Processing Of Metallic Materials Research Articles

Metal Material Processing Using Femtosecond Lasers: Theories, Principles, and Applications.

Metal material processing using femtosecond lasers is a useful technique, and it has been widely employed in many applications including laser microfabrication, laser surgery, and micromachining. The basic mechanisms of metal processing using femtosecond lasers are reviewed in this paper and the characteristics and theory of laser processing are considered. In addition to well-known processes, the recent progress relating to metals processing with femtosecond lasers, including metal material drilling, metal ablation thresholds, micro/nano-surface modification, printed circuit board (PCB) micromachining, and liquid metal (LM) processing using femtosecond lasers, is described in detail. Meanwhile, the application of femtosecond laser technology in different fields is also briefly discussed. This review concludes by highlighting the current challenges and presenting a forward-looking perspective on the future of the metal laser processing field.

Multi-objective fuzzy green scheduling optimization method of special vehicle body-in-white prototype shop considering equipment preventive maintenance

Based on the advantages of non-contact, flexibility, and small heat-affected zone, laser processing technology is widely used in material removal, addition, modification and other manufacturing fields. However, the emission of large amounts of smoke during laser processing of metal materials will result in environmental pollution in the job shop. Additionally, the processing time of laser equipment becomes uncertain as the power decays with prolonged use. Therefore, this paper is mainly focus on a multi-objective flexible job shop fuzzy green scheduling problem to minimize the fuzzy makespan, fuzzy total energy consumption and fuzzy total smoke emission. To solve it, an improved multi-objective particle swarm optimization algorithm has been designed. Firstly, a preventive maintenance strategy is proposed to reduce the makespan and equipment failure frequency by considering periodic power attenuation of laser equipment. Next, different particle updating strategies are employed to enhance particles’ exploration capabilities. Subsequently, five neighborhood structures are introduced to improve the performance of local search. Finally, comparison experiments are conducted with an expanded common benchmark, and a production case study in a special vehicle body-in-white prototype job shop. The results effectively demonstrate the feasibility and effectiveness of the developed model and improved multi-objective particle swarm optimization algorithm.

Exploring the enablers for building resilience in solar photovoltaic Energy supply chains

A solar photovoltaic energy supply chain (SPvESC) is a global network with several linkages, including mineral and metal mining, material processing, and module and panel manufacturing. Due to the wide range of uncertainties and the unfavorable environmental effects associated with current linear business models, this global network is vulnerable to disruptions. Strengthening the resilience of SPvESCs is crucial for addressing any disturbances. This requires identifying the key enablers of resilience in SPvESCs, an area that has been understudied in the existing literature. An enabler is an aspect that facilitates the achievement of a goal by another aspect. This research contributes to the existing literature by systematically investigating the enablers for SPvESCs to achieve resilience. Thus, the objective of this analysis is to identify enablers that have the potential to enhance the resilience of SPvESCs in Türkiye. This was done by applying the Nominal Group Technique (NGT) in conjunction with a review of the current literature. Neutrosophic (N)-DEMATEL was then utilized to determine the relationships between the identified enablers. Finally, the results were validated using N-DELPHI. The results revealed that sensing and seizing new business models, adaptability to changes in novel energy generation and information technologies, and business contingency plans for natural and man-made disasters were the most influential enablers. The findings provide implications for practitioners, policymakers, and researchers to help ensure improved resilience in SPvESCs.

Analysis of influence of deep processing of metallic mineral materials on electromagnetic wave absorption performance

In this paper, the effects of deep processing of metallic mineral materials on electromagnetic wave absorption properties were studied. Firstly, the background and significance of the research are introduced, and the importance of metallic mineral materials in the field of electromagnetic wave absorption is expounded. Then the basic principle of electromagnetic wave absorption and the characteristics and influencing factors of metal mineral materials are discussed. In the section of deep processing technology, different processing methods and their applications are listed. Through experimental design and method, the electromagnetic wave absorption properties of metal mineral materials after deep processing are tested and analyzed. The experimental results are obtained and discussed. Finally, the application prospect of metallic mineral materials in electromagnetic wave absorption field is prospected, and the technical improvement and future development direction are put forward. This study provides an important reference for deepening the understanding of electromagnetic wave absorption properties of metallic mineral materials, and provides a reference for further research in related fields.

