Article
Chemistry, Physical
Jacek Skiba, Mariusz Kulczyk, Sylwia Przybysz-Gloc, Monika Skorupska, Julita Smalc-Koziorowska, Mariusz Kobus, Kamil Nowak
Summary: This paper presents research on optimizing the unconventional plastic forming process of a copper alloy (CuCrZr) through hydrostatic extrusion (HE) and post-processing heat treatment. The study found that the post-processing treatment resulted in an improved microstructure, significantly increased hardness and strength, and maintained high electrical conductivity, thereby reducing electrode wear in the EDM process. The best results were obtained with a five-stage HE process combined with aging at 480 degrees C for 1 hour, reducing electrical discharge wear by over 50% compared to non-deformed copper electrodes.
Article
Materials Science, Multidisciplinary
Oliver Voigt, Urs Alexander Peuker
Summary: This study investigates the waste products of die-sink electro discharge machining (die-sink EDM) and explores their suitability as recycled materials in additive manufacturing (AM). The study finds that the waste particles fulfill the main requirements for AM usage in terms of size and shape, but chemical purity and the removal of undesired elements need improvement.
Article
Chemistry, Analytical
Timur Rizovich Ablyaz, Evgeny Sergeevich Shlykov, Karim Ravilevich Muratov, Sarabjeet Singh Sidhu
Summary: This study focuses on the wire-cut electro-discharge machining of polymer composite material (PCM) and demonstrates that by improving the workpiece conductivity and selecting appropriate process parameters, the cut-width accuracy can be significantly enhanced. Analysis of variance reveals that voltage and pulse duration play a crucial role in determining the cut-width, and the developed theoretical model proves to be effective within an acceptable range.
Article
Automation & Control Systems
Rui-Xue Zhang, Mo Chen, Xue-Cheng Xi, Wan-Sheng Zhao
Summary: This study proposes a dynamically variable attitude EDM machining method for deep narrow slots (DNSs) to improve machining efficiency. Experimental results show that this method has higher machining efficiency than the traditional fixed attitude method. The study also identifies the reasons for the improvement of machining efficiency through simulations and data analysis.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Chemistry, Physical
Shangyong Zhou, Zhenmin Luo, Tao Wang, Minyao He, Ruikang Li, Bin Su
Summary: Hydrogen energy, as a promising substitute for fossil energy, has witnessed significant development in recent years. However, safety issues regarding hydrogen limit its large-scale application. Research has shown that the minimum discharge pressure for hydrogen self-ignition is approximately 2 MPa, and factors such as discharge tube shape and bursting disc rupture significantly affect the characteristics of hydrogen self-ignition. Furthermore, the study of hydrogen self-ignition mechanism under special working conditions has been expanded through shock-induced ignition theory.
