Search Results (991)

The object of this study is welded joints of AISI 321 and Ti-6Al-4V, obtained by diffusion welding on developed conical surfaces. The problem of creating bimetallic joints of AISI 321 and Ti-6Al-4V with developed conical contact surfaces, using diffusion welding through an intermediate Electrolytic Tough Pitch Copper (Cu-ETP) copper layer, was solved. The joints were studied using micro-X-ray spectral analysis, microstructural analysis, and mechanical tests. High mutual diffusion of copper and titanium, along with increased concentrations of Cr and V in copper, was detected. The shear strength of the obtained welded joints is 250 MPa and 235 MPa at 30 min and 15 min, respectively, which is higher than the copper layer’s strength (180 MPa). The obtained results are explained by the dislocation diffusion mechanism in the volume of grains and beyond, due to thermal deformations during welding. Under operating conditions of internal pressure and cryogenic temperatures, the strength of the connection is ensured by the entire two-layer structure, and tightness is ensured by a vacuum-tight diffusion connection. The obtained strength of the connection (250 MPa) is sufficient under the specified operating conditions. Analysis of existing solutions in the literature review indicates that industrial application of technology for manufacturing bimetallic adapters from AISI 321 stainless steel and Ti-6Al-4V titanium alloy is limited to butt joints with small geometric dimensions. Studies of the transition zone structure and diffusion processes in bimetallic joints with developed conical contact surfaces enabled determination of factors affecting joint structure and diffusion coefficients. The obtained bimetallic adapters, made of Ti-6Al-4V titanium alloy and AISI 321 stainless steel, can be used to connect titanium high-pressure vessels with stainless steel pipelines. Full article

The escalating climate crisis and global disruptions have prompted a critical re-evaluation of operations management within manufacturing and supply systems. This conceptual article addresses the theoretical and strategic gap in aligning resilience and sustainability by proposing an Integrated Sustainable Operational Strategy (ISOS) framework. Drawing on systems theory, circular economy principles, and sustainability science, the framework synthesizes multiple operational domains—circularity, localization, digital adaptation, and workforce flexibility—across macro (policy), meso (organizational), and micro (process) levels. This study constructs a conceptual model that explains the interdependencies and trade-offs among strategic operational responses in the Anthropocene era. Supported by multi-level logic and a synthesis of domain constructs, the model provides a foundation for empirical investigation and strategic planning. Key propositions for future research are developed, focusing on causal relationships and boundary conditions. The novelty of ISOS lies in its simultaneous integration of three strategic pillars—circularity, localization, and digital resilience—within a unified, multi-scalar architecture that bridges fragmented operational theories. The article advances theory by redefining operational excellence through regenerative logic and adaptive capacity, responding directly to SDG 9 (industry innovation), SDG 12 (responsible consumption and production), and SDG 13 (climate action). This integrative framework offers both theoretical insight and practical guidance for transforming operations into catalysts of sustainable transition. Full article

As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article

Acoustic tweezers, as advanced micro/nano manipulation tools, play a pivotal role in biomedical engineering, microfluidics, and precision manufacturing. However, piezoelectric-based acoustic tweezers face performance limitations due to multi-physical coupling effects during microfabrication. This study proposes a novel approach using injection molding with embedded electronics (IMEs) technology to fabricate piezoelectric micro-ultrasonic transducers with micron-scale precision, addressing the critical issue of acoustic node displacement caused by thermal–mechanical coupling in injection molding—a problem that impairs wave transmission efficiency and operational stability. To optimize the IME process parameters, a hybrid multi-objective optimization framework integrating NSGA-II and MOPSO is developed, aiming to simultaneously minimize acoustic node displacement, volumetric shrinkage, and residual stress distribution. Key process variables—packing pressure (80–120 MPa), melt temperature (230–280 °C), and packing time (15–30 s)—are analyzed via finite element modeling (FEM) and validated through in situ tie bar elongation measurements. The results show a 27.3% reduction in node displacement amplitude and a 19.6% improvement in wave transmission uniformity compared to conventional methods. This methodology enhances acoustic tweezers’ operational stability and provides a generalizable framework for multi-physics optimization in MEMS manufacturing, laying a foundation for next-generation applications in single-cell manipulation, lab-on-a-chip systems, and nanomaterial assembly. Full article

