Journal of Manufacturing and Materials Processing

16 pages, 2122 KiB

Open AccessArticle

Ensuring Melt Track Width Consistency and Crack-Free Conditions Using Interpass-Temperature-Dependent Process Parameters for Wire-Arc-Directed Energy-Deposited Inconel 718

by Xavier A. Jimenez, Jie Song, Yao Fu and Albert C. To

J. Manuf. Mater. Process. 2024, 8(4), 140; https://doi.org/10.3390/jmmp8040140 (registering DOI) - 28 Jun 2024

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Abstract

Melt track width can vary in a wire-arc-directed energy-deposited material (DED) using a constant set of process parameters, leading to a lower-quality build. In this work, a novel framework is proposed that uses the data from the process parameter development stage to create [...] Read more.

Melt track width can vary in a wire-arc-directed energy-deposited material (DED) using a constant set of process parameters, leading to a lower-quality build. In this work, a novel framework is proposed that uses the data from the process parameter development stage to create optimized process parameters for a target layer width at different interpass temperatures without hot cracking. Inconel 718 is used as the model material since it is known to suffer from hot cracking during DED processing. In the proposed framework, a process window containing a few sets of process parameters (torch travel speed and wire feed rate) is established for crack-free deposition of Inconel 718, and these parameters are used to create a small database. A linear regression model is then employed to generate interpass-temperature-specific optimized process parameters for a target melt track width. The results demonstrate that the proposed approach can reduce the melt track width variation in the deposited walls from 12% to 3% error on average under different printing conditions. It also demonstrates that interpass temperature (IPT) can be used as a controlled variable and the optimized process parameters as initial values when applying control techniques to the process. Full article

(This article belongs to the Special Issue Advances in Directed Energy Deposition Additive Manufacturing)

20 pages, 6911 KiB

Open AccessArticle

Analysis of the Surface Quality and Temperature in Grinding of Acrylic-Based Resin

by Syed Mustafa Haider, Abbas Hussain, Muntazir Abbas, Shaheryar Atta Khan and Shoaib Sarfraz

J. Manuf. Mater. Process. 2024, 8(4), 139; https://doi.org/10.3390/jmmp8040139 - 28 Jun 2024

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Abstract

Polymeric resins are becoming increasingly popular in medical and engineering applications due to their properties, such as their low weight, high strength, corrosion resistance, non-allergenicity, and extended service life. The grinding process is used to convert these materials into desired products, offering high [...] Read more.

Polymeric resins are becoming increasingly popular in medical and engineering applications due to their properties, such as their low weight, high strength, corrosion resistance, non-allergenicity, and extended service life. The grinding process is used to convert these materials into desired products, offering high accuracy and surface quality. However, grinding generates significant heat, which can potentially degrade the material. This study investigates the grinding of acrylic-based resins, specifically focusing on the interplay between the grind zone temperature and surface finish. The low glass transition temperature (57 °C) of the acrylic necessitates the precise control of the grinding parameters (spindle speed, feed rate, depth of cut, and grinding wheel grain size), to maintain a low temperature and achieve high-quality machining. Thermal imaging and thermocouples were employed to measure the grind zone temperature under various grinding conditions. This study investigates the influence of four parameters: spindle speed, feed rate, depth of cut, and grinding wheel grain size. The best surface finish (Ra: 2.5 µm) was obtained by using a finer-grained (80/Ø 0.18 mm) grinding wheel, combined with slightly adjusted parameters (spindle speed: 11.57 m/s, feed rate: 0.406 mm/rev, depth of cut: 1.00 mm), albeit with a slightly higher grind zone temperature (~54 °C). This study highlighted the importance of balancing the grind zone temperature and surface finish for the optimal grinding of acrylic-based resins. Further, this research finds that by carefully controlling the grinding parameters, it is possible to achieve both a high surface quality and prevent material degradation. The research findings could be highly valuable for optimizing the grinding process for various medical and engineering applications. Full article

