Manufacturing Solutions Research Articles

Recent Progress in Hybrid Additive Manufacturing of Metallic Materials

Additive Manufacturing (AM) is an advanced technology that has been primarily driven by the demand for production efficiency, minimized energy consumption, and reduced carbon footprints. This process involves layer-by-layer material deposition based on a Computer-Aided Design (CAD) model. Compared to traditional manufacturing methods, AM has enabled the development of complex and topologically functional geometries for various service parts in record time. However, there are limitations to mass production, the building rate, the build size, and the surface quality when using metal additive manufacturing. To overcome these limitations, the combination of additive manufacturing with traditional techniques such as milling and casting holds the potential to provide novel manufacturing solutions, enabling mass production, improved geometrical features, enhanced accuracy, and damage repair through net-shape construction. This amalgamation is commonly referred to as hybrid manufacturing or multi-material additive manufacturing. This review paper aimed to explore the processes and complexities in hybrid materials, joining techniques, with a focus on maraging steels. The discussion is based on existing literature and focuses on three distinct joining methods: direct joining, gradient path joining, and intermediate section joining. Additionally, current challenges for the development of the ideal heat treatment for hybrid metals are discussed, and future prospects of hybrid additive manufacturing are also covered.

Enhanced high-temperature mechanical properties of laser-arc hybrid additive manufacturing of Al-Zn-Mg-Cu alloy via microstructure control

Recently, rapid and cost-effective additive manufacturing solutions for lightweight aluminum alloys with excellent high-temperature mechanical properties have been increasingly in demand. In this study, we combined laser-arc hybrid additive manufacturing with solution and artificial aging treatments to achieve Al-Zn-Mg-Cu alloy with favorable high-temperature strength via microstructure control. Hydrogen pores became the major defect in the as-deposited and heat-treated specimens. The continuous distribution of eutectics with hard-brittle characteristics at the grain boundaries was destructed following heat treatment. High-density η′ precipitates were uniformly dispersed in the heat-treated Al-Zn-Mg-Cu alloy, whereas appeared coarsened and dissolved at 473 K, owing to the rapid diffusion of Zn and Mg. The average 0.2% yield strength (318 ± 16 MPa) and ultimate tensile strength (362 ± 20 MPa) at 473 K after heat treatment were enhanced by approximately 58% and 51%, respectively, compared to those of the as-deposited specimen. In addition, the η′ precipitates contributed to lattice distortions and strain fields, which prevented dislocation motion and increased slip deformation resistance at high temperatures. The as-deposited specimen exhibited intergranular fracture at 473 K, with cracks preferring to propagate along the aggregated eutectics. However, crack propagation proceeded in the sections with more pores in the heat-treated specimen. Our approach may provide a valid option for achieving aluminum alloys with excellent high-temperature mechanical properties.

Dissimilar linear friction welding of Ni-based superalloys

Linear friction welding is a solid-state, near-net shape manufacturing method for metallic alloys which is characterised by complex deformation and metallurgical actions at the weld interface. However, a lack of understanding of the welding parameter interaction and subsequent welding mechanisms is hindering the joint integrity enhancement of dissimilar linear friction welding. In this study, we investigated the influence of various process parameters on macro/micro-formation, microstructural evolution, and properties to establish optimal welding conditions for the sound linear-friction-welded joint integrity of dissimilar superalloys, IN718, and the powder metallurgy FGH96. Increased oscillation frequency or decreased applied pressure promoted continuous dynamic recrystallisation and grain refinement, although discontinuous dynamic recrystallisation remained dominant. Enhanced dissolution of the strengthening phases (γ′ phase on the FGH96 side and δ phase on the IN718 side) was observed from the thermomechanically affected zone to the interface. The subsequent correlation between the microstructure and mechanical properties indicated that solid–solution strengthening was the dominant mechanism for enhancing interfacial bonding, which was promoted by mutual material deformation on both sides. Accordingly, to achieve synergistic plastic deformation in dissimilar linear friction welding, an optimisation strategy of welding parameter combination was proposed and validated by investigating hot compressive dissimilar Ni-based superalloys. The results of simulations of sub-size workpieces showed that using linear friction welding to manufacture bimetallic bladed disks, from conception to completion, was feasible. The paper offers an integrated solution for the full-scale manufacturing of an IN718/FGH96 blisk using linear friction welding based on microstructure–property interactions and relevant simulations, which can ideally serve as the basis for future bimetallic bladed disk manufacturing.

