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process parameters Analysis in Diamond Wire Saw Cutting NdFeB Magnet

MATERIALS 2025年第5期18卷 1173-1173页

作者： Peng, Chengwanli Li, Guanzheng Zhang, Xingchun Gao, Yufei Shandong Univ SDU ANU Joint Sci Coll Weihai 264209 Peoples R China Shandong Univ Sch Mech Engn Key Lab High Efficiency & Clean Mech Manufacture MOE Jinan 250061 Peoples R China Shandong Univ State key Lab Adv Equipment & Technol Met Forming Jinan 250061 Peoples R China Shandong Univ Shandong Key Lab High Performance Tools & Syst Jinan 250061 Peoples R China

Neodymium iron boron (NdFeB) magnetic materials are widely used in fields such as electronics, medical devices, power machinery, and hardware machinery. This paper conducted a three-factor and five-level orthogonal experiment on diamond wire saw cutting NdFeB to determine the influence degree of key factors such as workpiece feed rate, diamond wire speed, and workpiece processed size on the surface roughness Ra and waviness Wa of NdFeB slices. Further analysis was conducted on the influence of various parameters on the PV value (peak valley difference) of the waviness profile curve of the sawed surface. Finally, slicing processing was carried out under optimized process parameter combinations. The research results indicate that the primary and secondary order of process parameters affecting surface roughness Ra and waviness Wa is workpiece feed rate, wire speed, and sawed workpiece size, and the influence on the waviness PV value also shows a consistent trend. The optimal combination of processing parameters is workpiece feed rate of 0.1 mmmin-1, wire speed of 1600 mmin-1, and workpiece size of 10 mm. The obtained surface roughness Ra is 0.433 mu m and the waviness Wa is 0.037 mu m, respectively. The regression mathematical model for the waviness PV value is PV = 0.747 x vs-0.342 x vw0.546 x L0.109. The research results of this paper provide an experimental basis and guidance for optimizing process parameters of sawing NdFeB.

关键词： NdFeB magnet diamond wire saw surface waviness orthogonal experiment process parameters

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Influence of process parameters on residual stress in laser metal deposition of nickel-based superalloy

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WELDING IN THE WORLD 2025年第4期69卷 1057-1072页

作者： Yang, Maohong Wu, Guiyi Li, Xiangwei Zhang, Ruiyao Zhang, Shuyan Wang, Honghong Yevhenii, Illiashenko China Ukraine Inst Welding Guangdong Acad Sci China Ukraine Belt & Rd Joint Lab Mat Joining & Ad Guangzhou 510650 Guangdong Peoples R China Ctr Excellence Adv Mat Dongguan 523808 Peoples R China Wuhan Univ Sci & Technol Sch Mat & Met Wuhan 430081 Peoples R China Natl Acad Sci Ukraine Dept Electrothermal Proc Mat Proc EO Paton Elect Welding Inst Kazimir Malevich Str 11 UA-03680 Kiev Ukraine

This paper studied the impac t of process parameters in laser metal deposition on distribution and magnitude of residual stresses. A finite element method was used to create a residual stress model with parameters as variables. The study used a Taguchi L32 experimental design, with four levels for each parameter, and analyzed residual stresses along critical paths using quadratic functions. The results reveal that the impact of process parameters varies across different regions of the component. Melt pool size primarily affects the location of maximum residual stresses at the interface between the substrate and the deposited layer. Deposition length affects the concentration of residual stresses at the center of the interface between the substrate and the deposited layer. Substrate thickness has a substantial impact on residual stresses. Scanning strategy influences residual stresses at the edges of the upper surface of the deposited layer. Boundary conditions and yield strength affect residual stresses in various regions of the deposited layer. The coefficient of thermal expansion influences residual stresses at the interface between the base material and the deposited layer.