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13 pages, 3785 KiB

Open AccessArticle

Investigating Workpiece Deflection in Precise Electrochemical Machining of Turbine Blades

by Elio Tchoupe Sambou, Daniel Lauwers, Timm Petersen, Tim Herrig, Andreas Klink, Matthias Meinke and Wolfgang Schröder

J. Manuf. Mater. Process. 2024, 8(4), 138; https://doi.org/10.3390/jmmp8040138 - 28 Jun 2024

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Abstract

Precise electrochemical machining (PECM) is being used increasingly to produce turbine blades (high-pressure compressors) from difficult-to-machine materials such as Inconel. However, the challenges associated with PECM are particularly pronounced for filigree workpieces characterized by high aspect ratios and thin-walled geometries. The need for [...] Read more.

Precise electrochemical machining (PECM) is being used increasingly to produce turbine blades (high-pressure compressors) from difficult-to-machine materials such as Inconel. However, the challenges associated with PECM are particularly pronounced for filigree workpieces characterized by high aspect ratios and thin-walled geometries. The need for high-pressure flushing within the working gap to renew the electrolyte poses a dilemma because it induces unwanted deflection in these thin-walled structures. This problem is intensified by the mechanical oscillation of the tool applied to promote flushing efficiency. The superposition of mechanical tool oscillation and turbulent flushing, which exacerbate fluid–structure interaction, has been identified as the essential cause of workpiece deflection. The aim of this paper is to present an experimental setup coupled with numerical methods to better investigate the phenomenon of workpiece deflection during PECM. In the first part of this work, a novel tool system for investigating the phenomenon of workpiece deflection in PECM is presented. The tool system combines typical PECM tool–workpiece arrangements for double-sided machining and a unique electrolytic mask that provides optical access to the working gap, allowing in situ measurements. After validating the tool system by experimental tests, the workpiece deflection is investigated using high-speed imaging. In a next step, analytical studies of the flushing conditions during machining operations are carried out. These investigations are followed by a structural investigation of the workpiece to improve the understanding of the deflection behavior of the workpiece. In addition, the effect on the blade tip caused by the continuously decreasing moment of inertia of the blade due to their thinning during machining is analyzed. Full article

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13 pages, 1021 KiB

Open AccessArticle

Experimental Methodology to Identify Optimal Friction Stir Welding Parameters Based on Temperature Measurement

by Moura Abboud, Laurent Dubourg, Guillaume Racineux and Olivier Kerbrat

J. Manuf. Mater. Process. 2024, 8(4), 137; https://doi.org/10.3390/jmmp8040137 - 27 Jun 2024

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Abstract

Friction stir welding (FSW) is a widely employed welding process, in which advancing and rotational speeds consitute critical parameters shaping the welding outcome and affecting the temperature evolution. This work develops an experimental methodology to identify optimal FSW parameters based on real-time temperature [...] Read more.

Friction stir welding (FSW) is a widely employed welding process, in which advancing and rotational speeds consitute critical parameters shaping the welding outcome and affecting the temperature evolution. This work develops an experimental methodology to identify optimal FSW parameters based on real-time temperature measurement via a thermocouple integrated within the tool. Different rotational and welding speeds were tested on AA5083-H111 and AA6082-T6. Our results underscore the importance of attaining a minimum temperature threshold, specifically 0.65 times the solidus temperature, to ensure high-quality welds are reached. The latter are defined by combining temperature measurements with joint quality information obtained from cross-sectional views. Our research contributes to advancing the efficiency and effectiveness of friction stir welding in industrial settings. Furthermore, our findings suggest broad implications for the manufacturing industry, offering practical insights for enhancing weld quality and process optimization. Full article

(This article belongs to the Topic Development of Friction Stir Welding and Processing)

17 pages, 10529 KiB

Open AccessArticle

Heat Input Control Strategies in DED

by Sergei Egorov, Fabian Soffel, Timo Schudeleit, Markus Bambach and Konrad Wegener

J. Manuf. Mater. Process. 2024, 8(4), 136; https://doi.org/10.3390/jmmp8040136 - 27 Jun 2024

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Abstract

In the context of directed energy deposition (DED), the production of complex components necessitates precise control of all processing parameters while mitigating undesirable factors like heat accumulation. This research seeks to explore and validate with various materials the impact of a geometry-based analytical [...] Read more.