INTERNATIONAL JOURNAL OF HYDROGEN ENERGY
(2022)
Article
Automation & Control Systems
Mir Akmam Noor Rashid, Tanveer Saleh, Wazed Ibne Noor, Mohamed Sultan Mohamed Ali
Summary: The experimental investigation on the application of LBMM-mu EDM technique on stainless steel revealed the significant influence of laser input parameters, particularly scanning speed and power, on the performance of mu EDM. It was found that adjusting these laser parameters could either slow down or speed up the mu EDM processing time. The sequential machining technique was shown to reduce machining time, tool wear, and instability, while maintaining hole quality, compared to pure mu EDM process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Review
Materials Science, Multidisciplinary
Xuyang Zhu, Guangxian Li, John Mo, Songlin Ding
Summary: This paper reviewed the state-of-the-art technologies applied in machining semiconductors, summarized the advantages and disadvantages of each method, introduced the latest research outcomes, and discussed the future development trend.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Automation & Control Systems
Md Al-Amin, Ahmad Majdi Abdul-Rani, Rasel Ahmed, Muhammad Umair Shahid, Fatema Tuj Zohura, Muhammad Danial Bin Abd Rani
Summary: This research investigates the machining performance and surface features of 316L steel using EDM, with the utilization of nano multi-walled carbon nanotubes for improved responses. By conducting parametric optimization and utilizing non-dominated sorting genetic algorithm-II, the study achieves high material removal rate, low surface roughness, and thin recast layer thickness, showcasing the potential of EDM in instrument manufacturing industry.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Hongwei Pan, Zhidong Liu, Mingbo Qiu, Ming Zhang, Cong Deng
Summary: A concept of multichannel discharge WEDM under semiconductor characteristics was proposed to meet the increasing demand for wire electrical discharge machining (WEDM) under extreme conditions. Experiments on high-efficiency machining with multichannel discharge showed that it can achieve high machining efficiency, enhanced surface quality, and lower wear of electrode wire. The proposed multichannel discharge WEDM sets up the foundation for the establishment of the theoretical system of EDM under semiconductor characteristics.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Naveen Anthuvan Rex, Krishnaraj Vijayan
Summary: This study focuses on optimizing the machining of micro-holes using EDM and exploring ways to reduce debris accumulation in the sparking region. A hybrid process involving a low-frequency vibration platform and a flushing technique with a convergent nozzle was implemented. Experimental design and multi-response optimization were used to determine the best machining parameters. The results showed significant improvements in material removal rate and surface roughness using the optimized parameters.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2022)
Article
Chemistry, Physical
Jing Li, Wanwan Chen, Yongwei Zhu
Summary: The study introduced two-dimensional ultrasonic vibration into UE/DM, proposing the 2UE/DM method and optimizing parameters to achieve efficient and quality machining for MMCs.
Article
Dentistry, Oral Surgery & Medicine
Makdad Chakmakchi, Argiro Ntasi, Wolf Dieter Mueller, Spiros Zinelis
Summary: This study aimed to evaluate the effect of Cu and Ti electrodes on the surface and electrochemical properties of two types of dental alloys. The results showed that the use of Ti electrodes mitigates the degradation of electrochemical properties compared to Cu electrodes, making it safer for the fabrication of implant retained superstructures.
Article
Materials Science, Multidisciplinary
Oliver Voigt, Marco Wendler, Asim Siddique, Hartmut Stoecker, Caroline Quitzke, Urs A. Peuker
Summary: Different waste streams from electro discharge machining (EDM) were investigated for their potential use in additive manufacturing (AM). The results showed that the eroded powders from EDM fulfill the requirements for AM regarding particle size and shape, and have similar chemical composition to the machined alloy. However, the high carbon content in the powders leads to a transition in the microstructure. Remelting with slow heating and cooling rates can change the microstructure of the powders.
METALS AND MATERIALS INTERNATIONAL
(2023)
Article
Energy & Fuels
Yanlin Su, Wei Zhou, Junfeng Li, Lei Zhang, Jihui Gao, Pengxiang Wang, Yukun Qin
Summary: This study explores the challenges facing low volatile coal in industrial applications and verifies a novel non-contact microwave ignition method. It proposes the use of a switching atmosphere to ensure rapid microwave heating and ignition. The study finds that increasing the microwave power and O-2 proportion can prolong the burning time of the flame, and gas product analysis reveals the presence of the flame and the mechanism of plasma expanding the flame range.
Article
Thermodynamics
Rong Feng, Jiajian Zhu, Zhenguo Wang, Mingbo Sun, Hongbo Wang, Zun Cai, Bin An, Liang Li
Summary: A gliding arc discharge was used to ignite an ethylene-fueled scramjet combustor with an inflow speed of Ma = 2.92. The ignition process can be classified into direct ignition mode and re-ignition mode, with re-ignition mode being more likely in a local fuel-lean environment, exhibiting longer flame propagation time and a smaller flame kernel.