Currently, the shear-extrusion behavior of solid propellants (SPs), which comprise a significant volume fraction of micro-/nanoscale solid particles (e.g., octogen/HMX), nitroglycerin as a plasticizer/solvent, nitrocellulose as a binder, and other functional additives, is still insufficiently understood. While the rheology of highly filled polymers has been extensively documented, the rheological behavior of SPs within the practical processing temperature range of 80–95 °C remains poorly understood. This study investigated, in particular, the pressure dependence of the viscosity of SPs melts during steady-state shear flow. Steady-state shear measurements were conducted using a twin-bore capillary rheometer with capillary dies of varying diameters and lengths to explore the viscosity dependence of SPs. The results reveal that interface defects between octogen particles and the polymer matrix generate a melt pressure range of 3–30 MPa in the long capillary die, underscoring the non-negligible impact of pressure on the measured viscosity (η). At constant temperature and shear rate, the measured viscosity of SPs exhibits strong pressure dependence, showing notable deviations in pressure sensitivity (β), which was found to be greatly relevant to the contents of solvent and solid particles. Such discrepancies are attributed to the compressibility of particle–particle and particle–polymer networks during capillary flow. The findings emphasize the critical role of pressure effect on the rheological properties of SPs, which is essential for optimizing manufacturing processes and ensuring consistent propellant performance. Full article

Silicon carbide (SiC) half-bridge power modules are widely utilized in new energy power generation, electric vehicles, and industrial power supplies. To address the research gap in collaborative validation between electro-thermal coupling models and process reliability, this paper proposes a closed-loop methodology of “design-simulation-process-validation”. This approach integrates in-depth electro-thermal simulation (LTspice XVII/COMSOL Multiphysics 6.3) with micro/nano-packaging processes (sintering/bonding). Firstly, a multifunctional double-pulse test board was designed for the dynamic characterization of SiC devices. LTspice simulations revealed the switching characteristics under an 800 V operating condition. Subsequently, a thermal simulation model was constructed in COMSOL to quantify the module junction temperature gradient (25 °C → 80 °C). Key process parameters affecting reliability were then quantified, including conductive adhesive sintering (S820-F680, 39.3 W/m·K), high-temperature baking at 175 °C, and aluminum wire bonding (15 mil wire diameter and 500 mW ultrasonic power/500 g bonding force). Finally, a double-pulse dynamic test platform was established to capture switching transient characteristics. Experimental results demonstrated the following: (1) The packaged module successfully passed the 800 V high-voltage validation. Measured drain current (4.62 A) exhibited an error of <0.65% compared to the simulated value (4.65 A). (2) The simulated junction temperature (80 °C) was significantly below the safety threshold (175 °C). (3) Microscopic examination using a Leica IVesta 3 microscope (55× magnification) confirmed the absence of voids at the sintering and bonding interfaces. (4) Frequency-dependent dynamic characterization revealed a 6 nH parasitic inductance via Ansys Q3D 2025 R1 simulation, with experimental validation at 8.3 nH through double-pulse testing. Thermal evaluations up to 200 kHz indicated 109 °C peak temperature (below 175 °C datasheet limit) and low switching losses. This work provides a critical process benchmark for the micro/nano-manufacturing of high-density SiC modules. Full article

As an emerging energy-saving approach, bio-inspired drag reduction technology has become a key research direction for reducing energy consumption and greenhouse gas emissions. This study introduces the latest research progress on bio-inspired microstructured surfaces in the field of underwater drag reduction, focusing on analyzing the drag reduction mechanism, preparation process, and application effect of the three major technological paths; namely, bio-inspired non-smooth surfaces, bio-inspired superhydrophobic surfaces, and bio-inspired modified coatings. Bio-inspired non-smooth surfaces can significantly reduce the wall shear stress by regulating the flow characteristics of the turbulent boundary layer through microstructure design. Bio-inspired superhydrophobic surfaces form stable gas–liquid interfaces through the construction of micro-nanostructures and reduce frictional resistance by utilizing the slip boundary effect. Bio-inspired modified coatings, on the other hand, realize the synergistic function of drag reduction and antifouling through targeted chemical modification of materials and design of micro-nanostructures. Although these technologies have made significant progress in drag reduction performance, their engineering applications still face bottlenecks such as manufacturing process complexity, gas layer stability, and durability. Future research should focus on the analysis of drag reduction mechanisms and optimization of material properties under multi-physical field coupling conditions, the development of efficient and low-cost manufacturing processes, and the enhancement of surface stability and adaptability through dynamic self-healing coatings and smart response materials. It is hoped that the latest research status of bio-inspired drag reduction technology reviewed in this study provides a theoretical basis and technical reference for the sustainable development and energy-saving design of ships and underwater vehicles. Full article