Review on numerical simulation of ultrasonic impact treatment (UIT): Present situation and prospect

Ultrasonic Impact Treatment (UIT) is a surface treatment method that uses ultrasound to create high-frequency, high-intensity impact loads on the surface of metallic materials to improve material properties and durability. The current state of research on the numerical simulation of UIT is reviewed in this paper. Firstly, the working principle of UIT strengthening is introduced, which includes the application of high-intensity UIT to the surface of metallic materials. The UIT strengthening technology has achieved significant success in the industrial field, resulting in plastic deformation, surface compression and residual stress, thereby significantly improving material properties. Secondly, the influence of UIT on the microstructure is reviewed. It is found that the grain refinement and dislocation are successfully predicted by finite element simulation and other methods. The influence of UIT on residual stress is reviewed. It is found that UIT can effectively transform harmful tensile stress into compressive stress, and it has been found that it can be used to guide the industrial practice of welding, laser cladding and additive manufacturing. In general, UIT technology shows important potential in metal material processing, which is of great significance for improving material properties and promoting industrial practice.

Off-axis optical system for the monitoring of the Laser Metal Deposition process

The Laser Metal Deposition (LMD) is emerging among the additive manufacturing (AM) technologies of metals for its versatility. It takes advantage of the flexibility of a laser source and a powder flow to fabricate or repair components with very complex features. The challenging process conditions that characterize the processing of metallic materials (temperatures and stresses) underlie the occurrence of several defects that plague such AM processes. Thus, the necessity to develop monitoring systems that can comprehensively analyze the production phase arises. In the present work, an innovative off-axis optical system consisting of three cameras with appropriate filters is proposed for the monitoring of LMD process. The peculiarity of this system lies in the capability of monitoring the spatial evolution of the melt pool, enabling eventually a complete control of the deposition process. In fact, through the use of properly developed image processing algorithms, the system enables the tridimensional definition of the size and shape of the melt pool and at the same time the reconstruction of each deposited layer. The potential of the monitoring system was tested on a series of thin-walled components. Subsequently, the analysis results were validated by comparison with 3D scanning of the parts and analyses performed using a coaxial monitoring system.

Towards Lunar In-Situ Resource Utilization Based Subtractive Manufacturing

In recent years, space agencies, such as the National Aeronautics and Space Administration (NASA) and European Space Agency (ESA), have expanded their research activities in the field of manufacturing in space. These measures serve to reduce limitations and costs through fairing size, launch mass capabilities or logistic missions. The objective, in turn, is to develop technologies and processes that enable on-demand manufacturing for long-term space missions and on other celestial bodies. Within these research activities, in-situ resource utilization (ISRU) and recycling are major topics to exploit local resources and save transport capacity and, therefore, costs. On the other hand, it is important to carefully consider which items can be brought and which must be manufactured on the Moon. Consequently, on-demand needs in future space missions are considered regarding frequency, raw material and required manufacturing processes according to investigations by ESA and NASA. In conclusion, manufacturing in space state-of-the-art shows a strong focus on additive processes, primarily considering semicrystalline or amorphous plastics. The subtractive processing of metallic or ceramic materials, in turn, currently represents a research gap. Consequently, an approach for in-situ resource utilization-based subtractive manufacturing in space is presented to supplement the existing processes. The latter uses a high-pressure jet of water, with regolith simulate as abrasive in suspension, being directed at the workpiece, which is moved to separate metal and glass. Proof-of-concept results are presented, including suitable process windows, achieved cutting geometries, as well as the effects of parameter variations on the system technology and consumables used. The focus of the investigations supplements the general requirements for the design of machine tools for space applications with inertial process-specific boundary conditions as a step towards higher technology maturity.