Article
Chemistry, Physical
Maria Laura Gatto, Riccardo Groppo, Nora Bloise, Lorenzo Fassina, Livia Visai, Manuela Galati, Luca Iuliano, Paolo Mengucci
Summary: Cellularized scaffold based on Ti6Al4V alloy with reused powder was investigated in this study, showing good mechanical and biological performance through surface functionalization with different coatings. Powder recycling is a viable practice for reducing preclinical costs in the biomedical industry without compromising biomechanical performance.
Article
Engineering, Manufacturing
Adriano Nicola Pilagatti, Gabriele Piscopo, Eleonora Atzeni, Luca Iuliano, Alessandro Salmi
Summary: This study aims to explore solutions for the optimal design of passive heat sinks to be fabricated by additive manufacturing, in order to address the high thermal power generated by electronic systems due to ongoing miniaturization and complexity. By using CAE and thermal topological optimization tools, significant weight reduction and high efficiency can be achieved in topology optimized passive heat sinks manufactured by AM.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Automation & Control Systems
Seyed Kiomars Moheimani, Luca Iuliano, Abdollah Saboori
Summary: In this study, AISI 316L specimens were produced using directed energy deposition (DED) technology. The effect of substrate preheating on the microstructure, hardness, surface roughness, and mechanical properties of the samples was investigated. The results showed that samples produced on a preheated substrate had lower thermal gradient and cooling rate, as well as higher inclusion content. Additionally, samples deposited on a cold substrate exhibited better mechanical performance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Metallurgy & Metallurgical Engineering
Mohammad Hossein Mosallanejad, Saber Sanaei, Masoud Atapour, Behzad Niroumand, Luca Iuliano, Abdollah Saboori
Summary: CP Ti cubes were produced using laser powder bed fusion method with different process parameters, resulting in variations in microstructure, porosity, and corrosion behavior. Samples with lower laser power exhibited higher porosity and thinner alpha laths, while samples with higher laser power showed slight improvement in bioactivity. All samples formed stable oxide films on their surfaces after different immersion times, but samples with lower laser power demonstrated superior passivation behavior after 1 and 3 days of immersion.
ACTA METALLURGICA SINICA-ENGLISH LETTERS
(2022)
Article
Engineering, Manufacturing
Manuela Galati, Silvio Defanti, Abdollah Saboori, Giovanni Rizza, Emanuele Tognoli, Nicolo Vincenzi, Andrea Gatto, Luca Iuliano
Summary: Ti-6Al-2Sn-4Zr-2Mo (Ti6242) is a crucial structural material with a maximum service temperature of 540 C, commonly used in hot sections of power generation systems. However, the processability of Ti6242 through conventional manufacturing processes is challenging due to its higher thermal resistance. This study investigates the processability of Ti6242 complex geometry components through Electron beam powder bed fusion (EB-PBF) process and optimizes the hatching conditions and contour strategy to achieve fully dense material and low surface roughness. The influence of processing conditions on density, microstructure, and defect content is analyzed using X-Ray computer tomography (CT) analysis. The study also evaluates the density and accuracy of complex geometries, such as cylindrical tensile specimens and an impeller, produced using selected optimum process conditions.
ADDITIVE MANUFACTURING
(2022)
Article
Chemistry, Physical
Flaviana Calignano, Diego Manfredi, Silvia Marola, Mariangela Lombardi, Luca Iuliano
Summary: In this study, Cu-10Sn tin-bronze alloy was produced using the laser powder bed fusion process. Optimal process parameters were determined through experimental design to obtain fully dense samples with low surface roughness and high dimensional accuracy. The results showed that the simplified approach of using volumetric energy density may limit the direct correlation with the physical aspects of the process.
Review
Chemistry, Multidisciplinary
Alessandro Bove, Flaviana Calignano, Manuela Galati, Luca Iuliano
Summary: This review discusses the characteristics and properties of ceramic resins and the stereolithography process, as well as the complexity of post-processing phases.
