High-strength Parts Research Articles

Freeform trajectory generation for fiber reinforced polymer composites additive manufacturing with variable-deposition-width

Continuous carbon fiber-reinforced polymers (CCFRPs) printing is a unique additive manufacturing (AM) technique that enhances design flexibility and enables on-demand production of lightweight, high-strength composite parts. However, current trajectory generation methods for CCFRPs-AM have limited control over fiber placement and flexible matrix path infill, particularly in complex regions, often using constant deposition widths that restrict path coverage and mechanical properties. To address these limitations, this paper presents a variable-deposition-width (VDW) trajectory generation method for CCFRPs-AM. The approach integrates a streamline-based technique for fiber paths with a Voronoi diagram-based method for matrix path generation, optimizing path placement based on 2D stress fields while accommodating user-defined fiber paths. Mechanical tests by us on fabricated open-hole composite components demonstrate that the proposed approach enhances the interfacial bonding and increases the maximal loading capacity under tensile stress.

Influence of the Thickness of an Electrolytic Nanocopper Coating on High-Strength Cast Iron Parts on the Sound Pressure Level

Influence of the Thickness of an Electrolytic Nanocopper Coating on High-Strength Cast Iron Parts on the Sound Pressure Level

Microstructural evolution, enhanced mechanical properties, and complex shapes design in high solid content alumina ceramics through additive manufacturing

Manufacturing industrially profitable high solid-loading ceramic materials with finely designed complex shapes is an exciting yet challenging in sustainable additive manufacturing. Here, we propose a resin strategy to achieve a high solid-loading content of 62 vol% alumina slurry for 3D printing high-quality complex shapes using digital light processing (DLP) technology. Remarkably, both high solid-loading content and tuned sintering temperature emerge as key factors in ensuring optimal print quality and mechanical performance. With this strategy, the ceramic slurry containing 62 vol% exhibits lower shear rate and improved layer adhesion. The burnout treatment was designed based on the DSC-TGA results, followed by sintering in an air atmosphere. Comprehensive physical measurements were achieved, alongside precise structural characterization at multilength scales in situ. In depth exploration of post-sintering analysis revealed no changes in phase composition or chemical bonding. The optimum overall performance of sintered specimen exhibited shrinkage of 8.3 %, 8.8 %, and 11.5 % in the X, Y, and Z directions, with a bulk density of 3.76 g/cm3. Mechanical testing demonstrated superior flexural strength of 247.23 MPa, nanoindentation hardness of 30.9 GPa, and modulus of 428.35 GPa. This high-precision printing strategy may significantly contribute to understanding the structure-property relationship of DLP-3D printed Al2O3 ceramic and opening avenue for the applications of high-strength parts in demanding environments.

Research on microstructure and properties enhancement of TiN/GH5188 Co-superalloy composite fabricated by laser powder bed fusion

Improving mechanical properties effectively in Laser Powder Bed Fusion (LPBF) is a substantial challenge. Utilizing metal matrix composites with customizable TiN nanoparticle proportions presents an efficient strategy for fabricating high-strength LPBF parts. This study employed LPBF to fabricate TiN/GH5188 Co-based superalloy composites with alternative TiN nanoparticle contents (0, 0.5, 1, and 1.5 wt%). The effect of nano-TiN particles on the microstructure, texture evolution, and mechanical properties of TiN/GH5188 composites was investigated. Notably, the presence of nano-TiN acts as a reinforcing particle, facilitating the precipitation of the BCC strengthening phase, resulting in substantial strength enhancement. As the TiN content increases, the yield strength and microhardness consistently rise. At a 1.5 wt% TiN addition, a significant enhancement is observed, with yield strength rising by 22.0 % and microhardness increasing by 16.9 %. Although the aggregation of TiN precipitates into larger particles reduces ductility, the appropriate addition of TiN can effectively mitigate the microstructural anisotropy and induce a transition in the texture toward a non-preferred orientation, while maintaining high strength and ductility. A TiN/GH5188 composite containing 1 wt% TiN exhibits a yield strength and tensile strength of 822.4 MPa and 1131.8 MPa, respectively, accompanied by a microhardness of 334.3 HV. The elongation remains at 29.3 %, while exhibiting a non-preferred orientation (111) texture. Compared to GH5188, the yield strength, tensile strength and microhardness are increased by 17.6 %, 7.2 % and 12.1 %, respectively. This study demonstrates the significance of LPBF in producing high-performance TiN/GH5188 Co-superalloy composites and elucidates the potential mechanisms of TiN in improving microstructure and enhancing properties.