Direct Ink Writing of Nanocellulose and PEDOT:PSS for Flexible Electronic Patterned and Supercapacitor Papers

AbstractPrinted electronic paper identifies its interest in flexible organic electronics and sustainable and clean energy applications because of its straightforward production method, cost‐effectiveness, and positive environmental impact. However, current limitations include restricted material thickness and the use of supporting substrate for printing. Here, 2D and 3D electronic patterned paper are fabricated from direct ink writing (DIW) nanocellulose and PEDOT:PSS‐based materials using syringe deposition and 3D printing. The conductor patterns are integrated in the bulk of the paper, while non‐conductive sections are used as support to form free‐standing paper. The strong interface between the patterns of electronic patterned paper gives mechanical stability for practical handling. The conductive paper‐based electrode has 202 S cm−1 and is capable of handling electric current up to 0.7 A, which can be used for high‐power devices. Printed supercapacitor papers show high specific energy of 4.05 Wh kg−1, specific power of 4615 W kg−1 at 0.06 A g−1, and capacitance retention above 95% after 2000 cycles. The new design structure of electronic patterned papers presents a solution for additive manufacturing of paper‐based composites for supercapacitors, wearable electronics, or sensors for smart packaging.

Laser–Direct Current arc Hybrid Additive Manufacturing of Cu-Cr-Zr Alloy: Microstructure Evaluation and Mechanical Properties

Recently, there has been a growing requirement for rapid and cost-effective additive manufacturing solutions for copper alloys with favorable mechanical properties. In this research, laser–direct current arc hybrid additive manufacturing (LAHAM) was employed to fabricate Cu-Cr-Zr alloy. By way of multi-scale characterization including SEM, EBSD and TEM, the effect of scanning speed on the microstructure was systematically investigated in detail. Moreover, an evaluation of mechanical properties was carried out. The results indicated that columnar grains grew across layers with the growth direction tending to the center of the molten pool. When the scanning speed increased from 250 mm/min to 350 mm/min, the proportion of high-angle grain boundaries exceeded 69% and reached a maximum of 79% at 300 mm/min. A large amount of Cr phase was precipitated from the Cu matrix. Both submicron and nanoscale Cr precipitates were observed. Statistically, the area proportion of Cr precipitates was up to 26.3% at 300 mm/min. The changes of heat input and remelting effects were the main reasons for the change in the precipitate level. As a result, the mechanical properties of the Cu-Cr-Zr alloy were enhanced via precipitation strengthening. When the scanning speed was 250 mm/min, the Cu-Cr-Zr alloy sample exhibited an ultimate tensile strength of 311.3 ± 7.8 MPa with an elongation of 38.6 ± 5.6%.

Powerful End-To-End Technology Solutions

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Business Intelligence Using N-Beats And Rnn Methods End Influence On Decision Making In The Flexible Packaging Manufacturing

Today's complex decision-making solutions for intelligent manufacturing depend on the ability to be able to model a manufacturing system realistically, valid and consistent data integrated easily and in a timely manner, able to solve problems efficiently with computational effort to obtain optimal production and product quality optimizations continuously. When an organization uses a data-driven approach, it means that it makes strategic decisions based on data collection, analysis, and interpretations or insights. The purpose of this research is to analyze the business intelligence approach in optimizing print machines by speed, material and time. in this research, using the N-Beats is a deep neural architecture based on backward and forward residual links and a very deep stack of fully-connected layers and Recurrent Neural Networks (RNN). The novelty of this research is increasing machine speed using new insights by combining two deep learning methods. Observing and retrieving raw data from the printing machine process with sensors data for use and ensuring the justification of the addition of new methods. The result is expected to be able to provide new insights that can increase engine speed, the data based decision making provides businesses with the capabilities to generate real time insights and predictions to optimize their performance and provide confidence in decision making that are fast, precise and better.

