This paper describes the evaluation of an advanced substrate designed with a newly developed flexible polymeric material by spray coating, for use in an innovative additive laser structuring process, called Laser Induced Metallization (LIM). The evaluation was done by studying the feasibility to produce components with the LIM process and the relationship between the laser processing parameters and

Hybrid manufacturing is a combination of additive (deposition) and subtractive (machining) manufacturing in a single machine tool. Such a system can be used for near net shape manufacturing and component repair using either similar or dissimilar materials. Integrated into a single system, transition between additive and subtractive manufacturing can occur immediately and be leveraged to generate large

To improve the fretting wear resistance of TC6 alloy, AT40 coating and Al2O3/AT40 composite coating were prepared on TC6 respectively by atmospheric plasma spraying (APS) technology. The microstructure, composition and adhesion strength of the two coatings were studied, and the fretting wear behavior of TC6 substrate and the coatings were investigated. The results showed that, the two coatings were

Machining of carbon fiber-reinforced polymer (CFRP) with less damage remains to be a challenge because of anisotropy and inhomogeneity issues. Flood cooling will reduce the mechanical properties of CFRPs due to its hygroscopicity, however, dry grinding will result in thermal damage and deterioration of surface integrity, which cause it not suitable in aeroengine and aerostructure applications. Aiming

Electromagnetic pulse welding (EMPW) is an environmentally-friendly, fast, and efficient welding technology for dissimilar metals. In this study, a 28 kJ/20 kV EMPW system is designed and developed to carry out the EMPW experiment of welding 1060 aluminum plate and T2 copper plate. The complete process of the jet has been captured during the welding process through an integrated observation system

Cutting vibration has a large influence on the machining accuracy and surface quality of thin-walled parts. An innovative and effective cutting vibration suppression method suitable for the milling of thin-walled cavity parts is proposed in this paper which is based on the shear thickening property of the corn starch suspension. Cutting vibration signals with and without the corn starch suspension

This work reports on a methodology to extend Oxley’s analysis of the thick shear zone to account for HCP materials. Ultimately, the work extracts Zerilli-Armstrong (ZA) constitutive equation’ material parameters for AZ31B, an HCP crystal structure magnesium-based alloy. The methodology for accomplishing this utilizes three tasks namely: 1) Extension of thick shear zone approach for machining force

Triple-spiral micro-grooves on the tool-shoulder end-surface is a feature recently being used for improving material flow during micro-friction stir welding (µFSW). However, its effect on process responses in comparison to the plain tool-shoulder end-surface lacks recognition, which has been targeted in the present work. An additional contribution to the knowledge base of µFSW tools having such features

Minimum quantity lubrication (MQL) machining is an advanced near dry cutting technology in modern machining field. However, the cutting oil mist produced during the process of oil-based MQL affected the ambient air quality and endangered the health of employees. To avoid this drawback, a novel lubrication/cooling method called electrostatic minimum quantity lubrication (EMQL) which used SiO2 water-based

Previous investigations on the theoretical model to predict burr dimensions have normally been confined to a single geometric model, and the findings that have been proposed rarely take into account the influence of multi-physics factors on burr formation in the complex machining process. This paper proposes an analytical model to reveal subsurface plastic deformation behavior in machining of ductile

Strategies to investigate the primary shear zone in metal cutting are largely based on chip root examinations. This type of analysis is limited to providing only indirect results, because it is a post-process measurement. It is significantly influenced by the metallographic preparation of the chip root as well as the analysis method of the micrographs. Some applications require precise determination

Laser cladding is an additive manufacturing technology that enables rapid large-volume deposition of metal onto a substrate by forming a stable track on a target surface. It is now widely used for surface functionalization and parts repairing. In this paper, the full shape of the material deposition has been analytically modelled, including bulge (the part above the surface) and melt pool (the part

In gear skiving, tool wear is one of the primary issues owing to the large thermomechanical cutting load. However, the effective rake angle and depth-of-cut can vary continuously throughout a single cut, leading to a complex uncut chip geometry that significantly hinders the understanding of the cutting characteristics and adds further difficulty to the prediction of tool wear. This study proposes

Although die-casting is one of the most popular mass production processes of precise metal parts, the manufacturing environment of the die-casting factory remains at the traditional level. In this study, we developed three core technologies to realize a smart-factory platform for die-casting industry: 1) a novel cost-effective product-tracking technology to obtain high-quality process data providing