In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al₂₇Ca₃Cu₇ primary crystals and ultrafine eutectic particles of (Al,Cu)₄Ca and Al₂₇Ca₃Cu₇ phases in equilibrium with the aluminum solid solution. The solid solutions are additionally strengthened by alloying with Mn and micro additions of Zr, which contribute to the formation of coarsening-resistant phases without compromising the manufacturability of the alloys. Laser remelting, which simulates AM-typical solidification conditions, promotes the formation of a pseudoeutectic cellular structure without the occurrence of undesirable primary Al₂₇Ca₃Cu₇. The size of the dendritic cells and eutectic particles is 10 times smaller (for solidification rates of ~200 K/s) than that of the as-cast state. This structure provides for a higher hardness of the laser-remelted alloy (96 HV) as compared to the as-cast alloy (85 HV). Data for the alloy after 350–400 °C long-term annealing for up to 100 h show that the hardness of the Al–Ca–Cu–Mn–Zr alloys declines relatively slowly by ~7.5% as compared to the Zr-free alloy, whose hardness decreases by ~22%. Thus, one can consider these alloys as a promising candidate for AM processes that require high thermal stability. Full article

Current non-destructive testing (NDT) methods, such as those based on wave velocity measurements, lack the sensitivity necessary to detect early-stage damage in concrete structures. Similarly, common signal processing techniques often assume linearity and stationarity among the signal data. By analyzing wave attenuation measurements using advanced signal processing techniques, mainly Hilbert–Huang transform (HHT), this work aims to enhance the early detection of damage in concrete. This study presents a novel energy-based technique that integrates complete ensemble empirical mode decomposition with adaptive noise (CEEMDAN) and Hilbert spectrum analysis (HSA), to accurately capture nonlinear and nonstationary signal behaviors. Ultrasonic non-destructive testing was performed in this study on manufactured concrete specimens subjected to micro-damage characterized by internal microcracks smaller than 0.5 mm, induced through controlled freeze–thaw cycles. The recorded signals were decomposed from the time domain using CEEMDAN into frequency-ordered intrinsic mode functions (IMFs). A multi-criteria selection strategy, including damage index evaluation, was employed to identify the most effective IMFs while distinguishing true damage-induced energy loss from spurious nonlinear artifacts or noise. Localized damage was then analyzed in the frequency domain using HSA, achieving an up to 88% reduction in wave energy via Marginal Hilbert Spectrum analysis, compared to 68% using Fourier-based techniques, demonstrating a 20% improvement in sensitivity. The results indicate that the proposed technique enhances early damage detection through wave attenuation analysis and offers a superior ability to handle nonlinear, nonstationary signals. The Hilbert Spectrum provided a higher time-frequency resolution, enabling clearer identification of damage-related features. These findings highlight the potential of CEEMDAN-HSA as a practical, sensitive tool for early-stage microcrack detection in concrete. Full article

As digital transformation in manufacturing accelerates, process bottleneck prediction has emerged as a central task in industrial automation. To streamline manufacturing processes, where diverse tasks interact in complex ways, it is essential to identify in advance both the location and timing of bottleneck occurrences. However, manufacturing environments often lack high-performance computing resources and must rely on cost-effective, resource-constrained embedded devices, making fast and accurate prediction challenging. We present MicroForest, a lightweight decision tree-based model designed to predict multiple process bottlenecks simultaneously under such resource-constrained environments. MicroForest reassembles the high-information-gain nodes from dozens of large random forests into compact forests. Evaluated on a simulation containing up to 150 production tasks, MicroForest achieves 34%p higher recall scores compared to original random forests while shrinking model size by two orders of magnitude and accelerating inference latency by up to $7.2\times$. Compared with other recent work, MicroForest outperforms them with the highest prediction accuracy (F1 = 0.74) and shows a much gentler increase in latency as process complexity grows. Full article

Background: Acrylic resin-based materials are a versatile category used extensively in various dental applications. Processed by current modern technologies, such as CAD/CAM technologies or 3D printing, these materials have revolutionized the field of dentistry for the efficient creation of dental devices. However, despite their extensive use, a limited number of comparative studies exist that investigate how different processing methods—such as traditional techniques, 3D printing, and CAD/CAM milling—impact the nano-mechanical behavior and internal porosity of these materials, which are critical for their long-term clinical performance. Objectives: The purpose of this study is to evaluate the nanomechanical properties (hardness, elasticity, and stiffness) and micro-porosity of acrylic resin-based materials indicated for temporary prosthodontic appliances manufactured by new technologies (milling, 3D printing) compared to traditional methods. Methods: The hardness, elasticity, and stiffness measurements were performed by the nano-metric indentation method (nanoindentation), and the quantitative morphological characterization of the porosity of the acrylic resin samples obtained by 3D printing and CAD/CAM milling was performed by micro-computed tomography. Results: According to nanomechanical investigations, CAD/CAM milling restorative specimens exhibited the greatest mechanical performances (E~5.233 GPa and H~0.315 GPa), followed by 3D printed samples, while the lowest mechanical properties were registered for the specimen fabricated by the traditional method (E~3.552 GPa, H~0.142 GPa). At the same time, the results of porosity studies (micro-CT) suggested that 3D printed specimens demonstrated a superior degree of porosity (temporary crown—22.93% and splints—8.94%) compared to CAD/CAM milling restorative samples (5.73%). Conclusions: The comparative analysis of these results allows for the optimal selection of the processing method in order to ensure the specific requirements of the various clinical applications. Full article