Microbial production of trans-aconitic acid

Trans-aconitic acid (TAA) is a promising bio-based chemical with the structure of unsaturated tricarboxylic acid, and also has the potential to be a non-toxic nematicide as a potent inhibitor of aconitase. However, TAA has not been commercialized because the traditional production processes of plant extraction and chemical synthesis cannot achieve large-scale production at a low cost. The availability of TAA is a serious obstacle to its widespread application. In this study, we developed an efficient microbial synthesis and fermentation production process for TAA. An engineered Aspergillus terreus strain producing cis-aconitic acid and TAA was constructed by blocking itaconic acid biosynthesis in the industrial itaconic acid-producing strain. Through heterologous expression of exogenous aconitate isomerase, we further designed a more efficient cell factory to specifically produce TAA. Subsequently, the fermentation process was developed and scaled up step-by-step, achieving a TAA titer of 60 g L−1 at the demonstration scale of a 20 m3 fermenter. Finally, the field evaluation of the produced TAA for control of the root-knot nematodes was performed in a field trial, effectively reducing the damage of the root-knot nematode. Our work provides a commercially viable solution for the green manufacturing of TAA, which will significantly facilitate biopesticide development and promote its widespread application as a bio-based chemical.

Benchmarking framework for anomaly localization: Towards real-world deployment of automated visual inspection

Localizing defects in products is a critical component of industrial pipelines in manufacturing, retail, and many other industries to ensure consistent delivery of high quality products. Automated anomaly localization systems leveraging computer vision have the potential to replace laborious and subjective manual inspection of products. Recently, there have been tremendous efforts in this research domain investigating deep learning-based anomaly localization methods. However, such proposed methods, mainly considering product-specific evaluation, cannot be directly implemented for real-world use. Therefore, despite the advancements, there is still a gap between research and deployment of those methods to real-world production environments. Implementing any automated solution for manufacturing can involve a steep upfront investment. It is important to develop an industry-friendly benchmarking framework to ensure the feasibility and robustness of an automated quality control system. In this paper, we present a new anomaly localization benchmarking framework considering different aspects - (1) understand the performance of models in a generalizable product-agnostic manner, (2) explore pros and cons to find the most optimal modeling approach, (3) develop an efficient training and inference scheme with defect-free training samples and very few defective samples for evaluation, and (4) perform an ablation study of threshold estimation techniques to determine optimal threshold level for segmentation. We release a newly-labeled dataset for the research community with product-agnostic categorization of defective product images. To the best of our knowledge, this is the first anomaly localization work on developing a benchmarking framework focusing on real-world use. We believe domain experts from different industries will find this useful and can gain valuable insights to deploy automated visual inspection in production pipelines.

Concrete manufacturing with a low CO2 footprint

The object of the research is the current state of the climate action strategy for cement and concrete production, including possible levers for reducing CO2 emissions. It has been determined that the main source of carbon dioxide emissions per tonne of Portland cement, and subsequently per cubic metre of concrete, is the decarbonization of calcium carbonate, the main raw material component of Portland cement clinker. It also involves the combustion of fossil fuels, which are necessary for the decarbonization and firing of raw materials. Therefore, Portland cement with a reduced content of Portland cement clinker is considered as a solution for concrete manufacturing with a low CO2 footprint. Additionally, the potential of Ukraine in the development of a sustainable Portland cement clinker production approach based on using alternative fuels and alternative raw materials, which will positively affect the total amount of CO2 per ton of clinker, was evaluated. Improved quality performance of cement has been identified as a key direction in product portfolio management to promote cements with a lower clinker factor by increasing the content of active mineral additives. It is shown that the production of concrete with increased strength and durability requirements based on cements saturated with active mineral additives is an important task. Since active mineral additives have different origins, not all of them available for use in cement production exhibit hydraulic properties inherent in Portland cement clinker. Was investigated that «Complex Performance Testing System» (CPTS) as the main test method for evaluating the quality parameters of Portland cement with a reduced clinker factor in accordance with specific applications. This customer-oriented approach opens up the possibility of producing low-CO2 concrete. It has been shown that using the CPTS method, a reduction in the total amount of cement per cubic meter of concrete can be achieved, given the specified parameters of the concrete mix, which has a direct impact on the total amount of CO2/m3.

