Manufacturing Of Components Research Articles

Modeling plasticity-mediated void growth at the single crystal scale: A physics-informed machine learning approach

Modeling the evolution of voids during plastic flow as well as their effects on plastic dissipation is critical for both component manufacturing and lifetime estimation purposes. To this end, we propose a rate-dependent constitutive model to homogenize the effects of semi-randomly distributed voids on single crystal plasticity whilst capturing void interaction and plastic anisotropy. The present work focuses on the case of face centered cubic crystals to introduce an anisotropic gauge function applicable within the crystal plasticity formalism. The approach combines analytical methods to describe the micromechanics of the system in combination with symbolic regression to capture analytically intractable mechanisms from data. The hybrid framework uses a physics-informed genetic programming-based symbolic regression algorithm to solve a multiform optimization problem simultaneously producing a new gauge function and a new strain rate equation. This is also a multi-objective optimization problem with many competing objectives. A new search and selection step is introduced to the genetic algorithm that promotes convergence toward a global solution that better satisfies all the objectives. Overall, the symbolic equations produced leverage data-driven methods to achieve greater accuracy than comparable alternatives on an analytically intractable problem while maintaining model transparency.

Optimal supply chain green innovation and subsidy strategy: producer subsidy versus consumer subsidy

PurposeConsidering two types of subsidies for producers (supplier and manufacturer) and one for consumers based on product greenness and sales quantity, this study aims to formulate optimal supply chain green innovation and subsidy strategies, and to achieve this goal with the support of information systems.Design/methodology/approachThis study introduces a composite green-product supply chain where suppliers focus on green innovation for component greenness and manufacturers focus on green innovation for manufacturing process greenness. Game theory modeling is applied to investigate the differences of product greenness, supply chain members’ profit and social welfare under different government subsidy strategies.FindingsIncreasing the unit greenness subsidy coefficient can boost product greenness and supply chain members’ profits, but does not always raise social welfare. When the government exclusively offers subsidies to producers, subsidies should be allocated to suppliers when there is a significant disparity in supply chain green innovation costs. Conversely, it is more beneficial to subsidize manufacturers. Consumer subsidies have the potential to enhance both environmental and economic performance in the supply chain compared with producer-exclusive subsidies, but may not always maximize social welfare when supply chain members have low unit costs associated with green innovation.Originality/valueThis study examines the optimal decisions for green supply chain innovation and government subsidy strategies. Supply chain members and the government can use the information system to collect and evaluate the cost of upstream and downstream green innovation, and then develop reasonable collaborative green innovation and subsidy strategies.

Effect of combined parametric impacts on collapsing the wall quality of WAAM Al5356 component

Even though Wire and Arc Additive Manufacturing (WAAM) of the Al5356 component has garnered attention for making affordable, large-scale components, problems with porosity, humping, and undercut still exist. Therefore, optimising process parameters is crucial to achieving flawless products with consistent layer deposition. Hence in this research, the most important WAAM parameters including travel speed (TS), wire feed speed (WFS), and torch angle (TA), were examined in order to determine how they affected structural integrity while taking into account key responses such as porosity, pore diameter, and tensile strength. The Significance of Criteria Weighted Aggregated Sum Product Assessment (WASPAS) in conjunction with Intercriteria Correlation (CRITIC) was used to investigate the favourable circumstances and confirm that the TA is the most important parameter in the nucleation of pores. The verification studies demonstrate that a 58.2 % reduction in pore diameter results in a 31.8 % increase in tensile strength. An ideal TS and WFS of 65 cm/min and 5 m/min, with a maximum TA of 90°, were found to be the favorable conditions for printing Al5356 wall with a minimum porosity of 0.037 %, enhanced ultimate tensile strength of 278 MPa, and minimum pore diameter of 93 µm, according to the CRITIC associated WASPAS approach. Additionally, using the fractography, the damage process based on the porosity creation was investigated. The optimal parameters for generating a defect-free multi-layer structure were identified, hence enhancing the structure’s suitability for industrial use.

