Search Results (50)

This study evaluates the formability of single-pass and double-pass friction stir-welded AA6082 tailor-welded blanks produced at a 1000 rpm rotational speed and 100 mm/min welding speed. The objective is to understand the effect of multi-pass welding strategies on stir zone (SZ) softening, load-bearing capacity, and strain localization during biaxial stretching. Formability was assessed using limiting dome height (LDH) tests, supported by hardness mapping, tensile tests, 3D digital image correlation, and complementary finite element (FE) simulations. The results exhibit similar dome heights (~14 mm) in both weld conditions, but single-pass welds sustain 5 kN higher peak load, better strength, and ductility. Shell-based FE models reproduce the load–displacement response and strain localization within ~5% of experimental results. Full article

In conventional CNC machining, the workpiece clamping pose is registered with a preset CAD model under multiple geometric constraints to establish the machining reference frame. The tool path, generated from this model, is subsequently used to produce components of identical geometry. However, this paradigm proves inadequate when a final shape must accommodate morphological variations specific to each individual blank. Manual grinding, as an alternative, is not only inefficient and hazardous but also relies heavily on subjective quality assessment. To address these challenges, we propose an adaptive local-region milling strategy tailored for blanks with similar yet non-identical surface morphologies, enabling the finished geometry to adjust dynamically to each workpiece. Under conditions of under-constrained clamping, visual positioning is first employed to automatically locate the target regions. Line laser scanning is then conducted over the planned area to acquire high-density point clouds. Through segmentation, points lying outside the region to be machined are extracted, from which a theoretical post-machining surface is reconstructed. Milling toolpaths are subsequently planned based on this reconstructed model to compensate for surface variations across different blanks. Experimental validation on a three-axis CNC milling machine demonstrates that the proposed adaptive strategy effectively replaces manual grinding by removing the bulk of the machining allowance from locally variant surfaces. With the reconstructed model serving as the reference, 77.1 percent of the machining errors fall below 0.055 mm. These results confirm that the method yields a smooth and level surface finish, thereby meeting the fundamental requirements for such adaptive machining tasks. Full article

Tool wear significantly impacts the productivity and efficiency of sheet metal stamping operations, particularly in high-volume progressive die applications. This study presents an iterative calibration framework for Archard’s wear model, tailored to industrial stamping processes. The proposed methodology integrates finite element simulations with experimentally measured wear data obtained from production components, enabling data-driven calibration of the wear coefficient $K_{sim}$. The framework achieves high predictive accuracy, with deviations of 1.4–3.7% between simulated and optically measured wear depths and localization, after more than 15 million strokes. Rapid convergence is obtained within two to three calibration cycles, significantly reducing computational effort while maintaining physical fidelity. The simulation setup incorporates detailed modelling of contact pressure, sliding velocity, and stress distribution, validated using optical surface measurement systems and coordinate-based metrology. Beyond the specific industrial case, the framework demonstrates transferability to other sheet metal forming processes, such as bending, blanking, and coining, by leveraging physically based parameter adaptation across comparable pressure–velocity regimes. The approach enables predictive wear modeling in data-scarce environments and supports early-stage tool design workflows. Overall, the proposed methodology bridges the gap between empirical calibration and generalized simulation, contributing both methodological rigour and practical applicability to manufacturing science. Full article

Reliable surveillance of dissolved ²²²Rn in arid-region aquifers is challenged by very low natural activity and method-dependent biases, especially humidity sensitivity in electrostatic detectors and air–water partitioning during closed-loop aeration, which can obscure true concentrations needed for defensible drinking-water baselines under preventive frameworks. This study aimed to optimize and field-validate a low-background RAD7 Big-Bottle (RAD H₂O) closed-loop protocol tailored for arid conditions and apply it in a regional survey of groundwater used for potable supply in northeastern Saudi Arabia. Groundwater from wells across the region (shallow and deep completions) was collected and analyzed using isotope-resolved alpha spectroscopy (Po-218 and Po-214 windows) with strict chamber humidity control (≤7% RH), background checks, systematic blanks, duplicates, drift control (±10%), and uncertainty propagation. Air-phase chamber counts were mandatorily converted to water-phase activity using the CAPTURE parameterized by measured loop volumes, temperature, salinity, and humidity, and agreement was evaluated using regression diagnostics and Bland–Altman analysis. The optimized method achieved sub-Bq·L⁻¹ performance, with MDL improving from ~0.1645 Bq·L⁻¹ (30 min) to ~0.0233 Bq·L⁻¹ (1500 min) and ~0.0165 Bq·L⁻¹ (3000 min), and LOQ decreasing from ~0.50 to ~0.0707 and ~0.050 Bq·L⁻¹, respectively. Raw air-phase readings systematically overestimated dissolved radon by ~26% (slope ≈ 1.26), a bias removed by the validated air → water conversion. Surveyed ²²²Rn concentrations were uniformly low (0.03–3.20 Bq·L⁻¹), far below commonly used reference values (e.g., ~11.1 and ~100 Bq·L⁻¹), with no persistent spatial hotspots and broadly overlapping shallow/deep distributions, indicating variability dominated by local lithology and fracture-controlled flow rather than depth. A tiered monitoring scheme is recommended: short screening, routine baselining at ~900–1500 min total counting, and ~3000 min for ultralow verification, providing a transferable template for sustainable baseline programs in arid aquifers. Full article