The present work aims to evaluate distortion and residual stresses in thick plate weld joints of austenitic stainless steel. Quantification of residual stresses in thick austenitic stainless steel weld joint is important because it is not desirable to carry out stress relieving after welding owing to the susceptibility to sensitization in the heat-affected zone. Therefore, systematic studies were carried

Laser powder bed fusion (LPBF) process was utilized to prepare high-performance steel matrix composites (SMCs) consisting of a tool steel (1.2767 L) matrix with various contents of submicron-sized WC reinforcing particles. The influence of the content of WC reinforcing particles on constitutional phase, microstructural evolution, densification rate and mechanical properties of SMCs was investigated

The correlation between lamellar globularization and deformation modes during the primary hot processing of titanium alloy was evaluated by means of uniaxial compression, tension, torsion and plane strain compression tests. The microstructure evolution features and underlying globularization mechanisms were comparatively studied via Electron Backscattered Diffraction technique. Noticeable divergences

This study compared the arc shapes and microstructures obtained from gas tungsten arc welding of AZ91 magnesium alloy for different parameters of an external alternating cusp-shaped magnetic field which was applied during the welding process; the parameters included excitation currents of 1 A to 3 A and excitation frequencies of 0 Hz–100 Hz. The experimental results showed that the tungsten inert gas

Magnetic-controlled Electroslag Remelting (MC-ESR) process has been proposed to improve the inclusion removal efficiency in recent years. In this study, the effects of transverse static magnetic field (TSMF) on liquid melting film (LMF) and inclusion removal during this period in ESR process of GCr15 steel were studied by a series of MC-ESR experiments. The thickness of the characteristic position

A 10 mm 316 L stainless steel, filled by 1.2 mm 316 LSi, was joined using multi-layer laser-GMAW in the presence of a constant magnetic field. Results suggested that the addition of a 18 m T magnetic field resulted in an optimized weld bead formation with asymmetrical fusion line and grain growth by stabilizing the arc morphology and droplet transfer in the narrow gap. The interaction of arc current

Predicting springback in the bending of magnesium sheet is difficult because it has high mechanical anisotropy leading to significant differences in the material behaviour in tension and compression. The tension/compression yield mismatch in magnesium is affected by the twinning behaviour which depends on the grain size and the direction of loading in regard to the crystal (C-axis) orientation. In

Electron Beam Selective Melting (EBSM) is an advanced additive manufacturing technique used in many vital industrial fields. However, the lack of process monitoring and quality control is largely restricting the industrial application. The optical-based monitoring methods are hindered by the complex working conditions, such as intensive radiation, elevated temperature, and severe evaporation. Electronic

Understanding the thermal distortion induced by arc welding, laser, or induction heating is a challenge in academia and industry. This study presents the artificial thermal strain (ATS) method which was modified from strain as boundary (SDB) method, based on inherent strain theory, and its equivalent mechanical model to analyse the distortion mechanism. Experiments and numerical simulation of multi-pass

In the machining process of Carbon Fiber Reinforced Plastic (CFRP), fibers fracture in two modes, including shearing fracture and bending fracture. Studies show that both fractures originate from the combined action of normal and shear stresses, while specific stress states are different. In the present study, novel fiber fracture criteria are proposed, which are closely correlated with the specific

Chatter is a limiting factor during boring of deep holes with long slender boring bars. In this article, a new magnetorheological (MR) damper is introduced to increase the stability of the boring process. The sponge-type configuration of the damper utilizes a minimal amount of MR fluid in the annulus around the boring bar. The MR fluid layer and the electromagnetic circuit are externally applied to

Polylactic acid (PLA) based scaffolds have attracted worldwide attention as promising biodegradable implants in bone tissue engineering. PLA matrix is often incorporated with fillers to engineer composite scaffolds with improved mechanical properties and excellent biocompatibility. In the present study, PLA composite scaffolds were additively manufactured utilizing fused filament fabrication (FFF)

With the rapid progress of science and technology, many applications of hard and brittle materials require advanced and suitable machining-techniques. One technique in particular, ultrasonic vibration-assisted polishing (UVAP), has been studied intensively by researchers worldwide. These studies indicate that UVAP has the capability to improve the surface quality as well as the machining efficiency

A new steel chemical composition is combined with a new press hardening process, in which die-quenching is interrupted by opening the forming tool to permit slow cooling of the hot formed part through the anisothermal bainitic ferrite transformation. This promotes carbon partitioning to austenite before the forming tool is re-closed and die-quenching is resumed to near-ambient temperature. The final

