Article
Materials Science, Coatings & Films
M. Doubenskaia, A. Kulish, A. Sova, P. Petrovskiy, I Smurov
Summary: This study optimized the coating conditions and nozzle selection of laser cladding technology, finding that short nozzles with high gaps are more suitable for industrial cladding, while medium nozzles with low gaps are preferred for 3D direct fabrication.
SURFACE & COATINGS TECHNOLOGY
(2021)
Article
Automation & Control Systems
Mengya Chu, Guofu Lian, Mingpu Yao, Meiyan Feng, Changrong Chen, Xu Huang
Summary: This study established a numerical model to analyze the influences of the distance between the nozzle and substrate, carrier-gas flow rate, and powder feeding voltage on the utilization efficiency and forming efficiency of powders. The results showed that the optimal working distance and gas flow rate led to the highest powder utilization rate, and increasing the powder feeding voltage improved both the cladding area and the powder utilization rate.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Optics
Qing Chai, Xu He, Yan Xing, Guifang Sun
Summary: In this study, a numerical model of gas-powder flow was established using a Computational Fluid Dynamics (CFD) modelling method based on the v2-f turbulence model. The interaction between gas and powders was calculated using the drag force, and the collision force on the powder was calculated using the Hertz elastic theory. The calculated results of particle-wall collisions, overall powder flow distribution, and particle velocity at the nozzle outlet were verified. Additionally, the effects of different carrier gas flow rates and powder feeding rates on particle velocity and concentration distribution, with and without collisions, were compared and discussed. The results showed that particle collisions had significant implications for powder concentration distribution and movement state, and that the convergence could be improved by increasing carrier gas flow rate and reducing powder feeding rate.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Coatings & Films
D. V. Bedenko, O. B. Kovalev, D. V. Sergachev
Summary: This paper investigates the influence of the two-way coupling effect between gas-powder flow at high powder flow rates in direct material deposition technology on powder jet focusing. The experimental results are in good agreement with the numerical analysis results, highlighting the importance of two-phase two-way coupling and analyzing the efficiency of a triple coaxial nozzle with non-parallel channel arrangement.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Chemistry, Analytical
Caixia Yang, Yuegang Tan, Yi Liu, Ping Xia, Yinghao Cui, Bo Zheng
Summary: A coaxial powder feeding laser cladding method (CPFLCM) is proposed to overcome the poor shear resistance of bare optical fiber in harsh conditions, such as on aero-engines and in the marine environment. The study establishes a concentration field model of the powder flow and obtains the effective number model of particles and the corresponding laser attenuation rate. Through simulations and experiments, the accurate parameters of laser cladding are optimized, and the effectiveness of CPFLCM in connecting the optical fiber sensor to the substrate is verified.
Article
Automation & Control Systems
Heng Zhou, Yongqiang Yang, Di Wang, Yang Li, Shiqin Zhang, Zhiheng Tai
Summary: A numerical model of a ring-type coaxial nozzle was established to study the particle space trajectory and convergence property. Simulation results showed that using the mean diameter to replace the particle size distribution could accurately predict the flow characteristics and reduce computational resources. The developed ring-type coaxial nozzle was proven to efficiently transport powder and form excellent deposited layers.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Shaowei Zhou, Tianyu Xu, Chang Hu, Han Wu, Huailiang Liu, Xiuquan Ma
Summary: Three novel composite coatings were fabricated by hybridizing carbon nanotubes into reinforcement powder to improve the mechanical properties and surface appearance. The addition of CNTs effectively dispersed ceramic powders and prevented powder agglomeration, resulting in sound metallurgical bonding with the substrate. The presence of more Laves phase and NbC in the coatings, along with refined microstructures, led to progressively improved mechanical properties.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Automation & Control Systems
Huaming Liu, Yan Zhou
Summary: The research developed an interaction model for wide-beam laser and powder, including laser energy attenuation model and powder particle temperature distribution model. Results show that the distribution of the attenuation coefficient and powder temperature are asymmetrical, while laser power and powder feed rate have no influence on them.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Industrial
Yi Liu, Cheng-xin Li, Xiao-Fang Huang, Hui-Yu Zhang, Chang-jiu Li
Summary: SULC technology has great potential in underwater in-situ manufacturing/remanufacturing, allowing for the preparation of iron-based planar coatings with solidification structure distribution. The size and stability of the local dry region above the deposition point is influenced by the powder-feeding gas flow rate, while the laser power and powder-feeding rate are key factors in compensating for energy dissipation. Due to the local temperature gradient in SULC, the coating exhibits distinct solidification structure distribution.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Materials Science, Ceramics
Cheng Deng, Yanliang Yi, Menglong Jiang, Lianxi Hu, Shengfeng Zhou
Summary: This study systematically investigates the microstructure and oxidation behavior of Al2O3/CoNiCrAlY coatings synthesized on a K438 nickel-based superalloy substrate via laser cladding. The results show that increasing the Al2O3 content can decrease the grain size of the coatings and improve high-temperature resistance, but excessive formation of (Co,Ni)(Al,Cr)2O4 can cause degradation in high-temperature resistance.