This study introduced a pre-holed hot clinching process for hot stamping patchwork blanks, using the lower sheet pre-hole as a forming cavity to facilitate material flow and minimize deformation resistance. Evaluated through mechanical testing and finite element analysis (FEA), the process induced ausforming and maintained material homogeneity (~500 HV), and an optimal interfacial gap up to 10 mm effectively prevented localized soft-zone fractures. Results identified interfacial slip, driven by a critical differential surface expansion rate, as the primary mechanism for geometric anchoring and solid-state bonding. Experimental validation established optimal joining at a 60% penetration ratio and a 0.9 hole-to-punch diameter ratio. While prior studies on forge joining reported average maximum strengths limited to 1.2 kN due to the absence of a mechanical hook, the optimized pre-holed joints in this work achieved a superior tensile shear capacity of 11.5 kN. Furthermore, the cross-tension load reached 0.77 kN, representing a nearly tenfold increase compared to the 0.08 kN observed in the no-hole with offset condition. These results demonstrate that the pre-holed hot clinching method significantly enhances joint integrity while reducing the forming load from 70 kN without a pre-hole to 12 kN with a 10 mm pre-hole. Full article

Ultra-high-strength steel sheets were joined by forge joining during hot stamping. This study investigated the influence of punch cross-sectional shape and punch tip inclination shape on joint strength through experiments and finite element simulation, with applications in hat bending. The experiments systematically evaluated various punch geometries by varying the punch’s cross-sectional shape and the aspect ratio of rectangular punches. A second set of experiments focused on the influence of punch tip inclination shape. These experiments examined a rectangular punch with a slope. Joint strength is primarily assessed by measuring the tensile shear load. Finite element simulation was used to analyze joining mechanisms, investigating contact pressure and surface expansion rate distribution. The results from the experiments consistently indicated that, for a constant cross-sectional area, punch shapes with a larger punch perimeter on the upper sheet yielded a higher tensile shear load, though the changing inclination shape of the rectangular punch tip did not lead to an observed improvement in joint strength. Finite element simulation analysis revealed that punch shapes promoting a uniform distribution of contact pressure and surface expansion rate across the joint area tended to exhibit higher joint strength compared with the same punch cross-sectional area but less uniform distribution, a tendency that was more pronounced for the distribution of contact pressure than for the surface expansion rate. Full article

To address limitations such as cleaning difficulties or secondary contamination/damage of cultural relics caused by the uncontrollable diffusion of water/cleaning agent/dirty liquids during the cleaning process in traditional cleaning methods, this study, using cotton textiles as an example, systematically investigated the cleaning efficacy of four in situ methods (blank gel, cleaning gel, ultrasonic emulsification, and gel + ultrasonic emulsification synergistic cleaning) on eight types of stains, including sand, clay, rust, blood, ink, oil, and mixed solid/liquid stains. Building upon this, this study proposed an efficient, targeted, in situ, and controllable cleaning strategy tailored for fragile, stained textile relics. Results demonstrated that, regardless of the stain type, the synergistic cleaning method of G+U (gel poultice + ultrasonic emulsification) consistently outperformed the cleaning methods of blank gel poultice, cleaning gel poultice, and ultrasonic emulsification. Furthermore, the gel loaded with cleaning agents was always more effective than the blank gel (unloaded cleaning agents). The poultice methods of blank gel and cleaning gel were better suited for solid stains, while the ultrasonic emulsification cleaning method was more effective for liquid stains. Meanwhile, it was also found that the optimal cleaning method proposed in this study (the G+U synergistic cleaning method) was a cleaning method that restricted the cleaning agent within the gel network/emulsion system, and utilized the porous network physical structure of gel, the chemical action of emulsion’s wetting/dissolving dirt, and the cavitation synergistic effect of ultrasound to achieve the targeted removal of contaminants from relics’ surfaces. Crucially, the cleaning process of G+U also had the characteristics of controlling the cleaning area at the designated position and effectively regulating the diffusion rate of the cleaning solution within the treatment zone, as well as the reaction intensity. Therefore, the proposed optimal (the synergistic cleaning method of G+U) cleaning method conforms to the significant implementation of the “minimal intervention and maximal preservation” principle in modern cultural heritage conservation. Consequently, the synergistic cleaning method of G+U holds promise for practical application in artifact cleaning work. Full article

