Search Results (327)

Arc-based directed energy deposition (DED-Arc) processes represent a promising choice for developing flexible and eco-friendly manufacturing strategies for titanium components within the aerospace sector. Previous work has predominantly focused on using Ti-6Al-4V combined with machining for structural components. This study aims to establish a hybrid manufacturing route that integrates DED-Arc with flowforming (FF), focusing on the processability of Ti-15-3-3-3 in both stages. Sinusoidal path strategies for DED-Arc yield superior results in terms of process stability and geometrical accuracy, leading to near-net-shape preforms. In the FF process, a reduction of up to 80% in wall thickness across various techniques was achieved. The hybrid approach led to a buy-to-fly (BTF) ratio of 2.5:1, revealing the potential for significant material savings compared to conventional manufacturing routes. Full article

Background: Statistical shape modeling and generative tooth synthesis require dental point clouds in canonical poses. This study compared canonicalization methods and proposed a hybrid pipeline pairing principal-axis alignment with a neural orientation guide and a trained residual correction. Methods: Seven classical, neural, and hybrid methods were evaluated on 9060 upper tooth point clouds across seven classes from 3DTeethSeg (891 patients, 1805 held out for validation) and 1465 external first molars from FDI16. Alignment was measured by Chamfer Distance to per-sample target poses (CD Target, validation only), Chamfer Distance to class templates (CD Template, both sets), and geodesic rotation error. Results: Neural-guided PCA selection with residual refinement (gPCA-rPointNet) reached the lowest CD Target (0.62 ± 2.43 × 10⁻³) and geodesic rotation error (3.3 ± 14.5 degrees), with 98.2% of predictions below 15 degrees. On the external set, the four PCA-based methods gave a lower CD Template than methods without geometric initialization. Conclusions: A neural orientation guide placed before principal-axis candidate selection resolved the PCA eigenvector sign ambiguity responsible for 180-degree failures on near-symmetric tooth crowns. Residual correction further reduced rotation error. The same pipeline produced consistent canonical poses for first molars on the external dataset, with validation on other tooth classes remaining limited. Full article

Additive manufacturing (AM), also known as three-dimensional (3D) printing, has emerged as a revolutionary digital near-net-shape manufacturing technology, offering innovative solutions for the design and fabrication of complex, high-performance structures and equipment. This paper reviews the recent advancements and applications of metal AM technologies in the marine sector. Firstly, the principles and characteristics of three most widely adopted metal AM processes in this field are introduced: laser powder bed fusion (L-PBF), directed energy deposition (DED), and wire arc additive manufacturing (WAAM). Subsequently, the application status of metal AM is summarized in four key marine sectors: propulsion systems, underwater vehicle housings and structures, hull structures and shipboard equipment and components, as well as marine equipment repair and emergency support. Building on this, the major challenges for metal AM applications in the marine environment are further discussed, including the fabrication of large-scale components, standardization of materials and processes, integration of smart manufacturing and digital technologies, and sustainability and circular manufacturing. Finally, future trends are projected toward higher efficiency, intelligence, and environmental sustainability. It is indicated that metal AM will fundamentally reshape the manufacturing mode of marine equipment and support its high-performance, low-cost, intelligent and rapid-response development. Full article

Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable technique for producing large metallic components; however, coarse columnar microstructures, strong crystallographic texture, and significant residual stresses limit its widespread adoption. Hybrid WAAM processes that integrate deformation-based techniques have been developed to address these limitations. This review provides an analysis of deformation-assisted WAAM, covering interlayer rolling, friction stir processing (FSP), machine hammer peening, laser shock peening, and ultrasonic-vibration-assisted techniques. These hybrid techniques introduce additional thermomechanical parameters (strain, strain rate, and applied stress) that significantly influence microstructure evolution. The governing physical metallurgy mechanisms are discussed in detail, including dislocation accumulation, recovery, static and dynamic recrystallization, and severe plastic deformation. Studies from 2022 to 2025 are critically reviewed, highlighting the effectiveness of hybrid WAAM in promoting columnar-to-equiaxed grain transformation, reducing anisotropy, mitigating defects, and improving mechanical properties across aluminum, titanium, steels, and nickel-based alloys. The integration of auxiliary processes such as in situ machining and heat treatment is also discussed. This review establishes a process–structure–property framework for hybrid WAAM and provides guidance for the development of advanced additive manufacturing systems for the production of near-net-shape components, with reported yield-strength gains of 20–40%, elongation gains of 10–30%, and fatigue-life improvements of up to 60% relative to as-built WAAM. Full article