CERAMICS INTERNATIONAL
(2023)
Article
Materials Science, Multidisciplinary
Pawel Maniewski, Fredrik Laurell, Michael Fokine
Summary: Fused silica glass is a commonly used high-performance material, and additive manufacturing through laser cladding can achieve the preparation of transparent fused silica. The study focuses on deposition dynamics and the influence of different process parameters on the final deposition quality.
OPTICAL MATERIALS EXPRESS
(2021)
Article
Engineering, Manufacturing
Dengzhi Yao, Ju Wang, Hao Luo, Yuhang Wu, Xizhong An
Summary: In this study, the thermal behavior during laser powder bed fusion (LPBF) additive manufacturing was analyzed using the computational fluid dynamics (CFD) method. The influences of key operating parameters on the heat affected angle, depth, and related defects were systematically analyzed, and a thermal control map was constructed. The back propagation neural network (BPNN) model was utilized to predict the performance of molten layers, providing a convenient way to obtain a more precise thermal control map. The findings from this research will provide valuable references for obtaining qualified molten layers and high-performance parts with desired precision.
ADDITIVE MANUFACTURING
(2023)
Article
Materials Science, Multidisciplinary
Yao-Yao Wang, Xiao-Ning Yang, Shu-Yu Shi, Zheng Wu, Ri-Hong Han, Hai-Bo Qi
Summary: Adding different powders to the surface of the weld in laser welding of 6061 aluminum alloy can improve welding efficiency, but the characteristics and limitations of different powders need to be considered. By mixing different powders, various limitations can be overcome to a certain extent, achieving a better welding effect.
JOURNAL OF LASER APPLICATIONS
(2021)
Article
Materials Science, Multidisciplinary
Guofu Lian, Chenmin Zhao, Yang Zhang, Haiyan Hua
Summary: The study found that linear velocity and defocus have a significant impact on aspect ratio, laser power has a substantial effect on wetting angle, and defocus influences cladding efficiency. Multiobjective optimization resulted in the optimized parameter set of 1800 W, 10 mm/s, and 10 mm for smaller aspect ratio, larger wetting angle, and higher cladding efficiency.
Article
Materials Science, Multidisciplinary
Yugan Chen, Pingjun Tao, Weijian Zhang, Chaohan Zhang, Kunsen Zhu
Summary: In this study, Zr65Al7.5Ni10Cu17.5 crystalline powder and amorphous powder were laser clad onto the surface of AISI 1045 steel to improve its friction and wear performance as well as surface hardness. The results showed differences between the two powders in terms of thickness, bonding with the matrix, wear marks, and microhardness of the cladding layers. The amorphous powder had higher thickness, but also had more holes and lower friction performance compared to the crystalline powder.