This paper, based on the Johnson–Cook damage model, investigates the damage mechanism of high-strength steel tailor welded blanks (TWBs) (Usibor1500P and Ductibor500) during the forming process. Initially, specimens with varying notch sizes were designed and fabricated to perform uniaxial tensile tests to determine their mechanical properties. Then, the deformation process of the notched specimens was simulated using finite element software, revealing the distribution and variation of stress triaxiality at the fracture surface. By combining both experimental and simulation data, the parameters of the Johnson–Cook (J–C) damage model were calibrated, and the effects of temperature, strain rate, and stress triaxiality on material fracture behavior were further analyzed. Based on finite element analysis, the relevant coefficients for stress triaxiality, strain rate, and temperature were systematically calibrated, successfully establishing a J–C fracture criterion for TWB welds, Usibor1500P, and Ductibor500 high-strength steels. Finally, the calibrated damage model was further validated through the Nakajima-type bulge test, and the simulated Forming Limit Diagram (FLD) closely matched the experimental data. The results show that the analysis based on the J–C damage model can effectively predict the fracture behavior of tailor welded blanks (TWB) during the forming process. This study provides reliable numerical predictions for the damage behavior of high-strength steel laser-customized welded sheets and offers a theoretical basis for engineering design and material performance optimization. Full article

The temperature of the tools and the moisture content of the material play a significant role in the 3D forming of paperboard in terms of the degree of forming and the quality of the formed part. It is known that different forming mechanisms act within the paperboard in different areas of the deep drawing tools during the deep drawing of paperboard and that the success of the forming process is also based on a dynamic interaction between material moisture and tool surface temperature. However, it has not yet been investigated how the forming parameters can be influenced by an individually adjustable temperature for the individual tool areas and how they influence the complex interaction with the moisture content of the paperboard during the forming process. Due to the inhomogeneity of the natural fiber network of paperboard, rapid and directed temperature changes of the tools are also of interest in order to be able to react quickly to variations of material properties in order to prevent frequent process failure within a continuous production. In this paper, test tools with individually controllable heating zones were developed and the use of different heating technologies to improve the rate of temperature change was analyzed. These tools were used to investigate the influence of temperature in the individual sections of the deep drawing process and how the moisture content can be specifically controlled during the process. It was found that with modern heating technology, the deep-drawing tools can be tempered significantly faster and that a temperature difference between the blank holder zone and the drawing cavity zone has a positive influence on the formability and the fixation of the shape of the part produced. This effect was further enhanced by the fact that, thanks to the temperature tailored tool, it was possible to work with a very high moisture content of the paperboard. Full article

Detecting microplastics (MPs) in marine organisms is vital for understanding the ecological impact of MP pollution. Free-living marine nematodes, key players in benthic ecosystems, are often employed as bioindicators because of their sensitivity to environmental changes and thus hold promise as bioindicators for MP pollution too. This study investigated the detection of MPs in nematodes using µ-Raman spectroscopy combined with a tailored digestion protocol, targeting MPs in size ranges between 1 and 15 µm. While this is the first documented attempt to detect MPs in field-collected nematodes, significant challenges were identified. Contamination, particularly from airborne MPs and plastic-based laboratory materials, posed a major obstacle. We found higher numbers of <5 µm particles of polypropylene (PP), polyethylene terephthalate (PET), polylactic acid (PLA), polymethyl methacrylate (PMMA), and polystyrene (PS) in a natural community of nematodes compared to blank controls, suggesting the potential ingestion of small-sized MPs by nematodes in the real world. However, small MPs exhibited greater contamination challenges, underscoring the need for improved contamination control measures, such as open-air filters and plastic-free workflows. Despite these challenges, this study highlights the potential of µ-Raman spectroscopy as a valuable tool for detecting small-sized MPs in field-collected marine invertebrates, provided contamination risks are minimized. The likelihood of nematodes encountering MPs in marine sediments is high, but whether this translates to significant ingestion remains uncertain pending on the analysis of more field samples and the application of efficient measures of contamination reduction. Full article

