW process is controlled by a backpropagation neural network (NN). The feedback control of the welding process is controlled by the input parameters; root face and root gap, measured by a laser triangulation sensor. The NN is trained to adapt NN output parameters; wire feed and arc voltage override of the weld power source, in order to achieve consistent weld quality. The NN is trained offline with the specific parameter window in varying weld conditions, and the testing of the system is performed on separate specimens to evaluate the performance of the system. The butt-weld case is explained starting from the experimental setup to the training process of the IWS, optimization and operating principle. Furthermore, the method to create IWS for the welding process is explained. The results show that the developed IWS can adapt to the welding conditions of the seam and feedback control the welding process to achieve consistent weld quality outcomes. The method of using NN as a welding process parameter optimization tool was successful. The results of this paper indicate that an increased number of sensors could be applied to measure and control the welding process with the developed IWS. Full article

Thermo-deformation treatment refers to methods of strengthening during which strengthened layers with a nanocrystalline structure are formed in the surface layers by modifying the metal surface layer, which changes its phase and structural and chemical compositions, reduces grain size, and improves performance. Grinding of the metal structure was achieved by combining two methods simultaneously during this treatment: the action of a highly concentrated energy source on the surface layer and intense plastic deformation. The source of highly concentrated energy was generated in the contact zone of the tool-disc, which rotates at high speed during friction on the treated surface. Intense deformation was achieved due to the grooves on the tool’s working surface. Dynamic analysis of the thermo-deformation treatment process of flat surfaces of machine parts and a calculation scheme of the surface grinder machine’s elastic system, which is the three-mass model, were developed. When the groove width increased from 4 mm to 8 mm, the force amplitude in the contact zone increased from 10 N to 75 N. Accordingly, the thickness of the nanocrystalline layer increased from 190–220 μm to 250–260 μm, and its hardness increased from 9.3 GPa to 11.1 GPa. Full article

The residual stress state of the machined sub-surface influences the service quality indicators of a component, such as fatigue life, tribological properties, and distortion. During machining, the radius of the cutting edge changes due to tool wear. The cutting-edge rounding significantly affects the residual stress state in the part and the occurring process forces. This paper presents a tool wear prediction model based on in-process measured cutting forces. The effects of the cutting-edge geometry on the force behavior and the machining-induced residual stresses were examined experimentally. The resulting database was used to realize a Machine Learning algorithm to calculate the hidden value of tool wear. The predictions were validated by milling experiments using rounded cutting edges for different process parameters. The microgeometry of the cutting edge could be determined with a Root Mean Square Error of 8.94 μm. Full article

The time taken to exchange a cutting tool and the actual machining time are the components in a total production cycle time for a part, that affects productivity. Automated plate exchange systems strive for the simplest possible principles to achieve the shortest possible tool exchange time with sufficient accuracy. The tool holder in the presented article is based on the principle of a combination of translational, rotational movement, and stop surfaces by using a single pull–push rod for simple control. The article provides alternative tool holder designs and turning results of such holders using Rz-f dependence. The results of the time reduction are satisfactory and give a prerequisite for using a tool holder for the automated exchange of triangular cutting inserts. Moreover, the article provides the approach to reduce the mentioned total production cycle time by a reduction in the actual machining time for a part by use of tooltip radii, not by increasing the cutting speed. The triangular cutting insert can have three tooltips of three different tooltip radii for roughing and finishing. In addition, for reduction of the actual machining time, the double cutting tool with both the small tooltip radius for rouging and the large tooltip radius for finishing is presented. The double tool holders showed a 2.4-times reduction in the actual machining time for a part with Rz = 20 µm. Full article

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a final calibration step via cold forming are combined into one single step. The reduction of process steps and the reduced number of heating cycles present opportunities for improved energy efficiency compared to traditional processes. Based on a series of experiments, this paper aims at showing the potential of this new process in terms of obtainable hardness and microstructure. The influence of the active cooling system and the rolling feed is demonstrated. They are identified as essential with regard to both the geometry and the microstructural properties of the produced part. Finally, the repeatability of the process is analyzed, and potential disturbances are identified and ranked. Full article

Wire arc additive manufacturing (WAAM) is an emerging and promising technology for producing medium-to-large-scale metallic components/structures for different industries, i.e., aerospace, automotive, shipbuilding, etc. It is now a feasible alternative to traditional manufacturing processes due to its shorter lead time, low material waste, and cost-effectiveness. WAAM has been widely used to produce components using different materials, including copper-based alloy wires, in the past decades. This review paper highlights the critical aspects of WAAM process in terms of technology, various challenges faced during WAAM process, different in-process and post-process operations, process monitoring methods, various gases, and different types of materials used in WAAM process. Furthermore, it briefly overviews recent developments in depositing different copper-based alloys via WAAM process. Full article