In the context of directed energy deposition (DED), the production of complex components necessitates precise control of all processing parameters while mitigating undesirable factors like heat accumulation. This research seeks to explore and validate with various materials the impact of a geometry-based analytical model for minimizing heat input on the characteristics and structure of the resultant DED components. Furthermore, it aims to compare this approach with other established methods employed to avoid heat accumulation during production. The geometry of the fabricated specimens was assessed using a linear laser scanner, cross-sections were analyzed through optical microscopy, and the effect on mechanical properties was determined via microhardness measurements. The specimens manufactured using the developed analytical model exhibited superior geometric precision with lower energy consumption without compromising mechanical properties. Full article

(This article belongs to the Special Issue Advances in Directed Energy Deposition Additive Manufacturing)

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22 pages, 8069 KiB

Open AccessArticle

Effects of δ Phase and Annealing Twins on Mechanical Properties and Impact Toughness of L-PBF Inconel 718

by Wakshum Mekonnen Tucho, Bjorn Andre Ohm, Sebastian Andres Pedraza Canizalez, Andreas Egeland, Martin Bernard Mildt, Mette Lokna Nedreberg and Vidar Folke Hansen

J. Manuf. Mater. Process. 2024, 8(4), 135; https://doi.org/10.3390/jmmp8040135 - 27 Jun 2024

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Abstract

In this study, the effects of the δ phase and annealing twins on the hardness, tensile properties, and Charpy impact toughness of Inconel 718 fabricated using L-PBF were investigated. The as-printed components underwent two stages of heat treatment to modify their microstructure and [...] Read more.

In this study, the effects of the δ phase and annealing twins on the hardness, tensile properties, and Charpy impact toughness of Inconel 718 fabricated using L-PBF were investigated. The as-printed components underwent two stages of heat treatment to modify their microstructure and phases. The δ phase was induced through solid-solution heat treatment at 980 °C for 1 h, while annealing twins were formed at 1100 °C for 3 h. Following precipitation hardening, specimens containing δ precipitates exhibited a higher ultimate tensile strength (13%), yield strength (27%), and hardness (12%) compared to those rich in annealing twins. The enhanced mechanical strength was attributed to the presence of δ precipitates and differences in the extent of recrystallization, leading to variations in the density of retained lattice defects, including subgrain boundaries and primary phases. Conversely, specimens with annealing twins demonstrated a significantly higher impact toughness (four times) and ductility (twice) than those with δ precipitates. Annealing twins were found to enhance plasticity by impeding dislocation movement, while δ precipitates reduced plasticity by acting as sites for void formation and crack propagation. Microstructural, compositional, phase, crystallographic, and fractographic analyses were conducted using OM, SEM, TEM, and XRD techniques to identify the factors influencing the observed differences. The results indicate that the heat treatment approach involving annealing twins can effectively enhance the ductility of Inconel 718 while maintaining the necessary mechanical strength. Full article

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9 pages, 4839 KiB

Open AccessCommunication

by Fabio Giudice, Severino Missori and Andrea Sili

J. Manuf. Mater. Process. 2024, 8(4), 134; https://doi.org/10.3390/jmmp8040134 - 27 Jun 2024

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Abstract

Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of thick plates, [...] Read more.

Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of thick plates, a procedure with two simultaneous laser beams (working in a single pass) and consumable inserts as filler metal has been considered. Particular attention was paid to the choice of the filler metal (composition and amount), as well as welding parameters, which are crucial to obtain the right dilution necessary for a correct chemical composition in the weld zone. The first experimental investigations confirmed the achievement of a good weldability of the dissimilar pair ASTM A387 ferritic/AISI 304L austenitic steel, having ascertained that the microstructure of the weld zone is austenitic with a little amount of residual primary ferrite, which is the best condition to minimize the risk of hot cracking. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)

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18 pages, 5960 KiB

Open AccessArticle

Effect of Lattice Structure on Mechanical Properties of Ti-6Al-4V-Ta Alloy for Improved Antibacterial Properties

by Anel Zhumabekova, Malika Toleubekova, Tri Thanh Pham, Didier Talamona and Asma Perveen

J. Manuf. Mater. Process. 2024, 8(4), 133; https://doi.org/10.3390/jmmp8040133 - 26 Jun 2024

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Abstract

This study investigates the effect of a tantalum addition and lattice structure design on the mechanical and antibacterial properties of Ti-6Al-4V alloys. TPMS lattice structures, such as Diamond, Gyroid, and Primitive, were generated by MSLattice 1.0 software and manufactured using laser powder bed [...] Read more.

This study investigates the effect of a tantalum addition and lattice structure design on the mechanical and antibacterial properties of Ti-6Al-4V alloys. TPMS lattice structures, such as Diamond, Gyroid, and Primitive, were generated by MSLattice 1.0 software and manufactured using laser powder bed fusion (LPBF). The results indicate that Gyroid and Primitive structures at a 40% density exhibit superior ultimate compressive strength, which closely emulates bone’s biomechanical properties. To be precise, adding 8% tantalum (Ta) significantly increases the material’s elastic modulus and energy absorption, enhancing the material’s suitability for dynamic load-bearing implants. Nevertheless, the Ta treatment reduces bacterial biofilm formation, especially on Gyroid surfaces, suggesting its potential for infection management. Overall, all findings provide critical insights into the development of advanced implant materials, contributing to the fields of additive manufacturing, materials science, and biomedical engineering and paving the way for improved patient outcomes in orthopedic applications. Full article

(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)

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11 pages, 3526 KiB

Open AccessArticle

Identification of the Mechanism Resulting in Regions of Degraded Toughness in A508 Grade 4N Manufactured Using Powder Metallurgy–Hot Isostatic Pressing

by Colin D. Ridgeway, Terrance Nolan and Joeseph M. Pyle

J. Manuf. Mater. Process. 2024, 8(4), 132; https://doi.org/10.3390/jmmp8040132 - 26 Jun 2024

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Abstract

Powder metallurgy–hot isostatic pressing (PM-HIP) is a form of advanced manufacturing that offers the ability to produce near-net shape components that are otherwise not achievable via conventional forging or wrought manufacturing. Accessing the design space of PM-HIP is dependent upon the ability to [...] Read more.

Powder metallurgy–hot isostatic pressing (PM-HIP) is a form of advanced manufacturing that offers the ability to produce near-net shape components that are otherwise not achievable via conventional forging or wrought manufacturing. Accessing the design space of PM-HIP is dependent upon the ability to achieve uniform or known properties in finalized components, which has resulted in a number of programs aimed at identifying properties achievable via PM-HIP manufacturing. One result of these programs has been the consistent observation of a variation in toughness observed for the low-alloy steel ASTM A508 Grades 3 and 4N. While observed, the degree of variability and the mechanism resulting in the variability have not yet been fully defined. Thus, a systematic approach to evaluate the variation observed in impact toughness in PM-HIP ASTM A508 Grade 4N was proposed to elucidate the responsible metallurgical mechanism. Four unique billets manufactured from two heats of powder with different particle size distributions (PSDs) were fabricated and tested for impact toughness and tensile properties. The degradation in impact toughness was confirmed to be location-specific where the near-can region of all billets had reduced impact toughness relative to the interior of each billet. The mechanism driving the location-specific property development was identified to be mobile oxygen that follows the thermal gradient that develops during the HIP cycle and leads to a redistribution of mobile oxygen where oxygen is concentrated ~1” inboard of the original canister/billet interface. Redistributed oxygen then forms stable oxides along coincident prior particle and prior austenite grain boundaries, effectively reducing the impact toughness. With the mechanism now addressed, necessary actions can be taken to mitigate the effect of the oxygen redistribution, allowing for use in PM-HIP A508 Grade 4N in commercial industry. Full article