The increasing demand for sustainable industrial practices has intensified the search for manufacturing processes that minimize environmental impacts without compromising technical performance or economic viability. In this context, powder metallurgy has emerged as a promising alternative in mechanical manufacturing due to its potential for raw material reuse, waste reduction, lower energy consumption, and near-net-shape production. However, despite the growing body of research on this topic, there is still a lack of a comprehensive and integrated framework that systematically organizes and correlates the factors influencing sustainability across environmental, economic, and social dimensions, which limits a holistic understanding of the process. Therefore, this study aims to analyze and classify the main factors affecting sustainability in powder metallurgy. A Systematic Literature Review was conducted following the PRISMA method, using the Scopus, Web of Science and Wiley databases. The initial search identified 1753 articles, of which 56 were selected after applying inclusion and exclusion criteria. The analysis considers the three pillars of sustainability and examines how variables related to raw materials, energy consumption, processing technologies, waste reuse, product performance, and operational conditions influence process sustainability. The results enable the identification of the most recurrent factors in the literature and support the development of a structured theoretical framework, contributing to a more integrated understanding of sustainability in powder metallurgy. Full article

High-speed train aerodynamics have mainly been improved by passive design methods, such as streamlined noses, local fairings, and surface smoothing. These methods have achieved clear benefits, but several important aerodynamic problems remain difficult to solve by geometry optimization alone. Open-air drag is still affected by tail flow separation, base-pressure recovery, and disturbances around bogies and the underbody; crosswind safety is influenced by unsteady leeward-side separation and wake asymmetry; slipstream behavior depends on wake vortices, boundary-layer development, and complex near-ground underbody flow; and tunnel-related pressure transients arise from compression-wave generation, propagation, and reflection. These coupled effects mean that one fixed train shape cannot perform optimally in all operating conditions. For this reason, this review proposes that active flow control (AFC) should not be regarded only as a drag-reduction or stability-improvement technique for high-speed trains. Instead, it should be understood as a mission-adaptive aerodynamic control framework, in which different control actions are used for different operating scenarios. This paper first clarifies that passive optimization is increasingly subject to diminishing returns under multi-objective and engineering constraints. It then reviews AFC studies on drag reduction, base-pressure recovery, wake and slipstream control, underbody flow conditioning, crosswind mitigation, and tunnel pressure-wave suppression. Related AFC studies on bluff bodies, road vehicles, and other separated flows are included only when their physical relevance to trains is clear. The review further distinguishes gross aerodynamic improvement from net energy gain and identifies actuator power, durability, maintainability, acoustic impact, validation level, and full-scale transferability as decisive feasibility factors. Current research is still dominated by open-loop numerical studies with simplified actuation. Future work should therefore move toward multi-objective, closed-loop, energy-aware, sensor–actuator-integrated, and explainable machine-learning-assisted AFC. The main message is that the next step in train aerodynamics is not simply a better fixed shape, but a control-enabled train that can selectively redistribute aerodynamic authority across its mission profile. Full article

This study investigated how initial ingot thickness (400 mm vs. 520 mm) influences the microstructure and mechanical properties of Al–Zn–Mg–Cu alloys rolled to 80 mm. The combination of smaller initial thickness and lower total reduction (the 400-L route) results in lower dislocation density and a higher fraction of metastable η′ precipitates after T77 treatment. In contrast, the 520-L route, which involves a larger initial ingot thickness coupled with greater rolling reduction, yields higher dislocation density and a greater proportion of stable η phase. Texture also differs: the 400 mm ingot develops a strong S texture and high anisotropy, whereas the 520 mm ingot exhibits Brass texture and reduced anisotropy. Specifically, cross-rolling plus longitudinal rolling of the 520 mm ingot enhances recrystallization texture, giving a short-transverse yield strength of 528 MPa—within 6% of the longitudinal direction. This work offers valuable insights for controlling anisotropy in large 7xxx aluminum plates. Full article