关键词： Residual stress process parameters Influence patterns Taguchi experimental method Additive manufacturing

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Effect of process parameters and heat treatment on the microstructure and properties of a Cu-Cr-Si alloy manufactured by laser powder bed fusion

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MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND processING 2025年 927卷

作者： Bu, Xin Lei, Qian Zhang, Xiukuang Meng, Xiangpeng Hu, Hailong Mo, Xinde Liu, Bin Cent South Univ State Key Lab Powder Met Changsha 410083 Peoples R China Guilin Lijia Met Co Ltd Guilin 541004 Peoples R China Cent South Univ Sch Mat Sci & Engn Changsha 410083 Peoples R China C KINGDOM Cable Technol Co Ltd Changsha 410200 Peoples R China

Due to the high laser reflectivity, it is challenging to fabricate copper alloys with few defects and perfect forming quality by laser powder bed fusion (L-PBF). The Cu-Cr-Si alloy was fabricated by L-PBF with nearly full density, fine grains, and high performance. The optimum parameters for additive manufacturing Cu-Cr-Si alloy were obtained by orthogonal experiments. With a laser power of 450-475 W, a scanning speed of 400-500 mm/s, a hatching distance of 45 mu m, and a powder layer thickness of 30 mu m, Cu-Cr-Si alloy blocks with complete full density were fabricated, with an ultimate tensile strength of 303 MPa and an elongation of 36 %. After direct aging treatment at 500 degrees C for 45 min, the as-deposited Cu-Cr-Si alloys achieved an electrical conductivity of 63% IACS, an ultimate tensile strength of 686 MPa, and an elongation of 16 %. Refined and uniformly dispersed Cr precipitates were the main reason for the improvement of strength/hardness, and the precipitation is also effective in enhancing the electrical conductivity. This work provided theoretical guidance for the additive manufacturing of high-performance Cu-Cr-Si alloys by the L-PBF technology.

关键词： Cu-Cr-Si Laser powder bed fusion process parameters Electrical conductivity Mechanical properties

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Influence of process parameters on the formation and performance improvement of toothed parts in multipass cross-axis rolling

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2025年第2期138卷 353-365页

作者： Li, Kun Zhang, Chao Zhao, Shengdun Xi An Jiao Tong Univ Sch Mech Engn Xian 710049 Peoples R China State Key Lab Met Forming Technol & Heavy Equipmen Xian 710049 Peoples R China

The multipass rolling process with crossed axes of the rolling die and blank is an effective and advanced technique for forming toothed parts. Based on the forming characteristics of this process, this paper introduces evaluation indices for toothed part formation, including the fill index, blank utilisation coefficient, forming time, and energy consumption. Through theoretical derivation, mathematical expressions for each evaluation index were established. Using these indices, the effects of initial blank diameter, rolling die rotational speed, and the number of forming passes on the formation of toothed parts were analysed through finite element simulation. The simulation results indicate that the filling quality, blank utilisation, and energy consumption are primarily influenced by the initial blank diameter, while the forming time is most significantly affected by the number of forming passes. Meanwhile, rolling experiments were conducted under various process parameters, and the hardness of the formed teeth was measured. The experimental results show that as the blank diameter increases, visible defects at the tooth tips of the formed teeth disappear, which is consistent with the simulation results. Furthermore, the improvement in tooth hardness becomes more pronounced with an increasing number of forming passes. The maximum hardness of teeth formed after five passes exceeds twice that of the original blank. This study provides valuable technical guidance for the application of the multipass rolling process with crossed axes. Additionally, the established evaluation indices serve as a useful reference for research on the rolling processes of other complex-profile parts.