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15 pages, 2867 KiB

Open AccessReview

Optimizing Milling Parameters for Enhanced Machinability of 3D-Printed Materials: An Analysis of PLA, PETG, and Carbon-Fiber-Reinforced PETG

by Mohamad El Mehtedi, Pasquale Buonadonna, Rayane El Mohtadi, Gabriela Loi, Francesco Aymerich and Mauro Carta

J. Manuf. Mater. Process. 2024, 8(4), 131; https://doi.org/10.3390/jmmp8040131 - 26 Jun 2024

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Abstract

Fused deposition modeling (FDM) is widely applied in various fields due to its affordability and ease of use. However, it faces challenges such as achieving high surface quality, precise dimensional tolerance, and overcoming anisotropic mechanical properties. This review analyzes and compares the machinability [...] Read more.

Fused deposition modeling (FDM) is widely applied in various fields due to its affordability and ease of use. However, it faces challenges such as achieving high surface quality, precise dimensional tolerance, and overcoming anisotropic mechanical properties. This review analyzes and compares the machinability of 3D-printed PLA, PETG, and carbon-fiber-reinforced PETG, focusing on surface roughness and burr formation. A Design of Experiments (DoE) with a full-factorial design was used, considering three factors: rotation speed, feed rate, and depth of cut. Each factor had different levels: rotational speed at 3000, 5500, and 8000 rpm; feed rate at 400, 600, and 800 mm/min; and depth of cut at 0.2, 0.4, 0.6, and 0.8 mm. Machinability was evaluated by roughness and burr height using a profilometer for all the materials under the same milling conditions. To evaluate the statistical significance of the influence of various processing parameters on surface roughness and burr formation in 3D-printed components made of three different materials—PLA, PETG, and carbon-fiber-reinforced PETG—an analysis of variance (ANOVA) test was conducted. This analysis investigated whether variations in rotational speed, feed rate, and depth of cut resulted in measurable and significant differences in machinability results. Results showed that milling parameters significantly affect roughness and burr formation, with optimal conditions for minimizing any misalignment highlighting the trade-offs in parameter selection. These results provide insights into the post-processing of FDM-printed materials with milling, indicating the need for a balanced approach to parameter selection based on application-specific requirements. Full article

(This article belongs to the Special Issue Industry 4.0 and Smart Materials Processing for Enhanced Manufacturing)

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18 pages, 2501 KiB

Open AccessArticle

Enriching Laser Powder Bed Fusion Part Data Using Category Theory

by Yuchu Qin, Shubhavardhan Ramadurga Narasimharaju, Qunfen Qi, Shan Lou, Wenhan Zeng, Paul J. Scott and Xiangqian Jiang

J. Manuf. Mater. Process. 2024, 8(4), 130; https://doi.org/10.3390/jmmp8040130 - 24 Jun 2024

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Abstract

Laser powder bed fusion (LPBF) is a promising metal additive manufacturing technology for producing functional components. However, there are still a lot of obstacles to overcome before this technology is considered mature and trustworthy for wider industrial applications. One of the biggest obstacles [...] Read more.