Research on microstructure evolution of laser surface quenching of ductile cast iron

Abstract Ductile cast iron is widely used in the manufacturing of components and dies due to its excellent performance and low cost. Laser surface quenching can further improve its performance and extend its service life. This article uses scanning electron microscopy, electron backscattered scattering detection and microhardness tester to systematically analyse the microstructure evolution of the melted zone, hardened zone, and matrix of ductile cast iron with laser surface quenching. The hardening zone can be divided into two layers: one layer contains a large amount of martensite, graphite, and bits of residual austenite, and the other layer contains a composite structure of graphite, ferrite, layered martensite+austenite+Fe3C. On the basis of microstructure research, the determination and optimization methods of the depth of the laser surface hardening zone and the process are formed, providing a basis for the selection and optimization of the laser surface hardening process for ductile cast iron.

Looping: Load-oriented optimized paths in non-planar geometry

Effective material utilization in the additive manufacturing of lightweight components is of increasing importance. The Looping (Load-oriented optimized paths in non-planar geometry) method presented in this work enables the translation of desired material orientations into suitable manufacturing instructions. The desired material orientations are derived from the principal stress directions that would manifest for an isotropic material. By employing non-planar slicing, these orientations can be followed by the deposited material beads. The novel path planning algorithm combines load-orientation and path continuity. While this can be beneficial for load-oriented printing in general, it is an especially significant step for load-oriented printing of continuous fiber reinforced polymers. The ability to follow desired material orientations with continuous paths shows particularly high potential for highly anisotropic fiber reinforced polymers. The algorithms are implemented and demonstrated in a complete process chain. However, challenges remain in the optimization of the orientation and manufacturing system for fiber reinforced polymers, which are not the focus of this work. For this reason, the process chain is realized for a neat polymer. In this context, the developed method is computationally evaluated with respect to layer height, unfilled areas, manufacturing time, geometric accuracy, and physical fabrication. The continuous and load-oriented path planning algorithm is tested against a continuous contour parallel approach and planar slicing through tensile testing. The investigations show an applicability of the process chain to successfully produce complex parts with the desired load-oriented paths. The proposed algorithm shows an increase in mechanical performance compared to the contour parallel approach highlighting its potential for non-planar printing. However, it is also found that limitations of the non-planar manufacturing process still limit its potential to surpass optimally oriented planar printing for the investigated geometry.

Research on reconfigurable systems in discrete manufacturing workshops

Abstract With the development of smart manufacturing, the demand for personalized production has made reconfigurable systems in the manufacturing industry a focal point of research and application in high-end manufacturing. The paper analyzes the current status of the manufacturing industry and the challenges of reconfigurable technology. Furthermore, it designs and develops a reconfigurable system for discrete manufacturing of automotive components. The paper focuses on issues such as creating reconfigurable models, designing adaptive reconfiguration algorithms, accomplishing the creation of multi-layered models, the design of rule libraries, and algorithm implementation. The reconfiguration result scheme can be input into commercial software for performance simulation, and can directly integrate with production systems to complete production planning. This demonstrates the rationality of the reconfigurable models in the system, the correctness of the reconfiguration algorithms, and the effectiveness of the system, providing a theoretical basis for reconfigurable production lines.

FINANCIAL AND ECONOMIC PROSPECTS FOR CREATING GREEN ENERGY PROJECTS IN THE UKRAINE-POLAND COLLABORATION

This paper examines the economic and financial advantages of improving international collaboration between Ukraine and Poland in the development of alternative energy projects. It conducts a thorough evaluation of existing and forthcoming renewable energy generation technologies, using expert, Delphi, and methods based on statistics to identify the most promising and universally applicable solutions. The calculation of the payback period for small-scale green energy projects pays particular attention to the actual duration of the period in the case of small business ventures. The findings are summarized with a vision for the future Ukrainian-Polish cooperation in the scope of green energy cooperation and specific instruments and processes that could contribute to the success of the collaboration.The article outlines the potential approach that involves the isolation of the cooperation between Ukraine and Poland in green energy relying on the creation of investment and venture funds, public support for the manufacturing of a renewable energy component, and the establishment of non-volatile industrial complexes. Additionally, measures such as independent small alternative power plants and the initiatives for the development of the Ukrainian-Polish joint network of alternative energy are mentioned.The current war between Ukraine and Russia has drawn attention to the crucial need for energy security and diversification, making Ukraine-Poland collaboration on green energy projects all the more important. Ukraine may minimize its reliance on the Russian energy supply by focusing on renewable energy programs, while Poland can invest in sustainable energy to boost regional stability and economic progress. The article points out that the continuation and advancement of green energy initiatives require international cooperation. The paper offers detailed guidance on how the financial, economic, and technological opportunities and relations between Ukraine and Poland may be enhanced.