In gas tungsten arc welding (GTAW), columnar grains typically grow from the fusion line of a weld to its centerline because of high temperature gradient and small growth rate. This columnar grain often causes premature failure during bending or expansion in the center of the fusion zone. Equiaxed grains, on the other hand, reduce the occurrence of cracks and improve the ductility, strength, and toughness

Nickel-base alloy CM247LC is particularly sensitive for weld-cracking during powder-bed fusion, caused by an inappropriate laser spot diameter due to focus shifting. In this paper, the influence of a 4 mm focus shift on the melt pool geometry, intensity, relative Archimedean density, crack density, microstructure and texture is investigated, by using two different calibration procedures for the laser

In this study, the mechanical and magnetic properties of FeCoNiAl0.25Mn0.25 high-entropy alloy (HEA) were investigated by subjecting as-cast samples to cold rolling and annealing at different temperatures for 1 h. The as-cast and cold rolled HEAs show a single-phase face-centered cubic (FCC) structure. The annealing temperature has a noteworthy influence on the phase composition and microstructure

The yield-point phenomenon (YPP) is generally eliminated or reduced in aged sheet metals to avoid defects during metal forming applications; however, it may be beneficial in specific applications and could be induced to enhance certain properties. For example, bake hardening (BH), peculiarized by a sharply elevated yield stress after baking of pre-strained low carbon steel, can be used to improve the

Introducing small-sized functional features such as anti-drag and anti-icing micro structures on Carbon Fibre Reinforced Plastics (CFRPs) is challenging but a still unmet demand. Existing contact CFRP machining solutions may bring unavoidable tool wear and surface defects. Non-contact approaches may introduce significant thermal damage (laser), inconsistent features (waterjet), and limited achievable

A ferrite-austenite 12CrNi2 alloy steel additively manufactured by laser melting deposition (LMD) has been treated by various quenching methods, including direct quenching (DQ), inter-critical quenching (IQ) and step quenching (SQ), respectively, to form the martensite-ferrite dual-phase steel with a similar major volume fraction (62 vol.%) but different grain sizes and lath substructures of martensite

Mask stereolithography technology uses ultraviolet masks to print curable liquid materials. A key process for layer-by-layer bottom-up mask printing is the separation of cured layer from the vat bottom. For film-assisted separation, most studies focused on the separation process of the inert film that bonded to the vat bottom. The separation characteristics and mechanism of the widely used flexible

Advanced high strength steels (AHSS) used in automotive structural components are commonly protected using zinc coatings. However, the steel/zinc system creates the potential for liquid metal embrittlement (LME) cracking during welding. In this study, the effect of angular welding electrode misalignment as recommended by industry was investigated and resulted in LME cracking in the sub-critical heat

Nowadays, the Riv(et)-Bonding technique has become a major joining approach in the automotive industry. It effectively incorporates the benefits of the adhesive bonding and the self-pierce riveting (SPR), but overcomes their individual drawbacks. Finite element (FE) simulation of the SPR process now plays a very important role during the product design and manufacture processes in the automotive field

Additive manufacturing (AM) provides a higher degree-of-freedom manufacturing process for high-mix low-volume manufacturing. However, the as-built surface quality by AM processes is generally inferior to that fabricated by conventional subtractive manufacturing and the machinability investigation for post-processing of additively manufactured (AMed) parts is insufficient. In this paper, milling experiments

Ultrasonic metal forming technology has a great potential for highly productive manufacture of miniature parts. Extremely high plasticity can be achieved under the condition of ultrasonic impact loading of the small-height and thin samples (the so-called “ultrasonic dynamic impact effect”). Despite this, the wide use of ultrasonic micro-forming processes is restricted with some technical challenges

Previous studies have shown that sharp physical and chemical changes may induce the formation of swirl-like reaction phases in the ultrasonic spot welding (USW) of different materials. However, the mechanisms have not been well understood. In particular, swirl-like structures have seldom been discovered or discussed in the USW of Cu/Sn. In this study, swirl-like phases were observed in the USW of a

The evolution of crystallographic texture during the thermo-mechanical processing of aluminium sheet is accompanied by the development of plastic anisotropy and, most notably, the well-known earing phenomenon. In the present paper we analyse the formation of texture and earing properties in sheets of the Al-Mg alloy AA 5050A (ISO AlMg1.5(D)) along a process route resulting in temper H16 after cold

A novel composited process including solution treatment-hot gas forming and stress relaxation aging is proposed in this paper to form titanium alloys component with high precision and improved strength simultaneously. Firstly, solution and aging treatments were carried out to study the effects of processing parameters on microstructure and properties. Secondly, uniaxial tensile tests at solution temperature