APPLIED SCIENCES-BASEL
(2022)
Article
Biotechnology & Applied Microbiology
Maria Laura Gatto, Paolo Mengucci, Daniel Munteanu, Roberto Nasini, Emanuele Tognoli, Lucia Denti, Andrea Gatto
Summary: Attachment or entrapment of microbial cells and enzymes offer potential solutions for various industrial applications. This research focuses on manufacturing rigid polymer beads using two different additive manufacturing techniques to assess their economic viability, reusability, and stability for industrial application. The study provides valuable insights into the production and characteristics of these beads, offering a perspective for biotechnologists to transition from laboratory-scale to industrial-scale production.
BIOENGINEERING-BASEL
(2023)
Article
Materials Science, Multidisciplinary
Andrea Gatto, Camilla Cappelletti, Silvio Defanti, Fabrizio Fabbri
Summary: Additive manufacturing of metal parts in the motorsport industry is an important technology for producing lightweight and rigid parts. The corrosion resistance of additively manufactured AlSi10Mg was compared with traditionally manufactured aluminium alloys in the automotive industry. Corrosion tests were conducted with various corrosive agents and different treatments. Additively manufactured AlSi10Mg generally showed better corrosion resistance, but still had a higher corrosion rate compared to traditionally manufactured aluminium alloys.
Article
Computer Science, Information Systems
Riccardo Rossi, Roberto Vincenti Gatti, Flaviana Calignano, Luca Iuliano, Simona Chiarandini
Summary: A low-profile single-ridge waveguide magic-T structure is proposed with two T-junctions at X band. The use of slot coupling technique reduces the component dimensions in the E-plane, achieving a low profile. The device can be configured in two ways, with the sum and difference ports arranged in the same or opposite direction, which is attractive for designing beamforming networks with complex routing. A magic-T prototype is fabricated using laser powder bed fusion additive manufacturing techniques, showing good agreement between simulations and measurements.
Article
Engineering, Manufacturing
Giovanni Rizza, Manuela Galati, Paolo Antonioni, Luca Iuliano
Summary: A distinctive characteristic of the powder bed fusion with electron beam (PBF-EB) process is the sintering of the powder particles, which is crucial for the success of the subsequent melting and the overall process. This study systematically investigated the effects of different particle diameters, particle diameter ratios, and the impact of the rigid body motion of the particles in the sintering process. The results demonstrated that the sintering outcomes significantly depended on the EB-PBF process conditions.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Chemistry, Physical
Farideh Davoodi, Mohammad Taghian, Giuseppe Carbone, Abdollah Saboori, Luca Iuliano
Summary: Fast progress in near-net-shape production has led to increased interest in internal surface finishing. This literature review focuses on the development of non-traditional finishing methods and compares their working principles, capabilities, and limitations. A thorough assessment is conducted based on seven key features, with two selected methods determining the value for a hybrid machine.
Article
Engineering, Manufacturing
Silvio Defanti, Camilla Cappelletti, Andrea Gatto, Emanuele Tognoli, Fabrizio Fabbri
Summary: The Laser Powder Bed Fusion (L-PBF) process is capable of producing parts with high geometric complexity, but there is a trade-off between mechanical properties and productivity. This paper explores the optimization of part quality and process productivity by fine-tuning the process parameters, and it finds that high scan speed and low hatch distance lead to the best results, despite similar energy density.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)
Article
Computer Science, Information Systems
Giuseppe Addamo, Mauro Lumia, Flaviana Calignano, Fabio Paonessa, Giuseppe Virone, Diego Manfredi, Luca Iuliano, Oscar A. Peverini
Summary: This paper presents a design of a Ka/K-band antenna-feeding network for satellite telecommunication multi-beam applications. The system, manufactured using AlSi10Mg alloy through selective laser melting, demonstrates excellent performance with high frequency bands and isolation levels.