To develop new areas of application for laser-based powder bed fusion of polymers (PBF-LB/P), a deeper process understanding of the resulting mechanical properties, particularly for thin-walled and complex structures, is needed. This work addresses the influence of part thickness and orientation in detail. For a general understanding, two PBF systems were used. For comparison, the normalized energy density was determined for specimens of various thicknesses and orientations. It could be seen that the normalized energy density exhibited opposing trends for the two systems for progressively thinner samples. During the process, the exposure temperature development was observed using an infrared camera for a greater understanding of the developing part properties. To further investigate the fracture behavior, an infrared camera was used during tensile testing, which revealed various patterns depending on the PBF-System used. The results showed a machine-dependent difference in the exposure temperatures and elongation at break for z-oriented parts. While the surface roughness was independent of the thickness, the density, porosity, and the mechanical properties were affected significantly by the part thickness. The parts showed a brittle breaking behavior with a crack initiation from the short side of the tensile bar. These results improved process expertise, and in particular the mechanical performance of thin-walled structures caused by temperature variations in PBF-LB/P. Full article

X-ray-computed tomography (CT) is today’s gold standard for the non-destructive evaluation of internal component defects such as cracks and porosity. Using automated standardized evaluation algorithms, an analysis can be performed without knowledge of the shape, location, or size of the defects. Both the measurement and the evaluation are based on the fact that the component has no internal structures or cavities. However, additive manufacturing (AM) and hybrid subtractive procedures offer the possibility of integrating internal structures directly during the building process. The examination of powder bed fusion (PBF) samples made of Ti64 and PA12 showed that the standardized evaluation methods were not able to identify internal structures correctly. Different evaluation methods for the CT-measured values were analyzed and recommendations on a procedure for measuring internal structures are given. Full article

The development of thin-film photovoltaics has emerged as a promising solution to the global energy crisis within the field of solar cell technology. However, transitioning from laboratory scale to large-area solar cells requires precise and high-quality scribes to achieve the required voltage and reduce ohmic losses. Laser scribing has shown great potential in preserving efficiency by minimizing the drop in geometrical fill factor, resistive losses, and shunt formation. However, due to the laser induced photothermal effects, various defects can initiate and impact the quality of scribed grooves and weaken the module’s efficiency. In this regard, much research has been conducted to analyze the geometrical fill factor, surface integrity, and electrical performance of the laser scribes to reach higher power conversion efficiencies. This comprehensive review of laser scribing of photovoltaic solar thin films pivots on scribe quality and analyzes the critical factors and challenges affecting the efficiency and reliability of the scribing process. This review also covers the latest developments in using laser systems, parameters, and techniques for patterning various types of solar thin films to identify the optimized laser ablation condition. Furthermore, potential research directions for future investigations at improving the quality and performance of thin film laser scribing are suggested. Full article

The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major factor in limiting production rates of high-strength aluminium alloys in laser-based processes such as welding or the powder bed fusion of metals (PBF-LB/M). Going away from a Gaussian intensity distribution to ring-shaped profiles allows for a more even heat distribution during processing, resulting in more stable melt pools and reduced defect formations. Therefore, the aim of this study is to investigate the influence of different laser beam profiles on the processing of high-strength aluminium alloys by using a multicore fiber laser, allowing for in-house beam shaping. Single weld tracks on the aluminium alloy EN AW-5083 are produced with varying laser powers and weld speeds, as well as different beam profiles, ranging from Gaussian intensity distribution to point/ring profiles. The molten cross sections are analyzed regarding their geometry and defects, and the surface roughness of the weld tracks is measured. By using point/ring beam profiles, the processing window can be significantly increased. Hot cracking is considerably reduced for weld speeds of up to 1000 mm/s compared to the Gaussian beam profile. Furthermore, the melt pool width and depth are more stable, with varying parameters for the point/ring profiles, while the Gaussian beam tends to keyhole formation at higher beam powers. Finally, a strong decrease in surface roughness for the point/ring profiles, accompanied by a significantly reduced humping effect, starting even at lower beam powers of 200 W, can be observed. Therefore, these results show the potential of beam shaping for further applications in laser-based processing of high-strength aluminium alloys. Full article