In this study, high-strength steels B1500HS and B340LA were used as base materials, and laser welding experiments were conducted within a parameter range of welding power from 1500 W to 3000 W and welding speed from 15 mm/s to 35 mm/s. Microstructural analysis, microhardness testing, and uniaxial tensile tests were performed to systematically investigate the effects of different welding parameters on the weld microstructure and macroscopic mechanical properties, leading to the identification of an optimal welding parameter range that avoids defect-prone regions. The bending formability of tailor-welded blanks (TWBs) was evaluated using hat-shaped bending tests, with finite element simulations employed to analyze the effects of welding parameters on stress distribution and material hardening behavior. Based on the identified high-quality welding parameters, a suitable welding parameter range for reverse bending conditions was determined, effectively improving the bending formability of TWBs and providing theoretical guidance and experimental support for their engineering applications. Full article

Finite element (FE) analysis of the tensile test of TWB-HPF 22MnB5 steel was performed and compared with the experimental results. To improve the accuracy of the simulation, the damage theory of FLD and ductile damage theory were used in 2D and 3D simulations. The tensile strength of 22MnB5 steel was determined under various welding heat inputs for FE simulation. Crack propagation of the welded region indicated that the fracture was observed in the base metal under normal welding conditions. Also, the crack propagated along the HAZ region due to higher heat input of the welding, and lead fractures have been highlighted as a potential complication. Full article

The mechanical properties and cross-sectional geometric dimensions of the fusion zone (FZ), heat affected zone (HAZ), and base metal (BM) of 6xxx series aluminum alloys are inconsistent after filler wire welding, which reduces the formability of aluminum alloy tailor welded blanks (TWBs). This paper proposes a post-weld cold rolling-solution heat treatment (PWCR-SHT) composite process, and the effects of weld excess metal, plastic deformation, and SHT on the formability of aluminum alloy TWBs are studied. The results show that the PWCR-SHT composite process eliminates the weld excess metal and internal pores, reduces the stress concentration at the weld toe, eliminates the local strain hardening behavior, and causes recrystallization in the FZ region. The cupping value of aluminum alloy TWBs using SHT is 105% of BM, in comparison, the cupping value of aluminum alloy TWBs using the PWCR-SHT composite process is 119% of BM, which is the result of the combined effect of geometric dimensions consistency and mechanical properties consistency. Full article

This paper presents the effect of the complex strain state resulting from the asymmetric rolling of TRB products on the changes and distribution of the stress state in the material. The evaluation of the stress state in the material was based on measurements of the magnetoelastic parameter (MP) using the Barkhausen magnetic noise method. The key characteristics of the material under study that enabled the use of changes in the MP parameter to assess the stress state were ferromagnetism and a lack of texture. The first of these enabled the detection of the magnetic signals produced when a magnetic field is applied to the material, causing magnetic domains to align and sudden changes in magnetization. On the other hand, the absence of texture in the material precluded the occurrence of magnetocrystalline anisotropy, which could disturb the results of measurements of the magnetoelastic parameter in the material. In order to determine these features in the material under study, its chemical composition was determined, and a phase analysis was carried out using the X-ray diffraction method. The results of these tests showed the possibility of determining the stress state of the material by means of changes in the values of the MP parameter. On this basis, it was shown that in the TRB strips studied, there is a complex state of stress, the values of which and the nature of the changes depending on the direction of the measurements carried out, as well as on the amount of rolling reduction in the studied area of the strip. Full article

Friction stir welding, as a solid-state welding technique, is especially suitable for effectively joining high-strength aluminum alloys, as well as for multi-material welds. This research investigates the friction stir welding of thin aluminum and steel sheets, an essential process in the production of hybrid tailor-welded blanks employed in deep drawing applications. Despite its proven advantages, the welding process exhibits variable outcomes concerning formability and joint strength when utilizing an H13 welding tool. To better understand these inconsistencies, multiple welds were performed in this study, joining 1 mm thick steel to 2 mm thick aluminum sheets, with a cumulative length of 7.65 m. The accumulation of material on the welding tool was documented through 3D scanning and weighing. The integrity of the resulting weld seam was analyzed through metallographic sections and X-ray imaging. It was found that the adhering material built up continuously around the tool pin over several welds totaling between 1.5 m and 2.5 m before ultimately detaching. This accretion of material notably affected the welding process, resulting in increased intermixing of steel particles within the aluminum matrix. This research provides detailed insights into the dynamics of friction stir welding in multi-material welds, particularly in the context of tool material interaction and its impact on weld quality. Full article