Effect of ZrO2 content on mechanical properties of SiC ceramics prepared based on digital light processing

Digital light processing (DLP) technology shows promise in addressing the challenges of preparing high-strength, precise, and complex SiC ceramic structural parts. However, the low strength of DLP-printed SiC ceramic parts remains a persistent issue. To address this, a nano-ZrO2 particle enhancement strategy is proposed. This study systematically investigates the effects of ZrO2 content on slurry viscosity, curing depth, microscopic morphology, and the mechanical properties of SiC ceramics. The results indicate that increasing the ZrO2 content raises the viscosity of the SiC slurry and decreases the curing depth, which can adversely affect the printing quality of SiC ceramic green bodies. However, a higher ZrO2 content significantly reduces pore defects in the sintered parts, improving densification and mechanical properties. This underscores the importance of optimizing ZrO2 content. The SiC sintered parts reinforced with ZrO2 particles exhibited outstanding properties, including a relative density of 91.1 ± 3.2 %, Vickers hardness of 996.4 ± 93.8 HV, and a flexural strength of 201.5 ± 11.4 MPa. This study provides a straightforward and effective method for producing high-strength SiC ceramics via DLP.

Novel Aging Warm-Forming Process of Al-Zn-Mg Aluminum Alloy Sheets and Influence of Precipitate Characteristics on Warm Formability

Concurrently improving the formability and post-formed strength of Al-Zn-Mg alloy sheets is crucial for producing high-strength parts with complex shapes. A novel process of aging warm-forming (AWF) to form solution heat-treated and water-quenched aluminum alloy sheets is proposed in this paper. The as-quenched AA 7075 sheet was first pre-aged and then formed at the desired temperature. The automotive paint–bake process was then utilized as the second aging step to achieve the target strength of the formed part. Additionally, the post-formed strength and warm formability of specimens under the AWF process conditions, as well as the warm-forming of various heat-treated Al-Zn-Mg alloy sheets proposed in previous studies, were compared through tensile and limit dome height tests. Precipitate characteristics of specimens subjected to different warm-forming process conditions were examined to understand their impact on warm formability. The warm formability of Al-Zn-Mg alloy sheets was significantly enhanced, and the post-formed strength achieved was more than 90% of the strength of as-received AA 7075-T6 sheets under the AWF process condition. The results demonstrated the feasibility of this novel AWF process to manufacture Al-Zn-Mg alloy stamped parts for improved spring-back, formability, and good overall post-formed strength. The results also indicate that microstructural characteristics in Al-Zn-Mg alloy sheets under different warm-forming process conditions have a noticeable influence on warm formability and final mechanical properties.

Exploring Microstructural, Interfacial, Mechanical, and Wear Properties of AlSi7Mg0.3 Composites with TiMOVWCr High-Entropy Alloy Powder.