Overview of the ASME Boiler and Pressure Vessels, U stamps Certification for Pressure Vessels

The American Society of Mechanical Engineers (ASME) Code and Sections are important for the design, manufacturing, and maintenance of mechanical systems and components. This paper will present importance of ASME U stamp certification which is crucial for ensuring Boiler and Pressure Vessels quality, safety, and compliance with industry standards. ASME U stamp certification which is accepted across the more than 100 nations. This paper also covers ASME U stamp requirements, Certificate duration, Certification processes, and application of U stamp and importance of Single Certification Mark for U stamp

Sourcing renewable energy components: building resilient supply chains, reducing dependence on foreign suppliers, and enhancing energy security

The transition to renewable energy is essential for mitigating climate change and ensuring long-term energy security. As global demand for renewable energy technologies grows, establishing resilient supply chains becomes crucial. This paper examines strategies to build robust supply chains, reduce reliance on foreign suppliers, and enhance energy security. A major challenge in renewable energy is the dependence on a limited number of international suppliers, which risks supply disruptions due to geopolitical tensions, trade restrictions, or natural disasters. Diversifying suppliers can mitigate these risks by encouraging alternative suppliers and fostering competition (Smith, 2020). Local manufacturing is another critical strategy, promoting supply chain resilience, economic growth, and job creation. Countries like the United States and Germany have incentivized local manufacturing of solar panels and wind turbine components (Jones, 2021), ensuring a steady supply of parts and aligning with broader industrial policies. Maintaining strategic reserves of critical materials, such as rare earth elements and lithium, is essential for buffering against supply disruptions and price volatility, ensuring continuous production of renewable energy technologies (Brown, 2019). Strategic planning and investment in reserves are vital for a comprehensive energy security strategy. Technological innovation enhances supply chain resilience. Advances in materials science, manufacturing processes, and recycling technologies can reduce dependence on scarce materials and improve renewable energy system efficiency. Developing alternative materials for battery storage, for example, can reduce reliance on lithium and cobalt sourced from unstable regions (White, 2022). Public-private partnerships (PPPs) are crucial for advancing the renewable energy sector. By leveraging both sectors' strengths, PPPs can accelerate technology deployment, improve infrastructure, and foster innovation. Successful examples include government-private collaborations on offshore wind farms and smart grid technologies (Green & Associates, 2021). Favorable trade policies facilitate the global exchange of renewable energy technologies and components. Reducing tariffs, streamlining customs, and fostering international cooperation can enhance supply chain efficiency and reliability (Lee, 2020). This study advocates for trade agreements tailored to the renewable energy sector's needs. Integrated energy systems and smart grid technologies optimize renewable energy use and distribution. Advanced monitoring and control systems improve grid stability, reduce energy waste, and enhance renewable source integration (Adams, 2019). Investment in smart grid infrastructure is crucial for a resilient energy strategy. Robust policy frameworks are necessary to support these initiatives. Governments must enact policies providing clear guidance, incentives, and support for resilient renewable energy supply chains, including ambitious renewable energy targets, financial incentives for R&D, and regulatory stability (Martinez, 2021).

Effect of the brass waste recycling process on mechanical properties with investment casting for gear materials

This study is an experimental research to analyze the characteristics and mechanical properties of the casting process of recycled brass alloy, which will be used as a material for gears. Currently, the remaining production and waste from brass alloys continue to increase. Another thing is the increase in the need for brass gears, so environmentally friendly material engineering is needed to provide good quality and efficient energy use, especially during the casting process. The casting process uses an electric furnace that melts brass alloys at 526 up to 900 °C within 1 hour and molds to make test specimens. The results of microstructural testing for grain size in recycled brass alloys range from 74.63 μm to 84.57 μm. The maximum tensile strength produced is up to 225.2 MPa, the maximum yield strength is up to 179.8 MPa, and the maximum elongation is up to 7.3 %. The roughness of recycled brass alloys has a maximum Ra value (average roughness) of up to 0.836 μm. Validation was carried out by comparing the mechanical properties of CAC 302 brass products and the study results. The data shows that recycled brass's maximum yield strength value is 179.8 MPa and CAC 302 brass material is 175 MPa, but for the ultimate tensile strength value, the value of recycled brass is far below CAC 302 products. These results can be a consideration for the industry to be able to use recycled brass alloys for gear products because the yield strength value is not far from CAC 302 brass products. The impact result of this study produces recycled brass alloys that are environmentally friendly, efficient in smelting energy consumption, and have good yield strength. The results of this research can benefit the manufacture of gear components made of brass alloys.