6063 aluminum alloy has broad application prospects in aerospace and microelectronic thermal management systems due to its good thermal conductivity and moderate strength. However, its extremely high hot cracking susceptibility during the laser powder bed fusion (LPBF) process limits the direct manufacturing of complex components. This study proposes a strategy combining material composition modification with advanced structural design. By introducing TiH₂ nanoparticles (1.0~4.5 wt.%) to modify the 6063 aluminum alloy powder, Diamond-type porous structures based on triply periodic minimal surfaces (TPMS) were successfully fabricated using LPBF technology. The results show that the introduction of TiH₂ significantly suppresses the solidification cracking of the aluminum alloy. The underlying mechanism is that the L1₂-structured Al₃Ti particles, generated by the in situ decomposition of TiH₂ in the melt pool, provide high-density heterogeneous nucleation sites. This leads to a drastic decrease in the average grain size from 30.46 μm to 0.75 μm (a reduction of 97.5%), achieving a remarkable columnar-to-equiaxed transition (CET). In terms of mechanical properties, the 3.0 wt.% TiH₂ addition group exhibits excellent plateau stress (28.5 MPa) and energy absorption capacity, which is mainly attributed to the synergistic effect of fine-grain strengthening and Orowan dispersion strengthening. Thermal tests reveal that the thermal conductivity of the 3.0 wt.% group reaches 123 W/(m·K) at 100 °C. The healing of cracks reconstructs the macroscopic heat conduction paths, resulting in a significant improvement in thermal conductivity compared with the unmodified group. This work provides a theoretical reference for the development of high-performance, crack-free, and multi-functional integrated aluminum alloy components via additive manufacturing. Full article

Ceramics are widely evaluated for their extreme hardness, high-temperature stability, and corrosion resistance, which enable applications in harsh service environments. However, these same properties, high melting points, brittleness, and low thermal shock resistance, make conventional manufacturing of complex ceramic components difficult and expensive. Traditional processes often require costly diamond tooling or energy-intensive sintering and tend to produce only simple geometries, with significant waste material and risk of defects. Additive manufacturing (AM) has recently emerged as a promising route to fabricate intricate, near-net-shape ceramic parts without these drawbacks. By building components layer by layer, AM reduces the need for extensive machining and enables the fabrication of geometrically complex, near-net-shape ceramic structures with reduced material waste, although challenges such as porosity, interlayer defects, and cracking during post-processing remain. Nonetheless, ceramic AM technologies lag behind their metal and polymer counterparts, and significant challenges remain in achieving fully dense parts with reliable mechanical properties. This review provides an in-depth overview of the state of the art in ceramics and ceramic composite additive manufacturing. We detail the most widely used AM processes (stereolithography, binder jetting, material extrusion, powder bed fusion, inkjet printing, and direct energy deposition) and typical feedstock formulations for each technique. We examine the resulting mechanical properties (strength, toughness, hardness, wear resistance) and functional properties (thermal stability, dielectric behavior, biocompatibility) of additively manufactured ceramics, and discuss their current and potential engineering applications in the aerospace, defense, automotive, biomedical, and energy sectors. Persistent challenges, including porosity, shrinkage and cracking during sintering, achieving uniform microstructures, high process costs, and scalability issues, are analyzed, and we highlight promising future directions such as multi-material grading, integration of machine learning for process optimization, and sustainable manufacturing approaches. Despite significant progress, challenges remain in achieving fully dense structures, improving process reliability, and scaling ceramic AM for industrial applications, highlighting the need for further research in process optimization, material design, and multi-material integration. Full article