Heat treatment process and analysis of metal materials

With the rapid development of China's economy and society, the application range of metal materials has gradually been widely used in all walks of life. Whether in industry, agriculture, medical industry, etc., they all play a very important role. China's demand for metal materials is increasing day by day, and there is an urgent need for more and better quality metal materials to be consumed in the market. However, China is very scarce in metal materials research teams, talents, complete preparation processes and excellent equipment. It is necessary to strengthen the introduction of talent teams and excellent technology and strengthen the country's team building and mature guidelines system. Among the processing technologies of metal heat treatment, the heat treatment of metal is a fundamental processing technology. China has thrived in recent years and has already possessed complete equipment and facilities, scientific and excellent processing technology, and sound processing technology. In this way, metal materials with excellent properties can be produced, and the heat treatment process can significantly improve the strength, corrosion resistance, and fatigue strength of the metal and reduce the cost of processing. The impact on the environment cannot be ignored in the development process of metal materials. The processing of metal materials should not damage the environment but lose more for less. Therefore, improving metal material processing technology has become an urgent matter. This article will deeply analyze the performance of metal materials after heat treatment, the method of heat treatment processing technology and the innovation of metal heat treatment, and put forward relevant opinions for the heat treatment process of metal materials.

Analysis on the Key Parameters to Predict Flow Stress during Ausforming in a High-Carbon Bainitic Steel

Since flow stress is an important parameter in the processing and application of metallic materials, it is necessary to trace the flow stress during austenite deformation. Thermal compression deformation of austenite in a high-strength bainitic steel was conducted using a Gleeble-3500 thermo-mechanical simulator, within the deformation temperature range of 400 °C~900 °C. By analyzing the stress–strain curves and strain-hardening exponent, the effects of strain hardening and dynamic recovery on the dislocation density of the material during the thermal processing were considered in the present work. Based on the general form of the Kocks–Mecking–Estrin (KME) model, the effects of deformation temperature and strain on the key parameters of the model were clarified. Differing from other work which commonly terms m (strain rate sensitivity exponent) and k2 (dimensionless parameters for dynamic recovery) as constants, the current models consider the quantitative relationship between key parameters and deformation temperature and strain. The results show that m is an exponential function related to temperature and strain, which decreases with the increase in strain. Meanwhile, k2 is a temperature-dependent polynomial function that increases as the deformation temperature increases. Finally, a modified constitutive KME model was proposed to predict the austenitic plastic stress with strain. Using established m-ε and k2-T models, the predicted curves are in good agreement with the experimental measurements.

Recent trends on electro chemical machining process of metallic materials: a review

Recent trends on electro chemical machining process of metallic materials: a review

Electron-Beam Surface Processing of Metal Materials Manufactured by Additive Methods

Electron-Beam Surface Processing of Metal Materials Manufactured by Additive Methods

FINITE ELEMENT ANALYSIS OF TWIST CHANNEL ANGULAR PRESSING

The article deals with the analysis of the unconventional pressing process of metallic materials by twist channel angular pressing (TCAP) method. TCAP process is a modification of the equal channel angular pressing (ECAP) forming method, which can be used to prepare bulk materials with an ultra fine-grained structure. Simulation of the TCAP process is an important source of information on the effect of design and technological parameters on the grain refinement efficiency. The TCAP process was simulated using 3D finite element method (FEM).

Latest Advances in Manufacturing and Machine Learning of Bulk Metallic Glasses

In this review, two interrelated areas are focused on for the development of novel amorphous metallic alloys, namely, materials processing and machine learning techniques for the design of new alloy compositions. Findings, barriers, and opportunities are described, targeting powder production and sintering, additive manufacturing, and postprocessing techniques, followed by the latest developments in artificial intelligence algorithms for both the design of new alloys and for alloy classification tasks.