Article
Materials Science, Multidisciplinary
Din Bandhu, E. Venugopal Goud, Jay J. Vora, Subhash Das, Kumar Abhishek, Ramendra Kumar Gupta, Ashish Thakur, Soni Kumari, K. Devaki Devi
Summary: This study performed butt welding experiments using the processes of resistance metal powder welding (RMD) and gas metal arc welding (GMAW), and conducted macroscopic and microscopic analysis of the welds. The results showed that RMD welding produced better weld quality, smaller heat-affected zone, and finer grain refinement.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Automation & Control Systems
Francisco Javier Amigo, Gorka Urbikain, Luis Norberto Lopez de Lacalle, Pablo Fernandez-Lucio, Octavio Pereira, Asier Fernandez-Valdivielso
Summary: Machining processes on heat-resistant superalloys, such as turbine cases, rings, or shafts, are challenging and time-consuming. The use of high-feed turning technique, specifically the PrimeTurning (TM) tool, has shown potential in reducing machine downtimes and improving surface roughness. However, a deeper understanding of the high-feed turning process is required to prevent tool failures and reject parts. Experimental tests on Inconel 718 alloy revealed that a cutting-edge angle of 30 degrees reduces the likelihood of notches and improves surface roughness, while increasing the cutting-edge angle without adjusting the feed rate may result in tool fractures due to chip overload.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Jun Zha, Nagore Villarrazo, Gonzalo Martinez de Pisson, Yipeng Li, Huijie Zhang, Luis Norberto Lopez de Lacalle
Summary: This study proposes an evolutionary method to improve the machining accuracy of curved surfaces by including compensation for the machining error and making corrections after the manufacturing programming is fully developed. The experimental results show that this method effectively increases surface accuracy and reduces errors, demonstrating its potential to enhance the quality and productivity of manufacturing highly accurate curved surfaces.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Benat Inigo, Ander Ibabe, Luis Norberto Lopez de Lacalle, Gorka Aguirre
Summary: This study proposes an artefact-based fast and automated solution for mapping volumetric errors in medium size 3-axis machine tools. It enables the calibration of a 1m3 workspace in less than 1 hour without prior knowledge of temperature variations. By performing continuous measurements for seven days and identifying a volumetric error variation model, this study estimates uncertainties of individual parameters and motion errors using residual errors and propagates them to the TCP through Monte Carlo simulations. The model is used to understand the changes in volumetric positioning error over time and its generation within the kinematic chain of the machine.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Correction
Green & Sustainable Science & Technology
Felipe Marin, Adriano Fagali de Souza, Alexandre Mikowski, Luis Henrique Guarnieri Fontanella, Paulo Soares, Luis Norberto Lopez de Lacalle
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Alejandro Pascual, Naiara Ortega, Soraya Plaza, Luis Norberto Lopez de Lacalle, Eneko Ukar
Summary: This study presents an XRCT-based FEM methodology to assess the influence of porosity defects on the mechanical behavior and failure of L-PBF AlSi10Mg components. The defects are evaluated through XRCT scanning and porosity analysis, followed by FEM modeling. Tensile tests and further XRCT inspections are conducted to examine the relationship between fracture level and porosity.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Chemistry, Physical
Nagore Villarrazo, Soraya Caneda, Octavio Pereira, Adrian Rodriguez, Luis Norberto Lopez de Lacalle
Summary: This research examines the feasibility of using cryogenic cooling combined with MQL lubrication, known as CryoMQL technology, as a cutting fluid in the industrial environment. The study aimed to determine whether the energy savings achieved by this technology compensate for the increased environmental impact. Milling tests on carbon steel AISI 1045 were conducted to analyze the tool life, cutting edge wear, and energy consumption of the two technologies. The results demonstrated that CryoMQL not only increased tool life but also improved productivity and allowed for a more environmentally friendly process.
Review
Chemistry, Physical
Marta Ostolaza, Jon Inaki Arrizubieta, Aitzol Lamikiz, Soraya Plaza, Naiara Ortega
Summary: Multi-material structure fabrication has the potential to address critical challenges in today's industrial paradigm. Laser-directed energy deposition (L-DED) is preferred for multi-material additive manufacturing, especially in alloy design, metal matrix composites (MMC), and functionally graded materials (FGM). However, there are still challenges in tightly controlling the composition of the powder mixture, understanding the thermal history's influence, and studying the durability and failure modes of MMCs and FGMs.