This work introduces an original approach to the manufacturing of ionizing radiation-sensitive systems for radiotherapy applications—dosimetry. They are based on the Fricke dosimetric solution and the formation of macro-gels and capsules, and nano- and micro-gels. The reaction of ionic polymers, such as sodium alginate, with Fe and Ca metal ions is employed. Critical polymer concentration (c*) is taken as the criterion. Reaction of ionic polymers with metal ions leads to products related to c*. Well below c*, nano- and micro-gels may form. Above c*, macro-gels and capsules can be prepared. Nano- and micro-gels containing Fe in the composition can be used for infusion of a physical gel matrix to prepare 2D or 3D dosimeters. In turn, macro-gels can be formed with Fe ions crosslinking polymer chains to obtain radiation-sensitive hydrogels, so-called from wall-to-wall, serving as 3D dosimeters. The encapsulation process can lead to capsules with Fe ions serving as 1D dosimeters. This work presents the concept of manufacturing various gel structures, their main features and manufacturing challenges. It proposes new directions of research towards novel dosimeters. Full article

The enduring manufacturing goals are increasingly shifting toward ultra-precision manufacturing and micro-nano fabrication, driven by the demand for sophisticated products. Unconventional machining processes such as electrochemical jet machining (ECJM), electrical discharge machining (EDM), electrochemical machining (ECM), abrasive water jet machining (AWJM), and laser beam machining (LBM) have been widely adopted as feasible alternatives to traditional methods, enabling the production of high-quality engineering components with specific characteristics. ECJM, a non-contact machining technology, employs electrodes on the nozzle and workpiece to establish an electrical circuit via the jet. As a prominent special machining technology, ECJM has demonstrated significant advantages, such as rapid, non-thermal, and stress-free machining capabilities, in past research. This review is dedicated to outline the research progress of ECJM, focusing on its fundamental concepts, material processing capabilities, technological advancements, and its variants (e.g., ultrasonic-, laser-, abrasive-, and magnetism-assisted ECJM) along with their applications. Special attention is given to the application of ECJM in the semiconductor and biomedical fields, where the demand for ultra-precision components is most pronounced. Furthermore, this review explores recent innovations in process optimization, significantly boosting machining efficiency and quality. This review not only provides a snapshot of the current status of ECJM technology, but also discusses the current challenges and possible future improvements of the technology. Full article

Electret filter media are electrostatically charged during the manufacturing process to activate effective electrical separation mechanisms. In order to investigate the influence of humidity on these mechanisms, the electric field, and filtration efficiency, a Direct Numerical Simulation (DNS) study of the aerosol deposition within wetted fibrous nonwoven filter media used in masks was carried out. Initial experimental investigations determined key properties of the filter material, including porosity, fiber diameter, and surface charge density. Using Micro-Computed Tomography (µCT), preferred locations for droplet deposition within the filter were identified. Additional experiments quantified the amount of water absorbed by the filter medium and assessed its impact on the existing electric field. Numerical simulations examined various models with differing porosity and fiber diameter, incorporating different levels of water content to analyze the changes in the electric field, flow velocity, and resulting filtration efficiency. The results provide valuable insights into the significant effects of fiber change on filtration performance, demonstrating the electret filter’s ability to partially compensate for the negative impacts of water. Full article

The aim of this in vitro study is to investigate the adhesion, proliferation, and differentiation of human adipose-derived mesenchymal stem cells (hASC) on Trabecular Titanium scaffolds manufactured with different manufacturing processes (EBM and SLM). The in vitro adhesion and proliferation of hASC on titanium scaffolds with WST assays have been carried out. The comparison of the gene expression profiles of typical bone genes (Alp, Bglap, Col1a1, and Osx) through real-time PCR assays and the evaluation of extracellular matrix composition with immunofluorescence and SEM analysis have been performed. In addition, the possible osteoinductive properties of the two scaffolds have been investigated through real-time PCR and ALP assays. Data showed that Trabecular Titanium supports human adipose-derived mesenchymal stem cell colonization and induces differentiation in bone with the deposition of the abundant extracellular mineralized matrix regardless of the manufacturing process, proving that the micro- and macro-design features are the key factors responsible for the osteoinduction behavior. These features can only be achieved through tailored 3D printing process parameters. Full article