This study explored the impact of varying weight percentages of TiMoVWCr high-entropy alloy (HEA) powder addition on A356 composites produced using friction stir processing (FSP). Unlike previous research that often focused on singular aspects, such as mechanical properties, or microstructural analysis, this investigation systematically examined the multifaceted performance of A356 composites by comprehensively assessing the microstructure, interfacial bonding strength, mechanical properties, and wear behavior. The study identified a uniform distribution of TiMoVWCr HEA powder in the composition A356/2%Ti2%Mo2%V2%W2%Cr, highlighting the effectiveness of the FSP technique in achieving homogeneous dispersion. Strong bonding between the reinforcement and matrix material was observed in the same composition, indicating favorable interfacial characteristics. Mechanical properties, including tensile strength and hardness, were evaluated for various compositions, demonstrating significant improvements across the board. The addition of 2%Ti2%Mo2%V2%W2%Cr powder enhanced the tensile strength by 36.39%, while hardness improved by 62.71%. Similarly, wear resistance showed notable enhancements ranging from 35.56 to 48.89% for different compositions. Microstructural analysis revealed approximately 1640.59 grains per square inch for the A356/2%Ti2%Mo2%V2%W2%Cr processed composite at 500 magnifications. In reinforcing Al composites with Ti, Mo, V, W, and Cr high-entropy alloy (HEA) particles, each element imparted distinct benefits. Titanium (Ti) enhanced strength and wear resistance, molybdenum (Mo) contributed to improved hardness, vanadium (V) promoted hardenability, tungsten (W) enhanced wear resistance, and chromium (Cr) provided wear resistance and hardness. Anticipating the potential applications of the developed composite, the study suggests its suitability for the aerospace sector, particularly in casting lightweight yet high-strength parts such as aircraft components, engine components, and structural components, underlining the significance of the investigated TiMoVWCr HEA powder-modified A356 composites.

Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process

PurposeThis paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes due to hot-cracking issues.Design/methodology/approachThe multilayers AA6061 parts were fabricated by LFP to characterize for cracks and porosity. Mechanical properties of the LFP-fabricated AA6061 parts were tested using Vicker’s microhardness and tensile testes. The electron backscattered diffraction (EBSD) technique was used to reveal the grain structure and preferred orientation of AA6061 parts.FindingsThe crack-free AA6061 parts with a high relative density of 99.8% were successfully fabricated using the optimal process parameters in LFP. The LFP-fabricated parts exhibited exceptional tensile strength and comparable ductility compared to AA6061 samples fabricated by conventional laser powder bed fusion (LPBF) processes. The EBSD result shows the formation of cracks was correlated with the cooling rate of the melt pool as cracks tended to develop within finer grain structures, which were formed in a shorter solidification time and higher cooling rate.Originality/valueThis study presents the pioneering achievement of fabricating crack-free AA6061 parts using LFP without the necessity of preheating the substrate or mixing nanoparticles into the melt pool during the laser melting. The study includes a comprehensive examination of both the mechanical properties and grain structures, with comparisons made to parts produced through the traditional LPBF method.

High-Throughput Additive Manufacturing of Continuous Carbon Fiber-Reinforced Plastic by Multifilament.

Additive manufacturing (or 3D printing) of continuous carbon fiber-reinforced plastics with fused deposition modeling is a burgeoning manufacturing method because of its potential as a powerful approach to produce lightweight, high strength and complex parts without the need for a mold. Nevertheless, it cannot manufacture parts rapidly due to low throughput. This paper proposes a high-throughput additive manufacturing of continuous carbon fiber-reinforced plastics by multifilament with reference to fiber tape placement. Three filaments were fed and compaction printed simultaneously by a robotic manufacturing system. The coupled thermal-mechanical model of the filament deformation during printing was developed to eliminate the initial interval between the filaments and improved mechanical properties. Furthermore, the mathematical relationship between filament deformation and printing parameters consisting of printing temperature, printing speed and roller pressure was proposed using response surface methodology with the line width as the response. The tensile tests demonstrate that the tensile properties of printed parts are positively correlated with the line width, but not infinitely improved. The maximum tensile strength and tensile modulus are 503.4 MPa and 83.11 Gpa, respectively, which are better than those obtained by traditional methods. Void fraction and scanning electron microscope images also reveal that the appropriate line width achieved by the reasonable printing parameters contributes to the high-throughput multifilament additive manufacturing of continuous carbon fiber-reinforced plastics. The comparison results indicate that the high-throughput multifilament additive manufacturing proposed in this paper can effectively improve the speed of continuous carbon fiber-reinforced plastics additive manufacturing without degrading the mechanical performance.