Laser powder bed fusion (LPBF) is a promising metal additive manufacturing technology for producing functional components. However, there are still a lot of obstacles to overcome before this technology is considered mature and trustworthy for wider industrial applications. One of the biggest obstacles is the difficulty in ensuring the repeatability of process and the reproducibility of products. To tackle this challenge, a prerequisite is to represent and communicate the data from the part realisation process in an unambiguous and rigorous manner. In this paper, a semantically enriched LPBF part data model is developed using a category theory-based modelling approach. Firstly, a set of objects and morphisms are created to construct categories for design, process planning, part build, post-processing, and qualification. Twenty functors are then established to communicate these categories. Finally, an application of the developed model is illustrated via the realisation of an LPBF truncheon. Full article

21 pages, 44243 KiB

Open AccessArticle

Evaluation of Porosity in AISI 316L Samples Processed by Laser Powder Directed Energy Deposition

by Alessandro Salmi, Gabriele Piscopo, Adriano Nicola Pilagatti and Eleonora Atzeni

J. Manuf. Mater. Process. 2024, 8(4), 129; https://doi.org/10.3390/jmmp8040129 - 24 Jun 2024

Viewed by 236

Abstract

Directed energy deposition-laser beam/powder (DED-LB/Powder) is an additive manufacturing process that is gaining popularity in the manufacturing industry due to its numerous advantages, particularly in repairing operations. However, its application is often limited to case studies due to some critical issues that need [...] Read more.

Directed energy deposition-laser beam/powder (DED-LB/Powder) is an additive manufacturing process that is gaining popularity in the manufacturing industry due to its numerous advantages, particularly in repairing operations. However, its application is often limited to case studies due to some critical issues that need to be addressed, such as the degree of internal porosity. This paper investigates the effect of the most relevant process parameters of the DED-LB/Powder process on the level and distribution of porosity. Results indicate that, among the process parameters examined, porosity is less affected by travel speed and more influenced by powder mass flow rate and laser power. Additionally, a three-dimensional finite element transient model was introduced, which was able to predict the development and location of lack-of-fusion pores along the building direction. Full article

(This article belongs to the Special Issue Advances in Directed Energy Deposition Additive Manufacturing)

12 pages, 7962 KiB

Open AccessArticle

Chatter Mitigation in Turning Slender Components Using Viscous Fluids

by Matas Griskevicius, Vishal Kharka and Zekai Murat Kilic

J. Manuf. Mater. Process. 2024, 8(4), 128; https://doi.org/10.3390/jmmp8040128 - 21 Jun 2024

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Abstract

This paper investigates the performance of a novel viscous passive damping solution to mitigate the chatter vibrations issue in the context of turning thin-walled cylindrical shell components for aerospace and other industries. This study involves the use of two different viscous fluids, motor [...] Read more.

This paper investigates the performance of a novel viscous passive damping solution to mitigate the chatter vibrations issue in the context of turning thin-walled cylindrical shell components for aerospace and other industries. This study involves the use of two different viscous fluids, motor oil and silicone oil, which have viscosities of 102 cSt and 350 cSt, respectively, to fill the in-house developed tube components with the aim of improving machining performance. Fast Fourier Transform (FFT) graphs were studied for chatter analysis, and surface roughness parameters such as average surface roughness (Ra) and mean roughness depth (Rz) were considered for studying the effectiveness of the viscous damping fluids. The results obtained with viscous damping were then compared with an undamped/unfilled tube with the same geometry. The cutting experiments showed that the motor oil reduced the excessive vibrations while silicone oil was able to eliminate them. For the tube with motor oil, the magnitude of the process sound at chatter frequency was reduced by 6.6 times as compared to an unfilled tube, whereas for the tube with silicone oil, the amplitude at chatter frequency was reduced by 14.8 times. Moreover, the surface quality of the tubes with motor oil and silicone oil shows almost equal improvement, indicating the need for future research on the type and amount of viscous fluids for implementing the concept in real cases. Full article

(This article belongs to the Special Issue Advances in Machining of Difficult-to-Cut Materials)

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J. Manuf. Mater. Process., Volume 8, Issue 4 (August 2024) – 13 articles

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