关键词： Cross-axis rolling Forming evaluation indices process parameters Tooth profile Hardness improvement

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Effect of process parameters and Geometry on the Quasi-Static and Dynamic Behavior of Additively Manufactured Lower-Extremity Metallic Lattice Bone Implants: A Design-of-Experiment Study

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3D PRINTING AND ADDITIVE MANUFACTURING 2025年

作者： Ghadami-Badrlou, Siamak Khajehzadeh, Mohsen Razfar, Mohammad Reza Amirkabir Univ Technol Dept Mech Engn 350Hafez AveValiasr Sq Tehran *** Iran

Additively manufactured metallic lattice biomaterials have revolutionized the mechanical properties of lower-extremity bone and joint implants. Most designers have followed a quasi-static approach, where material properties are solely represented by their elastic modulus. In reality, however, the human body experiences repeated dynamic and impact loads in vivo, and bone acts as a passive shock absorber and wave modulator. Most importantly, bone cells sense no load under quasi-static loading and must rather be subjected to impact loads at frequencies near their natural frequencies and high enough accelerations to conduct optimum mechanotransduction. This indicates the necessity of developing a dynamic design strategy that further considers damping and natural frequency. This research is an attempt to study the dynamic performance of selective laser melted lattice implants with the help of design of experiments and finite-element method (FEM). In many cases, lattice implants exhibit up to 80% similar values of elastic modulus and natural frequency to the bone. Regarding the damping, however, the similarity rarely reaches 10%. For the most part, the dynamic material properties of the implants are more significantly affected by their geometry and printability rather than process parameters. Damping decreases with power and increases with porosity and scanning speed. Natural frequency increases with power and remains almost constant with scanning speed. Generally, any change to the process parameters and geometry that improves the elastic modulus affects the natural frequency and damping directly and inversely, respectively. Capturing the main trends of dynamic behavior successfully, FEM accuracy is controlled by the geometry and hence can be distorted by manufacturing defects. All in all, there is a balance between the elastic modulus and damping. Dynamic performance improves with porosity, albeit up to an optimum point.

关键词： lattice materials damping material dynamics bone implant additive manufacturing selective laser melting process parameters design of experiment

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Effect of process parameters on the weld quality of 3D printed PLA-CF sheets by FSW process

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POLYMER COMPOSITES 2025年第0期

作者： Anac, Nergizhan Kocar, Oguz Palaniappan, Sathish Kumar Parmaksiz, Furkan Mutlu, Emel Rangappa, Sanjay Mavinkere Siengchin, Suchart Zonguldak Bulent Ecevit Univ Fac Engn Dept Mech Engn TR-67100 Zonguldak Turkiye King Mongkuts Univ Technol North Bangkok Sirindhorn Int Thai German Grad Sch Engn Dept Mat & Prod Engn Nat Composites Res Grp Lab Bangsue 10800 Thailand

Friction stir welding (FSW) process is commonly used in the joining of similar/dissimilar materials. FSW involves process parameters that can affect the weld quality. To enhance this, it is important to accurately determine the process parameters. In this study, the weldability of 3D printed carbon fiber-reinforced polylactic acid (PLA-CF) sheets has been investigated using FSW. The process was carried out with three different tool pin geometries (triangle, square, and screw), feed rates (20, 40, and 60 mm/min) and tool rotational speeds (1250, 1750, and 2250 rpm). Tensile tests were conducted and hardness measurements were taken to discuss the effects of process parameters on weld quality. Temperature values were measured to examine the impact of tool pin geometry on the heat generation during welding. Finally, visual and microstructure examinations were conducted in the weld zone to assess the changes in weld strength. As a result, it has been determined that weld strength is significantly influenced by the process parameters. Accordingly, the best weld quality was achieved with triangular pin profile at a traverse speed of 40 mm/min and a rotation speed of 1250 rpm (UTS: 43.6 MPa, efficiency 79.6%), while for square pin (UTS: 49.2 MPa, efficiency 89.8%) and screw pin (UTS: 44.9 MPa, efficiency 81.9%) geometries, the optimal values are 20 mm/min and 2250 rpm. The distribution of CF reinforcement is uniform in high weld strength samples, while with lower weld quality samples, the distribution is irregular. This indicates that the reinforcement of CF has significant effect on weld *** Investigate the weldability of 3D printed PLA-CF plates through FSW process. Examines the impact of pin geometry, feed rates, and tool rotational speeds. Determine the welding strength and temperature generated during welding. Choice of the square pin geometry is more suitable for joining PLA-CF plates. Visual and microstructure examinations were conducted in the weld z