Material Analysis of a Sample Airless Wheel That Can Be Used in The Landing Gear of Small UAVs for Smart Agriculture Using the Finite Element Method

Unmanned Aerial Vehicles (UAV) in categories 1 and 2 are small in size and have a maximum gross take-off weight between 5 - 40 N and 40 - 250 N, with a normal operating altitude of 120 m above ground level. One of the major concerns for UAVs is the weight of aerial vehicles, which is aided primarily by material changes. Tires for UAVs are primarily made of ABS, rubber silicone, and nylon to reduce flight problems. These tires add to the dead weight and drag during flight.
 In response to these issues, a rigorous analysis was performed to select the best possible configuration using various materials such as Acrylonitrile Butadiene Styrene (ABS), rubber silicone, and nylon materials. UAV wheel manufacturing is commonly known as the production of high-strength light-weighing parts. It also provides a broader range of design options and favors an iterative design approach, so it is important the method of production. To achieve the best results, the iterative design approach was used in the analysis application. The study incorporated a design for airless tires with 40 spokes, leveraging Autodesk Inventor Pro for modeling. Subsequently, the designs underwent Finite Element Analysis to assess static radial strength. Bending and torsion stresses during landing were deemed negligible owing to the lightweight nature of categories 1 and 2 UAVs and were thus excluded from the analysis.
 The modeled wheel design in Autodesk Inventor Pro analysis based on Finite Element Analysis of the airless wheels revealed that wheels made of rubber silicone exhibited superior shock absorption, with a deformation of only 2.314 mm at 625 N upon impact during UAV landing maneuvers.

Influence of discharge energy on electromagnetic compaction characteristics of copper powders with same compression amount

Electromagnetic powder compaction technology is an effective method for producing high density and strength parts. In this work, the influence of discharge energy on the electromagnetic compaction characteristics of copper powders with same compression amount was studied through experiment investigation and numerical simulation. The finite element simulation, micro morphology observation, and compressive strength testing were conducted. Results showed that the propagation direction of stress was 45° from top to bottom of compacts. At 7–9 kJ, there was a turning phenomenon in the direction of stress propagation at the upper edge position due to the restriction of shim. As the discharge energy increased, the pores on the upper end face shifted towards reduction and concentration, ultimately forming local defects with large pores. This method could be used to improve the compaction quality of the local position of compacts. The compressive strength of compacts also increased gradually and then almost linearly, and the maximum value was 164.07 MPa. The relationships between volume strain and compaction time were obtained, R-square exceeded 0.9997 under different discharge energies, indicating high reliability.

Microstructure and mechanical properties of welds at keyhole closures in variable-polarity plasma arc aluminum welding

The variable-polarity plasma arc (VPPA) keyhole welding technology offers an efficient solution for producing defect-free aluminum alloys, but a keyhole is left at the end of the welding process. Traditional manual TIG welding, which involves filling keyholes, often lacks productivity and can result in inconsistent weld quality, hindering the production of high-strength and high-precision parts. In this study, a keyhole self-closing method was proposed, and the microstructure and mechanical properties of keyholes closed by the proposed method were compared to those closed by manual TIG welding. The results showed that the self-closed keyhole had a smaller fusion line wide, and the weld zone had a uniform distribution of equiaxed crystal, with fewer pore defects. While the manual TIG welding-filled keyhole had a higher density of dislocations, which leads to an increase in the microhardness. The presence of pores in the manual TIG welding-filled keyhole reduces its tensile strength and elongation, which were lower than those of the self-closed keyhole by 61.5 MPa and 5.8 %, respectively. The self-closing method can effectively address the keyhole retention issue in VPPA keyhole welding. By using this method, higher-quality welds with better microstructure and mechanical properties can be produced, which can have important implications for various industrial applications, and in applications where mechanical properties are critical.

Efficient net shape forming of high-strength sheet metal parts by Transversal Compression Drawing

In this contribution, a new forming method is presented for high-strength steel sheet metal materials called Transversal Compression Drawing (TCD). For TCD, the blankholder of the conventional deep drawing process is replaced by sliders introducing a vertical force along the blank edge. Compared to conventional deep drawing, compressive stresses are thereby superimposed in the flange area of the sheet metal material, reducing the springback of formed components and the forces required during the process. Proof of this is provided here on the basis of numerical investigations in which conventional deep drawing and TCD are compared using the example of an “S-Rail” component made from DP980. Results of these investigations reveal that with TCD a maximum reduction in springback by more than 5 mm is achieved, leading to an improvement in the component´s overall shape accuracy of more than 55%. Furthermore, frictional work is decreased by − 6.92 kJ/kg, resulting in an overall reduction of maximum forming forces by 67.4%. Besides, TCD enables a trim-free net shape forming of the final part contour in a single operation and an increased material utilization of 4.5% from coil to part. Not least, no sheet thinning occurs with TCD, whereas a maximum thinning of 12% is observed with the conventional deep drawing process.

Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts.

Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. However, the existing additive manufacturing processes for CCFRP parts have numerous disadvantages. Resin- and extrusion-based processes require time-consuming and costly post-processing to remove the support structures, severely restricting the design flexibility. Additionally, the production of small batches demands considerable effort. In contrast, laser sintering has emerged as a promising alternative in industry. It enables the creation of robust parts without needing support structures, offering efficiency and cost-effectiveness in producing single units or small batches. Utilising an innovative laser-sintering machine equipped with automated continuous fibre integration, this study aims to merge the benefits of laser-sintering technology with the advantages of continuous fibres. The paper provides an outline, using a finite element model in COMSOL Multiphysics, for simulating and identifying an optimised operating point range for the automated integration of continuous fibres. The results demonstrate a remarkable reduction in processing time of 233% for the fibre integration and a reduction of 56% for the width and 44% for the depth of the heat-affected zone compared to the initial setup.

The Effect of the Surface Topography of High-Speed Steel Cutting Blades Made Using Various Methods on Their Technological and Functional Properties.

Indication of the proper scope of application of high-speed steels (HSS) produced by conventional methods and powder metallurgy for cutting tool blades requires a thorough assessment of their properties in various cutting conditions. According to common knowledge, the properties of tools made of both types of steel are largely determined by the arrangement of carbide phases. It turns out, however, that the surface morphology of the cutting blades is at least as important for their operational properties. This was already indicated by the preliminary research of the authors of the article, in which it was found that the surface topography significantly affects their durability depending on the applied value of the cutting speed in dry machining conditions and in the presence of a cooling lubricant. As it turned out, contrary to the literature data, blades made of sintered HSS do not have better service properties in all cutting conditions than blades made by conventional methods (e.g., in forging and hot rolling processes). Hence, it was necessary to determine the justified range of use of both types of steel for cutting blades. Cutting blades with a similar chemical composition from conventional high-speed steel and those produced in the powder metallurgy process were tested. Wear curves were determined on the basis of the tests. On this basis, for the assumed value of the blunting index, the tool life of the cutting edges was determined during the cutting of selected structural steel, commonly used for high-strength machine parts. Tests of the cutting ability of the blades were carried out without and with the use of a cooling--lubricating liquid. In order to correctly interpret the obtained results of the wear and durability tests of the cutting edges, verification tests were carried out. A detailed analysis of the research material made it possible to determine the recommended range of applicability of conventional and sintered HSS for the tested case.

Influence of filler concentration and type on rheological and mechanical properties of liquid isoprene rubber for high-strength parts via material extrusion

This study investigates the rheological behavior and material extrusion performance of liquid isoprene rubber (LIR) compounds filled with carbon black (CB), silica (Si), and recycled crumb rubber (CR) fillers for potential additive manufacturing applications. The rheological properties of the LIR mixtures were characterized using flow curve analysis and temperature sweeps, identifying shear-thinning behavior and temperature-dependent viscosity ultimately reflecting the final dimensional tolerance of the prints. Vulcanization time (t90) was determined using oscillatory rheometry, and the effect of filler concentration on t90 was evaluated. Mechanical testing was conducted to assess the hardness and tensile properties. The results demonstrate the influence of filler concentration on the rheological properties, printability, and mechanical performance of the LIR compounds thus resulting in the printing of high-strength (σu > 5 MPa) isoprene rubber parts capable of being additively manufactured.