High-performance cutting materials are central to modern production engineering. Cemented carbides dominate industrial tooling, while polycrystalline boron nitride (PcBN) is established for hard turning and finishing nickel-based alloys. The associated tool manufacturing chains are energy- and effort-intensive, motivating approaches that reduce material losses and primary energy demand. This study quantifies energy consumption across the production of solid carbide cutting tools with a focus on near-net-shape green machining, its impact on subsequent grinding and material recirculation. It also quantifies energy consumption for regrinding PcBN cutting tools. Power measurements were recorded during green machining and tool grinding of cylindrical versus pre-contoured (green-machined) blanks, including coolant units for the carbide tools during operation. Tool performance of the carbide tools was assessed via milling tests in 42CrMo4; PcBN reground tools were evaluated in Inconel 718. In the process chain of carbide tool production, specific energy decreased from 6.98 to 6.36 kWh/kg (−8.88%) despite +0.461 kWh/kg for green machining; direct recirculation of green-machined material saved an additional 5.861 kWh/kg. Reground PcBN inserts achieved comparable tool life to new tools while reducing energy by ≈85% per insert. The dominant levers for energy reduction are shorter grinding times in the presence of high machine and coolant base loads and systematic regrinding of high-embodied-energy tools. Full article

Accurate delineation of tumor margins is critical for complete resection and minimizing recurrence, yet existing imaging modalities such as MRI, CT, and fluorescence imaging suffer from limitations including high cost, limited accessibility, and intraoperative constraints. In this study, we propose a low-cost, non-invasive approach for subsurface imaging based on near-infrared (NIR) illumination combined with deep learning. A controlled experimental setup was developed in which structured patterns displayed on an electronic paper screen were concealed beneath a tissue-mimicking chicken phantom and imaged using a NIR-sensitive camera under halogen illumination. A convolutional autoencoder based on a U-Net architecture was trained on approximately 10,000 paired samples to reconstruct hidden structures from highly scattered surface images. The proposed method achieved strong reconstruction performance, with the best model reaching a peak signal-to-noise ratio (PSNR) of 20.14 dB, structural similarity index (SSIM) of 0.92, and feature similarity index (FSIM) of 0.94, significantly outperforming conventional Wiener filtering. Qualitative results demonstrated accurate recovery of subsurface shapes with minor smoothing artifacts. While generalization to out-of-distribution samples remains limited, the findings highlight the potential of combining NIR imaging and deep learning for safe, rapid, and cost-effective subsurface visualization. This work establishes a foundation for future development toward clinically relevant tumor margin detection. Full article

Polyether Ether Ketone (PEEK) is a high-performance polymer increasingly utilized in additive manufacturing due to its exceptional thermal, chemical, and mechanical properties. Thus, they are used to produce aerospace brackets, fuel system parts, seals, compressor valve plates, etc. This study investigates the mechanical performance of both neat PEEK and glass fiber-reinforced PEEK (PEEK + GF) composites fabricated via fused deposition modeling (FDM). The effects of print speed, print orientation, and post-heat treatment were systematically evaluated. Among the tested orientations, the 0° print direction with post-heat treatment at 250 °C yielded highest tensile strength of ~80 MPa, outperforming the 45° and 90° orientations. Print speeds ranging from 5 to 20 mm/s and annealing temperatures between 250 °C and 300 °C significantly influenced material properties. For neat PEEK, both tensile strength and microhardness improved with increasing print speed and post-heat treatment, peaking at 20 mm/s and 250 °C. However, annealing at 300 °C led to performance degradation, attributing to gas-induced porosity within the material. The PEEK + GF composites achieved a maximum ultimate tensile strength (UTS) of approximately 83 MPa under the same optimal conditions (20 mm/s print speed and 250 °C post-treatment). This enhancement is attributed to improved fiber alignment along the print path, increased crystallinity, and superior interfacial bonding. Notably, the composites did not exhibit the microstructural damage observed in neat PEEK at the higher annealing temperature. Full article