关键词： friction stir welding heat generation mechanical properties PLA-CF process parameters

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Effect of process parameters on wire-arc direct energy deposited Inconel 718 superalloy

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RAPID PROTOTYPING JOURNAL 2025年第5期31卷 950-967页

作者： Kumar, Parveen Singh, Ratnesh Kumar Raj Sharma, Satish Kumar Thapar Inst Engn & Technol Dept Mech Engn Patiala India Chandigarh Engn Coll Dept Mech Engn Mohali India

PurposeOwing to its leverage of high deposition rate, the wire arc additive manufacturing (WAAM) process is being adopted for the development of IN718 alloy used in aerospace, transportation and energy sectors. The purpose of this study is to observe the effect of process parameters on the mechanical properties of the IN718 ***/methodology/approachThis study emphasizes the effect of WAAM process parameters on mechanical and metallurgical properties of developed multilayer structures of IN718 alloy by means of orthogonally designed *** results show that high current and voltage settings, combined with low welding speed, provide increase bead width, height and effective wall area, while resulting in decrease surface waviness, hardness and tensile properties. The scanning electron microscopy and energy dispersive spectroscopy results show the presence of secondary precipitates such as NbC and Ni3(Al, Ti) in low-heat samples, which improve the mechanical properties of the material. However, the presence of Laves phases deteriorates the mechanical properties in high-heat samples. The electron backscatter diffraction results confirmed the presence of more grain boundaries and highly textured surfaces in lower heat samples, which improves mechanical ***/valueThe effect of process parameters on the microstructural features and mechanical properties along with bead characteristic are studied in-depth and influence of each parameter are discussed.

关键词： Wire arc additive manufacturing Super alloy Taguchi process parameters Microstructure Tensile properties

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Effect of process parameters on the growth and microstructure of anodic films on 6061 aluminum alloy in alkaline electrolytes

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SURFACE ENGINEERING 2025年第1期41卷 55-64页

作者： Xue, He Shi, Longfeng Liu, Cancan Liang, Jun Nanjing Tech Univ Coll Mat Sci & Engn Nanjing 211816 Peoples R China Dongguan Univ Technol Res Inst Interdisciplinary Sci Dongguan 523808 Peoples R China Dongguan Univ Technol Sch Mat Sci & Engn Dongguan 523808 Peoples R China

This study investigates the anodizing of 6061 aluminum alloy using an alkaline solution composed of sodium hydroxide (NaOH), sodium tetraborate (Na2B4O7) and potassium pyrophosphate (K4P2O7). The effects of the electrolyte compositions as well as temperature and voltage on the growth and microstructure of anodic films were investigated. Results showed that all these parameters have effects on the current density of the anodizing process and thickness of the anodic films. The current density increases with process parameters except for Na2B4O7, while as the process parameters increase, the anodic film thickness initially increases and then decreases. The morphology of the anodic film is notably affected by variables NaOH, Na2B4O7, temperature, and voltage. Increasing NaOH concentration and temperature resulted in a decrease in surface uniformity, while Na2B4O7 exhibited an opposite effect. Voltage significantly affected the diameter of the anodic film's pores, resulting in larger pores at higher voltages, which leading to poorer dyeing effect for the anodized samples.

关键词： anodic films alkaline solution process parameters current density thickness porous oxide films

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Influence of additive manufacturing process parameters on Ti6Al4V surface properties and performances

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2025年第11-12期137卷 5487-5498页

作者： Yahyaoui, Houda Ben Moussa, Naoufel Habibi, Mohamed Ghanem, Farhat Mareau, Charles Univ Tunis Mech Mat & Proc Lab LR99ES05 ENSIT 5 Ave Taha Hussein Tunis 1008 Tunisia Univ Carthage Preparatory Inst Engn Studies Bizerte Zarzouna 7021 Tunisia Univ Quebec Trois Rivieres Dept Mech Engn Quebec City PQ Canada LAMPA Arts & Metiers Inst Technol 2 Bd Ronceray F-49035 Angers France