Material Optimization for Structural Strength of Hexacopter Landing Skid Using Finite Element Method

Hexacopter is a type of UAV that has six propellers with a load of 15 kg or about 147 N in this study. Then, to support the landing of the hexacopter and to support it while being on the ground, landing skid is needed. The landing skid is designed using 3D printing from selected materials to find out which material is best used for the landing skid, including PLA, PETG, and ABS. 3D-printing supports the production of lightweight and high-strength parts. This research method uses finite element to compare several materials and uses SolidWorks to simulate static load and drop test by landing skid. The results show that PETG material is the best material with the highest safety factor in the static load and has the lowest strain value in the drop test.

Effect of Ingate Length on Microstructure and Properties of Semi-Solid Squeeze Casting CuSn10P1 Alloy

It is easy to occur solid-liquid separation during semi-solid rheological forming, which leads to poor uniformity of microstructure and properties and limits its application in high strength and toughness parts. In this paper, a semi-solid CuSn10P1 alloy slurry was prepared by an enclosed cooling slope channel (for short ECSC). The effect of ingate length on microstructure and properties by semi-solid squeeze casting was studied. The results showed that the proper increase of the length of the ingate is beneficial to improve the uniformity of the microstructure and properties of the semi-solid squeeze casting. The microstructure uniformity and properties are the best when the ingate length is 20mm. The ultimate tensile strength and elongation of semi-solid squeeze casting CuSn10P1 alloy with 20 mm ingate length reached 419.2 MPa and 13.4%.

The Optimization of Welding Spots’ Arrangement in A-Pillar Patchwork Blank Hot Stamping

With increasingly severe environmental problems, energy saving and environmental protection have become two important issues to be solved in the automobile industry. Patchwork blank hot-stamping technology can be used to obtain light-weight and high-strength parts and is thus increasingly used in the manufacture of autobody parts. Because the main blank and the patched blank need to be connected through spot welding before forming, the welding spots’ arrangement has a great influence on the formability of the part. In this study, a thermal–mechanical coupling finite element analysis model of A-pillar patchwork blanks was established. With the thickness of the patched blank, the distance between the welding spot and the external contour of the patched blank, and the number of welding spots as optimization variables, together with the maximum thinning rate and the maximum welding spot force as objectives, the influence of welding spot arrangement on forming quality was analyzed, and the welding spots’ arrangement was optimized using a central composite design (CCD), the response surface method (RSM), and the genetic algorithm (GA). The results showed that when the initial welding spot was located close to the contour of the patched blank, the bending moment was greater when the weld spot passed through the die corner, leading to the rupture of the welding spot or its surrounding base material due to the greater thinning rate. When the patched blank was thicker than the main blank, the main blank cracked during the forming process due to a greater increase in the thinning rate. The optimal solution of the weld spot arrangement on the A-pillar patchwork blanks was a 1.2 mm thick main blank, 0.8 mm thick patched blank, a distance of 29 mm between the weld spot and the contour line of the patched blank, and 16 weld spots. Hot-stamping experiments were conducted using the optimized weld spots’ arrangement, and high-quality parts were obtained.

An analysis of different cutting strategies to improve tool life when machining Ti-5Al-5V-5Mo-3Cr alloy

Ti-5Al-5V-5Mo-3Cr is a near-beta titanium alloy generally employed in the production of high strength parts. Its high tensile strength and light weight, compared to Ti-6Al-4V, make it a suitable choice for landing gear parts and advanced structural components. However, due to its high strength-to-weight ratio, mechanical strength at elevated temperatures, and oxidation resistance, the cutting zone experiences high cutting temperatures, which, combined with a low rate of heat transfer during the machining process, consequently, generates stress, causing premature tool failure. In this paper, several distinct experimental approaches were applied, different machining condition combinations (tools and coolants) were compared, cutting tool wear performance was diagnosed, and, finally, optimized cutting parameters were identified. The main objective of this research was to understand how these parameters affect tribological behavior when machining Ti-5Al-5V-5Mo-3Cr. One of the PCD tools possessed the longest life under high pressure coolant of 28 %–170 % longer than the other tool materials. The main wear mechanism was a combined abrasion, adhesion/attrition, diffusion, and oxidation. Optimizing cooling conditions can affect cutting forces substantially, minimizing residual stress, improving the surface roughness, and reducing the work-hardening during machining. Therefore, the results show that the combination of coolant and cutting tool material leads to longer tool life and improved surface integrity.