Quantifying oxidative, glycolytic, and phosphagen energy system contributions during exercise is challenging due to their simultaneous activation and reliance on indirect estimation. This narrative review critically examines the methodological foundations, assumptions, and practical implications of current approaches used to estimate energy system contributions during continuous and intermittent exercise, with the aim of clarifying how these methods shape the interpretation of bioenergetic responses. Oxidative contribution, primarily estimated through oxygen uptake (VO₂) integration, typically exceeds (~75–88%) in continuous efforts longer than 6 min and can reach values above ~87% when exercise duration allows full development of VO₂ kinetics, particularly in trained young adult cohorts. In contrast, supramaximal efforts shorter than 30–90 s involve markedly lower oxidative contribution, commonly below ~50% and as low as ~8–19%. Glycolytic contribution is inferred from net blood lactate concentration accumulation and increases with exercise intensity, ranging from ~3–5% in longer severe-intensity efforts to values up to ~60% during brief maximal tasks lasting 15–30 s. Phosphagen contribution is estimated using the fast component of post-exercise VO₂ recovery or theoretical phosphocreatine breakdown models, and can reach ~39–48% in maximal efforts lasting 10–15 s, while declining to values below ~10% in prolonged exercise. Each method is shaped by exercise duration, intensity, structural format, and physiological assumptions, contributing to methodological heterogeneity and limiting direct comparability between studies. Advances in portable gas analyzers, near-infrared spectroscopy, and biosensing technologies have improved temporal resolution and ecological validity. To enhance the accuracy and practical application of energy system profiling, standardized and integrative frameworks are urgently required. Full article

Selective laser melting (SLM), a pivotal additive manufacturing (AM) technology for titanium alloys, enables near-net-shape forming of complex structures with relative densities of up to 99.9%, making it indispensable in aerospace, biomedical, and marine engineering. This review comprehensively updates the state of the art on SLM-fabricated TC4 (Ti-6Al-4V) alloy, addressing critical gaps in previous studies by integrating novel research progress, in-depth mechanistic analyses, and multi-dimensional comparisons. The core focus is on the unique thermal cycle (10⁶–10⁸ °C/s heating/cooling rates) of SLM, which induces a predominant needle-like martensitic α′ phase (99.7%) and minimal β phase (0.3%), leading to intrinsic anisotropy and low ductility. Room-temperature tensile strength reaches 1315.32 MPa with 9.6% elongation, and high-cycle fatigue limits the range from 417 to 829 MPa, strongly dependent on process parameters and post-treatment. Corrosion anisotropy is systematically analyzed: the XY plane (parallel to scanning direction) exhibits superior corrosion resistance in 1 M HCl (fewer pits and lower corrosion current density) and 3.5% NaCl (more stable passive film) compared to the XZ plane (deposition direction). Novel insights include: (1) synergistic effects of SLM process parameters (laser power–scanning speed–hatch spacing) on defect evolution and microstructure uniformity; (2) atomistic mechanisms of α′→α + β phase transformation during post-heat treatment; and (3) corrosion–mechanical coupling behavior in harsh environments (e.g., marine and biomedical). Post-treatment strategies are refined: annealing at 800 °C for 2 h achieves 1099 MPa tensile strength and 17.4% elongation, while hot isostatic pressing (HIP) reduces porosity from 0.08% to 0.01% and weakens fatigue anisotropy. This review also identifies unresolved challenges (e.g., in situ defect monitoring and multi-field regulated performance) and proposes future directions (e.g., AI-driven process optimization and functional gradient structures). Full article

The β grain size in titanium alloys during industrial forging is critical for balancing toughness, cost-effectiveness, and processability. To address the industrial challenge of high cost and difficulty in refining β grains to the tens of micrometers scale, this study investigates the feasibility of achieving a superior strength–ductility balance in TC18 alloy with near-industrial coarse β grains (296~857 μm) under room temperature tension. A pronounced inverse correlation is observed between β grain size and both strength and ductility. The yield strength–grain size relationship follows the Hall–Petch effect, while the anomalous increase in ductility for fine-grained specimens is attributed to three factors. First, smaller grains provide a higher grain boundary density, promoting stress redistribution and mitigating stress concentrations. Second, more uniform stress distribution induces thinner, denser kink bands that enhance plasticity. Third, strain-induced martensite evolves from discrete nanoscale particles to discontinuous lines and ultimately coalesces into continuous planar bands along the (112)β and (110)β planes. This phase transformation, which initiates below a critical grain size of ~500 μm, further alleviates stress concentrations towards slip bands and contributes to dynamic work hardening. The findings demonstrate that coordinated deformation mechanisms enable excellent mechanical performance even in coarse-grained microstructures, providing a practical pathway for optimizing industrial-grade titanium alloys. Full article