Indirect optical geometry measurements with a stream of particles as micro probes

The manufacturing of micro-structured components with varying geometries and materials requires precise and versatile applicable geometry measurement techniques. Optical measurement approaches enable high-precision measurements, but they rely on cooperative surfaces. To overcome the dependency on the optical surface response, the surface of a measured object is determined indirectly using an aerosol flow with fluorescent particles and a confocal fluorescence microscope. To precisely extract the surface position from the scanned fluorescence signal of the particles in the surrounding air, a model-based signal processing is proposed. To assess the measurement capabilities and the influence of the aerosol supply flow, geometry and flow measurements are performed on a flat plate geometry and a step geometry. As a result, a measurement uncertainty of ▪ with no systematic error was achieved for the flat plate experiment, despite the different boundary layer flows at the different measurement positions. In contrast to this, a significant systematic measurement error occurred in the wake flow region of the step geometry because of flow separation and, thus, no detectable particles directly behind the step. In summary, the findings clarify an in principle achievable sub-micrometre resolution with improved optics and a large number of detected particles, but also emphasise the necessity of a sufficient particle supply for enabling indirect optical geometry measurements.

In-situ chemically synthesized Fe3O4/K-geopolymer composite with microwave absorbency for additive manufacturing

In this work, we utilized an in-situ chemical synthesis method to fabricate a Fe3O4/K-geopolymer (KGP) composite to be applied in a microwave absorbent field. This material, as a type of ceramic precursor, is highly expected to be a 3D printing material to prepare microwave absorbing components with complex shapes. The investigation results demonstrate that the material possesses a large effective microwave absorbing bandwidth of 3.7 GHz with the minimum reflection loss reducing to −12.2 dB when the generated Fe3O4 percent reaches 12 wt% in the KGP composite. This microwave absorbent performance can be attributed to a synergistic effect between the eddy current loss caused by the improved electrical conductivity of magnetic nanoparticles and the interfacial polarization effect from the geopolymer matrix and magnetic medium interface. Also, we used direct ink writing technology to print two-dimensional components with desirable patterns. Thickness-dependent wave absorption evaluation results confirmed a maximum reflection loss of −25.9 dB at 15.2 Hz was obtained from the printed sample containing 9.0 wt% Fe3O4 for a layer thickness of 10 mm, indicating that wave consumption effectiveness was determined by porous microstructures, magnetic loss of Fe3O4 nanoparticles as well as suitable impedance matching. The preparation method and synthesized material pave the way for integrated manufacturing of 3D printing components with microwave absorbing performance.

Optimizing frequencies of functionally graded material plates via multi-objective genetic algorithm: Positioning point supporters for maximum performance

In the presented study, an approach is introduced for optimizing the vibrational characteristics of aerospace structures that are composed of Functionally Graded Materials (FGM). The focus is placed on the strategic positioning of point supporters to enhance the structural performance under various operational conditions. The effective elasticity properties of the FGMs are determined using the Mori-Tanaka method for homogenization. The deformation behavior of these structures is analyzed by employing the first-order shear deformation theory. Solutions are computed through the 2D Ritz method, which utilizes Chebyshev polynomials, forming the basis for the objective function of a multi-objective genetic algorithm. This algorithm is designed to optimize the positioning and the number of point supporters aimed at targeting specific vibration frequencies. The Non-dominated Sorting Genetic Algorithm II (NSGA-II) is utilized to efficiently generate Pareto optimal solutions, which illustrate the trade-offs between conflicting objectives. The validation of the solution method is achieved through comparisons with experimental data, confirming the accuracy and practical relevance of the approach. The application of the optimization framework is extended to various configurations of aerospace structures, including diverse compositions of FGM and different boundary conditions. This methodology is shown not only to enhance the operational performance of aerospace structures but also to contribute to the precise design and manufacturing of components in aircraft and satellites, aligning with the central interests of aerospace engineering.