Ultrasonic constitutive model and its application in ultrasonic vibration-assisted milling Ti3Al intermetallics

Ultrasonic vibration-assisted technology is widely utilized in the performance research and manufacturing process of metallic materials owing to its advantages of introducing high-frequency acoustic systems. However, the acoustic plasticity constitutive model and potential mechanism, involving Ti3Al intermetallic compounds, have not yet been clarified. Therefore, the Ultrasonic-K-M hybrid acoustic constitutive model of Ti3Al was established by considering the stress superposition, acoustic thermal softening, acoustic softening and acoustic residual hardening effects according to the dislocation density evolution theory and crystal plasticity theory. Meanwhile, the mechanical behavior of ultrasonic vibration-assisted tension (UVAT) and microstructure of ultrasonic vibration-assisted milling (UVAM) for Ti3Al was investigated. Dislocation density to be overcome from initial deformation to failure of Ti3Al was calculated in UVAT and was verified in UVAM. The results indicated that the Ultrasonic-K-M model showed a good agreement with the experimental data. There was an obviously softening phenomenon after introducing the ultrasonic energy field in the Ti3Al whole deformation region, and the degree of softening was positively correlated with amplitude. Furthermore, the maximum reduction ratio in yield strength of Ti3Al was 16 % and the maximum reduction value in ultimate tensile strength was 206.91 MPa. The elongation rose first and then fell as amplitude enlarged, but only as the vibration was applied in the whole deformation region, the elongation was always greater than 14.58 %. In addition, The UVAM process significantly reduced the dislocation density increment to be overcome for Ti3Al material removal by 1.37 times, and promoted dislocation motion and cancellation to make twisted dislocations evolve into parallel dislocations. As the amplitude increased to 4 μm, the depth of the disturbed area of the plastic deformation layer increased by a maximum of 2.5 times.

Current Status and Way Forward of Microwave Hybrid Heating in India: A Bibliometric Analysis

Automotive and aerospace industries are keen to employ unique techniques and novel materials to reduce weight and cost and improve part performance. The application of microwave technology in the processing of metallic materials is a relative breakthrough in this direction. Recently, microwave hybrid heating (MHH) has evolved to extend the technique's utility further. Several studies on MHH have been carried out worldwide in the last three decades, and India is the prime contributor. This article documents a systematic and bibliographic review of MHH (between 1998-2022) in the Indian scenario. For this purpose, 125 documents are chosen from Scopus Core Collection and analyzed using a bibliometric analysis tool. The research status is examined based on the time distribution of articles, geography, top-cited documents, citation mapping of journals and researchers, mapping of co-occurrence, analysis of authors' keywords, country-wise publications, and cluster assessment. The result establishes that India is dominating, followed by theUSA. Moreover, there is an increasing trend in the number of publications. A guideline is also included to revive the research community's interest to mature the process further.

Напрями та завдання промислової політики України в умовах війни та повоєнного відновлення

The aim of the article is to determine the priorities of industrial policy in the conditions of wartime and in the post-war recovery, to substantiate its efficient instruments for ensuring transformational changes in the economy and the formation of a qualitatively new structure of industry. The article identifies directions of transformational changes in the industry, which consist in ensuring an increase in its structure of the share of industry branches that form high added value, as well as the development of industrial processing of products that are currently exported in the form of raw materials. The necessity of determining the priorities of the State support of strategic industries of Ukraine for the transformation of the industrial structure in the post-war recovery is substantiated. The article proposes a number of measures of the State policy aimed at the regulatory and legal consolidation of the lists of strategic industries and industrial enterprises of Ukraine, maintaining the adaptability and functionality of production chains in strategic industries, laying the financial foundation for the formation of growth points in the strategic industry branches. As the priorities of stimulating industrial processing are defined the processing of agricultural, mineral, both metal and secondary raw materials. Fostering the processing of agricultural raw materials involves stimulating domestic production and the use of equipment for the food processing industry, the formation of cooperatives for the production of finished food products by small and medium-sized enterprises. The implementation of the potential for the processing of mineral and metal raw materials will be ensured by the development of partnership with the EU in the field of critical raw materials, the promotion of attracting international investment in the industry with the provision of their control by the State authorities. Stimulating the recycling requires the identification of promising areas of recycling for the production of final industrial products, the use of available recycling facilities for the processing of waste generated as a result of the war.

Research and application of plasma characteristic models for pulsed laser processing of metal materials.