MKS Instruments presents multiple measurement solutions for additive manufacturing

PhotonicsViewsVolume 20, Issue 3 p. 82-82 Product ReportFree Access MKS Instruments presents multiple measurement solutions for additive manufacturing First published: 20 June 2023 https://doi.org/10.1002/phvs.202370316AboutPDF ToolsExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL No abstract is available for this article. Volume20, Issue3June/July 2023Pages 82-82 RelatedInformation

Performance review of the joints for the ITER poloidal field coils

For large scale magnets wound with cable-in-conduit conductors, the safe operation of the joints is of paramount importance to guarantee adequate reliability and stability margin of the whole magnet. For this reason, during the R&D activities undertaken for the development of the ITER magnet system, several experimental campaigns were launched to study the AC and DC performance of the joint and limit the risk of thermal runaways at the joints during the tokamak operation. The joint electrical resistance must be limited below specified values to avoid excessive heating generated by the transport current. Moreover, in presence of time-varying fields, different types of losses arise at the joints, which can be associated to their superconducting and resistive parts. The relative importance of these losses depends on the joint manufacturing solution. The aim of this investigation is to analyze the performance at different working conditions of the joints for the connection of the conductors of the poloidal field (PF) coils of the ITER magnet system. This work presents, for the first time, a wide review of the test campaign performed from 2016 to 2021 on the PF joint samples during the three manufacturing phases, namely pre-qualification, qualification and production. The values of electrical resistances and losses under sinusoidal field variations are reported in the paper at different operating conditions, thus building a useful database to assess the joint performances during the machine operation. The data here collected show the impact of the manufacturing techniques on the joint performances and, furthermore, represent a useful tool for the validation of numerical and analytical models of joints.

Microwave heating of graphene nanoplatelet polymer composites: Experimental and finite element study

AbstractCompared with contemporary electrofusion techniques that use embedded wires for Joule heating, microwave heating may facilitate the joining of thermoplastic polymer components, promising shortened fusion periods, superior heating uniformity, and reduced energy consumption. This study investigates the fabrication of multifunctional polylactide acid (PLA) composites with strong microwave absorption using graphene nanoplatelets (GNP). GNP/PLA nanocomposites were fabricated using a two‐step scalable manufacturing method, that is, solution blending and hot compression molding. The GNP content of the composites ranged from 0% to 8% by weight. The samples were characterized for dielectric permittivity, heat capacity, and electrical and thermal conductivity. Thermal imaging was used to investigate the efficacy of microwave heating in GNP/PLA nanocomposites as a function of microwave power and filler weight fractions. The microwave heating process in GNP composites was studied using multi‐physics finite element software. The experimental results were compared to numerical model predictions for maximum temperature and microwave energy absorbed. The produced nanocomposites were discovered to have strong microwave absorption characteristics and hence rapid heating, making this type of composite a prospective choice for gasket materials that facilitate fusion bonding for thermoplastic‐based components via localized heating.