This study investigates the effect of additive manufacturing process parameters on the surface characteristics and performances of titanium Ti6Al4V, used for orthopedic implants. Parts were manufactured by selective laser melting, using a variety of volumetric energy densities, ranging from 58 to 152 J/mm3. Through a rigorous optimization of process parameters coupled with optical examinations of porosity distribution and morphology, a volumetric energy density of 58 J/mm3 was identified as an optimal manufacturing condition that resulted in extremely high densities of 99.8% in Ti6Al4V titanium alloy. X-ray diffraction measurements revealed the development of anisotropic residual stress states, characterized by elevated tensile stresses oriented along the build direction. Phase analysis results indicate a predominant martensitic acicular alpha ' structure, resulting from the rapid heating and cooling kinetics intrinsic to additive manufacturing, with a minor residual prior-beta phase. Optical examinations reveal a microstructural transition from equiaxed prior-beta grains to a columnar structure correlated with an increase in scanning speed (decrease in volume energy density). Corrosion tests were performed in Ringer's solution at 37 degrees C to simulate physiological conditions. It has been established that the presence of elongated pores combined with high tensile residual stresses can significantly compromise the corrosion resistance of additively manufactured parts. Minimizing porosity, through optimized SLM process parameters, significantly improved corrosion resistance. This resulted in a continuous and dense passive film, reducing the corrosion rate by 72%, from 22 to 6 mu m/year. These findings enable prosthesis manufacturers to enhance additively manufactured implant performances, extending their longevity.

关键词： Selective laser melting Ti6Al4V process parameters Surface characteristics Corrosion resistance

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The influence of high-speed laser cladding process parameters on the interfacial structure of nickel-based single-track cladding layers on copper surface

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OPTICS AND LASER TECHNOLOGY 2025年 183卷

作者： Zhou, Li Wu, Hailin Ma, Guozheng Wang, Haidou Zhou, Yujie Mou, Honglin Zhao, Haichao Li, Yang Tan, Na Guo, Weiling Army Acad Armored Forces Natl Key Lab Remfg Beijing 100072 Peoples R China Army Acad Armored Forces Natl Engn Res Ctr Remfg Beijing 100072 Peoples R China China Three Gorges Univ Coll Mech & Power Engn Yichang 443002 Peoples R China China Univ Geosci Beijing Sch Engn & Technol Beijing 100083 Peoples R China Tianjin Univ Technol & Educ Tianjin Key Lab High Performance Precis Forming Te Tianjin 300222 Peoples R China

Preparing high-quality cladding layers on substrates with high laser reflectivity and thermal conductivity, such as copper alloys, has been a long-standing challenge in the laser processing industry. However, the advent of highspeed laser cladding technology (HSLC) offers a novel solution to this issue. HSLC modifies the laser energy distribution proportion in traditional laser cladding, allocating the laser energy majority to powder melting, thus significantly enhancing processing efficiency. However, during practical processing, empirically-based processes often encounter engineering problems such as rough coating surfaces and easy detachment of the coating. Through single-factor experimental methods, this paper identifies that laser power and powder feed rate significantly impact the single-track cladding layers forming quality and the substrate surface melting. Singletrack cladding layers with good forming quality exhibit planar crystal structures, while locally melted areas on the copper substrate surface exhibit columnar crystal structures. The copper substrate surface melting can effectively extend the interfacial elements' diffusion distance, with a maximum extension distance of approximately 8 times. Coupling with finite element simulation, it was revealed that the melting heat of the copper substrate surface mainly comes from the absorption of penetrating laser energy by high-temperature nickel droplets after deposition on the substrate surface. Therefore, the essence of controlling the copper alloy surface melting through process parameters is to regulate the melting state of the powder and the laser energy that penetrates the powder, thereby affecting the absorption of laser energy by the copper alloy substrate surface.

关键词： High-speed laser cladding process parameters Copper alloys Cladding layer

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