Size shrinkage and compressive behaviour of Al2O3 honeycomb structures fabricated via Digital Light Processing technology

Al2O3 ceramic have excellent chemical inertness, superior heat resistance, and excellent corrosion resistance, so they are considered ideal materials for manufacturing high-performance components such as thermal end devices in aerospace, heat dissipation panels in electronic communication, and exhaust filters in the automotive industry. Digital Light Processing (DLP) is a useful technology to fabricate complex Al2O3 ceramic components. However, the size shrinkage effect of DLP-fabricated components need to be investigated deeply before its further application. In this work, we utilized DLP technology to fabricate Al2O3 ceramic honeycomb structures and systematically investigated their microstructure, size shrinkage, and mechanical properties. Our findings revealed that the Al2O3 ceramic grains exhibit flake-like structures with an average diameter of 1–2 μm, and the ceramic particles are tightly bonded. The shrinkage rates in the X and Y axes were 7.54 % and 7.42 %, respectively, while the Z-axis exhibited a more significant shrinkage of 13.04 %. This anisotropic shrinkage in different direction was attributed to accumulation of the interlayer bonding under gravity action during debinding and sintering process. The compressive stress-strain curve of the honeycomb structures demonstrated a typical brittle compressive behavior, including elastic, stress plateau, and brittle fracture stages. The honeycomb structures exhibited an elastic modulus of 54.49 ± 1.22 MPa and a compressive strength of 10.22 ± 0.42 MPa. The fracture analysis indicated that the fractures region of honeycomb structures initiated at the corners of the honeycomb structures, indicating their easy-broken compared to the walls. These findings provide valuable guidance for the high-precision and high-performance manufacturing of complex Al2O3 ceramic components.

Orthogonal experimental method to investigate the effect of process parameters on the mechanical properties of thin-walled parts by PBF-LB/M

Lightweight thin-walled parts are widely used in the aviation and aerospace industries, and with the further increase in the complexity of their features, the traditional manufacturing process can no longer fully meet the high requirements of industrial component manufacturing. In this work, thin-walled parts are processed by Laser based powder bed fusion of metals (PBF-LB/M), and the effects of process parameters on residual stress, hardness, mechanical properties and microstructure of thin-walled parts are systematically investigated. The simulation results show that the maximum equivalent residual stresses are distributed in the combination of the solid and the substrate, and the minimum equivalent residual stresses are mainly distributed in the top two ends and the middle part of the solid, and the stress distribution is symmetrical. In addition, the maximum equivalent residual stress increases with the increase of laser power, and decreases with the increase of scanning spacing or scanning speed. The experimental results show that with the increase of laser energy density, the tensile strength and yield strength of thin-walled parts show a tendency of increasing first and then decreasing. Finally, high-quality thin-walled parts were successfully fabricated by the optimized process parameters, and their tensile and yield strengths were increased by 6.1% and 15.9%, respectively.

An inline point-tracking approach for the real-time monitoring of the free-form bending process

In order to make free-form bending a process of choice for the manufacturing of structural components, a robust strategy for process monitoring is required. Although the technology is particularly suitable for the production of bending components with variable and complex geometry, fluctuations in the process conditions, as well as in the quality of the semi-finished products can results in geometrical deviations from the target geometry. Currently, the quality assessment of the bent components can be done only offline by random sampling, with a considerable time and cost effort. In this contribution, a real-time process monitoring is realised and applied to free-form bending for the first time. First of all, an inline strategy based on single-point tracking for the assessment of the geometry is investigated through an extensive numerical sensitivity analysis. Successively, the method is implemented experimentally and validated with real tests. Finally, a small-batch series of deviating components is produced, and the developed strategy is adopted to perform a real-time process monitoring. The study highlights the potential of an inline measurement strategy for the process monitoring in free-form bending, and its advantages compared to the current offline methods.

Significantly enhancing the ductility of high-strength Cu-15Ni-8Sn alloy via an optimized combined process of deformation and heat treatment

The Cu-15Ni-8Sn alloy (UNS C72900) is a vital material for the manufacturing of precision instrument components. Employing the conventional process of “solution treatment + large cold deformation + isothermal aging” can result in a tensile strength exceeding 1200 MPa but a mere elongation of approximately 2.0 %. To enhance the reliability and service life of the Cu-15Ni-8Sn alloy, this study proposed an optimized process involving “solution treatment + large cold deformation + recrystallization heat treatment + small cold deformation + heating aging” to obtain low dislocation density, fine grains and precipitates, and uniform element distribution, thereby significantly enhancing the ductility while maintaining high strength. Compared to the conventional process, the total elongation under the optimized process was increased from 2.0 % to 11.7 %, while the tensile strength was slightly decreased from 1214 MPa to 1191 MPa. This study could offer optimized insights into the comprehensive mechanical property improvement of spinodal decomposition strengthened copper alloys.