Validation of High-Availability Model for Edge Devices and IIoT

Competitiveness in industry requires smooth, efficient, and high-quality operation. For some industrial applications or process control and monitoring applications, it is necessary to achieve high availability and reliability because, for example, the failure of availability in industrial production can have serious consequences for the operation and profitability of the company, as well as for the safety of employees and the surrounding environment. At present, many new technologies that use data obtained from various sensors for evaluation or decision-making require the minimization of data processing latency to meet the needs of real-time applications. Cloud/Fog and Edge computing technologies have been proposed to overcome latency issues and to increase computing power. However, industrial applications also require the high availability and reliability of devices and systems. The potential malfunction of Edge devices can cause a failure of applications, and the unavailability of Edge computing results can have a significant impact on manufacturing processes. Therefore, our article deals with the creation and validation of an enhanced Edge device model, which in contrast to the current solutions, is aimed not only at the integration of various sensors within manufacturing solutions, but also brings the required redundancy to enable the high availability of Edge devices. In the model, we use Edge computing, which performs the recording of sensed data from various types of sensors, synchronizes them, and makes them available for decision making by applications in the Cloud. We focus on creating a suitable Edge device model that works with the redundancy, by using either mirroring or duplexing via a secondary Edge device. This enables high Edge device availability and rapid system recovery in the event of a failure of the primary Edge device. The created model of high availability is based on the mirroring and duplexing of the Edge devices, which support two protocols: OPC UA and MQTT. The models were implemented in the Node-Red software, tested, and subsequently validated and compared to confirm the required recovery time and 100% redundancy of the Edge device. In the contrast to the currently available Edge solutions, our proposed extended model based on Edge mirroring is able to address most of the critical cases, where fast recovery is required, and no adjustments are needed for critical applications. The maturity level of Edge high availability can be further extended by applying Edge duplexing for process control.

Study of an Iron Age Gilded Silver Earring by XRF, SEM-EDS and Multifocus OM

The use of gold for artefact productions underwent substantial developments during Iron Age in western Europe, with the diversification of alloy compositions and the introduction of new technologies and aesthetics. This work presents a detailed study of a Late Iron Age earring from the western Iberian Peninsula and a discussion taking into consideration the alloys and technologies used at the time. The earring has a complex structure, composed of block- and strip-twisted wires and granulation. Characterization by multifocus optical microscopy, portable X-ray fluorescence spectrometry (pXRF), micro-XRF and scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS) were performed to obtain information on the chemical composition and manufacturing techniques. Results show that the earring was manufactured with wires and granules made of a silver-rich alloy, covered with a gold-rich layer 45 μm thick on average, which acted as an external coating making the entire earring resemble gold. This is a rare example of an Iron Age gilded earring, and its detailed study provides further information on the manufacturing solutions adopted by the Iron Age goldsmiths.

The History of Electrospinning: Past, Present, and Future Developments

AbstractElectrospinning has rapidly progressed over the past few decades as an easy and versatile way to fabricate fibers with diameters ranging from micrometers to tens of nanometers that present unique and intricate morphologies. This has led to the conception of new technologies and diverse methods that exploit the basic electrohydrodynamic phenomena of the electrospinning process, which has in turn led to the invention of novel apparatuses that have reshaped the field. Research on revamping conventional electrospinning has principally focused on achieving three key objectives: upscaling the process while retaining consistent morphological traits, developing 3D nanofibrous macrostructures, and formulating novel fiber configurations. This review introduces an extensive group of diverse electrospinning techniques and presents a comperative study based on the apparatus type and output. Then, each process's advantages and limitations are critically assessed to identify the bona fide practicability and relevance of each technological breakthrough. Finally, the outlook on future developments of advanced electrospinning technologies is outlined, with an emphasis on upscaling, translational research, sustainable manufacturing and prospective solutions to current shortcomings.

Design and Fabrication of Imprint Machine

Abstract: This Research Paper aimed at automating the process of marking serial numbers or identification codes on metal, wood, plastic components. This Machine accurately punch numbers onto metal, wood, plastic parts with varying sizes and thicknesses. The machine's design includes a robust frame, a pneumatic system, and a control system that allows for precise control of the number punching process. The punching mechanism consists of a series of hardened steel punches that can be easily replaced and adjusted to accommodate different numbers and character sizes. The control system allows operators to input the desired serial number or identification code, control the punching force, and regulate the individual spacing. The machine also includes safety to prevent injury to operators and damage to the metal parts. Overall, the design and fabrication of a imprint machine for metal parts will provide an innovative solution for manufacturers looking to streamline their product identification process.