Article
Materials Science, Multidisciplinary
Kiran Wakchaure, Rakesh Chaudhari, Ajaykumar Thakur, Kishan Fuse, Luis Norberto Lopez de Lacalle, Jay Vora
Summary: Submerged friction stir welding (SFSW) was used to weld 6 mm thick 6061Al-T6 alloy plates under different water temperatures. The results showed that submerged samples had finer grain size and higher microhardness, and defect-free joints were obtained. Moreover, water temperature had a significant effect on the welding results, with joints welded at 80 degrees C exhibiting the highest tensile strength and microhardness.
Article
Thermodynamics
Sakshum Khanna, Sagar Paneliya, Parth Prajapati, Rakesh Chaudhari, Jay Vora, Hussam Jouhara
Summary: This study demonstrates a modified synthesis route for fabricating n-hexacosane-impregnated graphene nanosheets (GrPCM) nanocomposite. The exfoliation of graphene sheets during the hydrothermal and sonication process increases the surface area for improved impregnation and interaction with n-hexacosane. The GrPCM nanocomposites exhibited enhanced thermal stability, higher thermal conductivity, and improved latent heat compared to pure PCM materials. The findings suggest that GrPCM3 is an excellent composite material for efficient heat transfer processes.
THERMAL SCIENCE AND ENGINEERING PROGRESS
(2023)
Article
Engineering, Manufacturing
Jay Vora, Yug Shah, Sakshum Khanna, Vivek K. Patel, Manoj Jagdale, Rakesh Chaudhari
Summary: This study identified current, pulse-off-duration (Toff), and pulse-on-duration (Ton) as vital input factors for the WEDM process of Ti6Al4V. Empirical models were generated and validated using ANOVA, showing a significant impact of these factors on material removal rate (MRR) and surface roughness (SR). Additionally, the use of expanded graphite (EG) nano-powder was found to improve the WEDM process, increasing MRR by 45.35% and reducing SR by 36.16%.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Chemistry, Physical
Jay Vora, Rudram Pandey, Pratik Dodiya, Vivek Patel, Sakshum Khanna, Vatsal Vaghasia, Rakesh Chaudhari
Summary: This study investigates and optimizes the bead geometries of SS-309L using a GMAW-based WAAM process. The Box-Behnken design approach is used for trials, and regression models are developed. The optimized parameters yield a maximum BH of 9.48 mm and a minimum BW of 5.90 mm for single-layer depositions.
Article
Engineering, Multidisciplinary
Aizpea Urresti-Ubillos, Jon Inaki-Arrizubieta-Arrate, Oihane Murua-DelaMata, Miren Aristizabal, Eneko Ukar, David Lopez-Bolanos
Summary: The aim of this research is to characterize the 15CDV6 powder material for Laser Directed Energy Deposition (LDED) processes. The novelty of this work lies in the fact that this aeronautical steel has never been used before in powder LDED process. The 15CDV6 steel powder was atomized specifically for this study to ensure its quality, and its chemical composition and particle shape were measured. The suitability of the 15CDV6 steel for L-DED process was studied through single bead tests, overlapping beads deposition, and thin wall construction, with the results of each sequence serving as the basis for the next.
Article
Engineering, Mechanical
Inigo Aldekoa, Ander del Olmo, Leonardo Sastoque-Pinilla, Sara Sendino-Mouliet, Unai Lopez-Novoa, Luis Norberto Lopez de Lacalle
Summary: This paper presents a study on sensorless machine variable monitoring for tool wear monitoring in broaching in real production environments. The research establishes a correlation between the variables of a broaching machine's servomotors and the condition of the broaching tools. The authors propose an effective method for measuring broaching tool wear without external sensors, and provide a detailed explanation of the methodology for reproducibility. The results show high predictive accuracy, with a coefficient of determination surpassing 0.9, using machine learning models trained on data collected from trials on an electromechanical vertical broaching machine.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2023)