Plasma characteristic models were established in cylindrical coordinates according to the plasma expansion characteristics of pulsed laser processing of metal materials, mainly including plasma expansion characteristic models and a change rate model for the collisional ionization effect. The plasma characteristics (expansion dimension, expansion velocity, electron density and collision rate) for the pulsed laser machining of a bronze grinding wheel were obtained by using the plasma characteristic models. The results show that the expansion velocity direction can be changed after plasma collision, resulting in particles returning and depositing onto the processed material surface. Plasma spectrum measurements for the pulsed laser machining of a bronze grinding wheel and grinding tests were carried out. Based on the measured spectral data, the plasma electron temperature and plasma electron density were calculated, and the topography of the machined grinding wheel surface was observed, which confirms that black particles can return to cover the grinding wheel surface. Through grinding experiments, it is verified that the returning particles reduce the height of the abrasive protruding binder and block the chip space around the abrasive particles, resulting in reduced grinding performance. The experimental calculation data and numerical simulation results are basically consistent with each other, which not only verifies the correctness and feasibility of the plasma characteristic models but also provides theoretical guidance and process optimization for subsequent research into laser machining of materials.

Solidification Processing of Metallic Materials in Static Magnetic Field: A Review

The application of a static magnetic field (SMF) to solidification processing has emerged as an advanced strategy for efficiently regulating the macro/micro structures and the mechanical performance of metallic materials. The SMF effects have been proved to be positive in various processes of metal solidification. Firstly, this review briefly introduces two basic magnetic effects, i.e., magnetohydrodynamic effects and magnetization effects, which play crucial roles in regulating metal solidification. Further, the state of the art of solidification processing in the SMF, including undercooling and nucleation, interface energy, grain coarsening and refinement, segregation and porosity, are comprehensively summarized. Finally, the perspective future of taking advantage of the SMF for regulating metal solidification is presented.

Efficiency enhancement by transient electron dynamic control in shaped femtosecond laser fabrication of metals

Ultrafast laser pulse train processing has been widely used to improve the efficiency and quality of nonmetallic material processing. However, it is commonly believed that the split of one pulse into sub-pulses for metallic material will suppress the ablation with near-threshold laser fluence. In this article, a high-efficiency metal processing by femtosecond laser double pulses train with different energy ratio is performed in the aspects of theory simulation and experiment. In theory, a Femto-picosecond and Nano-micrometre multiscale framework combining photoelectric effect and electron-phonon-coupled heat transfer proved that the pulse train can effectively control the electron properties, so as to enhance processing efficiency. Theory-guided experiments indicate that the ablation crater reaches maximum ablation depth with a sub-pulse energy ratio optimized pulse train, which is 40%–100% deeper than that of single pulse processing. This method can be used for femtosecond laser processing of various metal materials with high efficiency and high quality, and is helpful to solve the manufacturing bottleneck challenges in the fields of aviation, mechanics, electronics and materials engineering.

An Overview on the Process Development and the Formation of Non-Dendritic Microstructure in Semi-Solid Processing of Metallic Materials

Semi-solid metal (SSM) processing has been an attractive method for manufacturing near-net-shape components with high integrity due to its distinct advantages over conventional forming technologies. SSM processing employs a mixture of solid phase and liquid metal slurries and/or non-dendritic feedstocks as starting materials for shaping. Since the original development from 1970s, a number of SSM processes have been developed for shaping components using the unique rheological and/or thixotropic properties of metal alloys in the semi-solid state, in which the globular solid particles of primary phase are dispersed into a liquid matrix. In this paper, the progress of the development of shaping technologies and the formation of non-dendritic microstructure in association with the scientific understanding of microstructural evolution of non-dendritic phase are reviewed, in which the emphasis includes the new development in rheomoulding, rheo-mixing, rheo/thixo-extrusion and semi-solid twin roll casting, on the top of traditional rheocasting, thixoforming and thixomoulding. The advanced microstructural control technologies and processing methods for different alloys are also compared. The mechanisms to form non-dendritic microstructures are summarised from the traditional understanding of mechanical shear/bending and dendrite multiplication to the spheroidal growth of primary phase under intensively forced convection. In particular, the formation of spheroidal multiple phases in eutectic alloys is summarised and discussed. The concluding remarks focus on the current challenges and developing trends of semi-solid processing.