Reconstruction of the bending line for free-form bent components extracting the centroids and exploiting NURBS curves

Free-form bending belongs to the kinematics-based forming processes and allows the manufacturing of arbitrary 3D-bent components. To obtain the desired part, the tool kinematics is adjusted by comparing the target and obtained bending line. While the target geometry consists of parametric CAD data, the obtained geometry is a surface mesh, making the bending line extraction a challenging task. In this paper the reconstruction of the bending line for free-form bent components is presented. The strategy relies on the extraction of the centroids, for which a ray casting algorithm is developed and compared to an existing Voronoi-based method. Subsequently the obtained points are used to fit a NURBS parametric model of the curve. The algorithm parameters are investigated with a sensitivity analysis, and its performance is evaluated with a defined error metric. Finally, the strategy is validated comparing its results with a Voronoi-based algorithm, and investigating different cross-sections and geometries.

Study of Injection Molding Process to Improve Geometrical Quality of Thick-Walled Polycarbonate Optical Lenses by Reducing Sink Marks.

This study investigates the challenges and potential of conventional injection molding for producing thick-walled optical components. The research primarily focuses on optimizing process parameters and mold design to enhance product quality. The methods include software simulations and experimental validation using polycarbonate test samples (optical lenses). Significant parameters such as melt temperature, mold temperature, injection pressure, and packing pressure were varied to assess their impact on geometric accuracy and visual properties. The results show that lower melt temperatures and higher mold temperatures significantly reduce the occurrence of dimensional defects. Additionally, the design of the gate system was found to be crucial in minimizing defects and ensuring uniform material flow. Effective packing pressure was essential in reducing volumetric shrinkage and sink marks. Furthermore, we monitored the deviation between the predicted and actual defects relative to the thickness of the sample wall. After optimization, the occurrence of obvious defects was eliminated across all sample thicknesses (lenses), and the impact of the critical defect, the sink mark on the planar side of the lens, was minimized. These findings demonstrate the substantial potential of conventional injection molding to produce high-quality thick-walled parts when these parameters are precisely controlled. This study provides valuable insights for the efficient design and manufacturing of optical components, addressing the growing demand for high-performance thick-walled plastic products.

Flow boiling heat transfer enhancement of R134a in additively manufactured minichannels with microengineered surfaces

Additive manufacturing (AM) of metal components has opened new frontiers in heat transfer applications owing to its wide design freedom, which enables previously unexplored geometries with enhanced thermal performance to be developed. Open minichannels, on the other hand, consist of an extra manifold situated above the common flow channels, have been demonstrated to effectively reduce pressure drop and two-phase flow instability by mitigating backflow and maldistribution. In this paper, we synergized open minichannel design methodology with an ultrascalable surface microstructuring method for AM AlSi10Mg to improve flow boiling heat transfer performance of R134a. Experiments were conducted at the refrigerant mass flow rates (ṁ) of 0.005 kg/s to 0.01 kg/s (corresponding to mass fluxes of 73 to 146 kg/m2⋅s), and effective heat fluxes (qeff) of 1.8 kW/m2 to 141 kW/m2, by supplying 2 ℃ subcooled liquid to the minichannel inlet at saturation pressure (Psat) of 7.27 bar. The effects of heat flux, nucleation site density, mass flow rate and location of nucleation sites on the harmonic-average heat transfer coefficient (have) and pressure drop (ΔP) along the flow direction are investigated and compared against a conventionally manufactured (Al6061) counterpart. Our results show that the proposed etching process significantly improves the cooling performance of AM microstrucured minichannels, resulting in 210% higher have than Al6061 with negligible pressure drop penalty. The flow visualization results reveal a sequential order of nucleation site activation with increasing heat flux for microstructured open minichannels, which starts from the top of fins, followed by the corners and other three surfaces within the channels. This also results in the non-negligible effects of mass flow rate on cooling performance for microstructured minichannels, with approximately 10%–66% higher have at the lowest mass flow rate. Besides, the pressure drop penalty resulting from plain AM rough surface is also reduced by up to 13% through the proposed microstructuring process. In all, this work not only successfully identifies the dominant mechanisms in AM microstructured open minichannels, but it also provides useful minichannel design guidelines for high-performance two-phase cooling devices by AM.