Structural optimisation for controlled deflections of additively manufactured single material beams

Closely controlling the mechanical behaviour and characterization of the deflection of a beam structure is a well-known and widely studied engineering problem. The progress in additive manufacturing methods and the possibilities to closely control the material property variations with the controlled placement of materials further widen the opportunities to achieve given beam deflection criteria. The multi-material additive manufacturing solutions suffer from the lack of real engineering material options, and the quality and performance of the printed parts are usually unsuitable for producing functional parts. A novel cellular structured solution is proposed here, which utilises optimisation of geometries of individual cells of a single material structured beam to obtain deflection profiles closely matched with preset conditions under different loading conditions. The cellular geometry of the structured beam is continually altered for searching and converging on the optimal structure of the cells by the covariance matrix adaptation evolution strategy algorithm in an iterative manner. The optimised beam structures could also be physically produced with single material additive manufacturing methods and the experimental and numerical beam deflection responses correlated closely.

In situ-formed micro silk fibroin composite sutures for pain management and anti-infection

Surgical sutures close wounds and promote healing. Sutures need to meet appropriate mechanical properties and biocompatibility, so complex and high-cost braiding processes have been developed for better mechanical properties. However, they still cannot work ideally in some scenarios, such as pain and infection. Pain is the most common symptom in almost all injuries, infections, and diseases. Inadequate management of pain leads to untoward physical and psychological outcomes in patients. For these purposes, we designed a multifunctional composite suture of micro silk fibroin fiber (SF). It was extracted in situ ultra-long and ultra-fine SFs where a single thread can reach hundreds of meters from a cocoon. The suture can adsorb anti-infection vancomycin by turning pH and then coated with methacrylated gelatin as a sheath to load a pain-killer ibuprofen (SMG-VC-IB). SMG-VC-IB can withstand a tension force of nearly 18 N, two times the Mersilk® suture. SMG-VC-IB can maintain prolonged release for efficient pain management and anti-infection. We applied PET/CT to investigate objective metabolic data in brain regions and found that the pain-killer reached efficacy in our built pain model of quadriceps femoris incision in rats. We found SMG-VC-IB reduced metabolic levels in pain-related brain regions, including the classical pain matrix. It was also verified that the pain-killer ibuprofen from sutures helps to pass through the postoperative inflammatory period to a comfortable recovery period. Our research presented an eco-friendly manufacturing solution for designing multifunctional composite sutures for pain management and infection control.

Transforming Industrial Manipulators via Kinesthetic Guidance for Automated Inspection of Complex Geometries.

The increased demand for cost-efficient manufacturing and metrology inspection solutions for complex-shaped components in High-Value Manufacturing (HVM) sectors requires increased production throughput and precision. This drives the integration of automated robotic solutions. However, the current manipulators utilizing traditional programming approaches demand specialized robotic programming knowledge and make it challenging to generate complex paths and adapt easily to unique specifications per component, resulting in an inflexible and cumbersome teaching process. Therefore, this body of work proposes a novel software system to realize kinesthetic guidance for path planning in real-time intervals at 250 Hz, utilizing an external off-the-shelf force-torque (FT) sensor. The proposed work is demonstrated on a 500 mm2 near-net-shaped Wire-Arc Additive Manufacturing (WAAM) complex component with embedded defects by teaching the inspection path for defect detection with a standard industrial robotic manipulator in a collaborative fashion and adaptively generating the kinematics resulting in the uniform coupling of ultrasound inspection. The utilized method proves superior in performance and speed, accelerating the programming time using online and offline approaches by an estimate of 88% to 98%. The proposed work is a unique development, retrofitting current industrial manipulators into collaborative entities, securing human job resources, and achieving flexible production.