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Effects of Micro-arc Oxidation process parameters on Micro-structure and Properties of Al2O3 Coatings Prepared on Sintered 2024 Aluminum Alloy

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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE 2024年第4期33卷 1862-1873页

作者： Yan, Huanyuan Liu, Wensheng Ma, Yunzhu Wang, Tao Wu, Lei Yang, Lun Tang, Siwei Cent South Univ Natl Key Lab Sci & Technol High Strength Struct Ma Changsha 410083 Peoples R China

In this work, Al2O3 ceramic coatings were prepared the surface of powder metallurgy (PM) 2024 aluminum alloy via the micro-arc oxidation (MAO) technique. The effects of the current density and the oxidation treatment time on the microstructure and properties of the MAO coatings were investigated. The results reveal that the oxide film mainly comprises the gamma-Al2O3 phase, the amorphous Al2O3 phase, and a small amount of the mullite phase. There are traces of W in the coatings, which exist in the form of W, WO3, and W18O49. With increasing current density, the thickness and surface roughness of the MAO coatings prepared on the PM 2024 alloy increase, while their surface hardness first increases and then decreases. The increase in the current density promotes the transformation of the amorphous Al2O3 phase into the gamma-Al2O3 phase. The maximum hardness value of 1270 HV is obtained at a current density of 20 A dm(-2). The MAO coatings provide superior corrosion protection for the PM 2024 aluminum alloy, and the MAO coatings obtained at a current density of 15 A dm(-2) exhibit the highest corrosion resistance.

关键词： current density microstructure micro-arc oxidation oxidation time powder metallurgy aluminum alloy process parameters

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Numerical Investigation on the Effects of process parameters on the Pre-Holed Self-Piercing Riveted Joint Quality

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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE 2024年 1-18页

作者： Wang, Chao Cheng, Aiguo Li, Wangzhen Sun, Youping Luo, Guojian Hunan Univ State Key Lab Adv Design & Mfg Technol Vehicle Changsha 410082 Peoples R China Guangxi Univ Sci & Technol Sch Mech & Automot Engn Liuzhou 545006 Peoples R China Guangxi Univ Sci & Technol Guangxi Key Lab Automobile Components & Vehicle Te Liuzhou 545006 Peoples R China

Although the self-piercing riveting (SPR) process is widely used in the automotive industry, it faces challenges in achieving mechanical interlock when joining high-strength steel. In this paper, the pre-holed self-piercing riveting (PH-SPR) process is adopted to join high-strength steel to aluminum alloy. This paper aims to investigate SPR joinability and select suitable rivets and dies for different steel-aluminum combinations. A 2D axisymmetric numerical model is developed using LS-DYNA commercial software to simulate the PH-SPR process with varying process parameters (e.g., rivet hardness, geometric dimensions of rivet and die, hole size, and material and thickness of sheet). The accuracy of the FE model is verified by comparing the forming quality parameters between the experimental test and the simulation result. The results show that (i) the rivet with strength of 0.9 GPa is suitable for the bottom sheet with yield stress of 89 MPa, and the rivet with strength of 1.34 GPa is appropriate for the bottom sheet with yield stress greater than 165 MPa. (ii) The increasing rivet diameter, rivet length, and hole size can improve forming quality, and the decreasing die depth and top sheet thickness can enhance the undercut. (iii) The undercut of the joint with 1.2 mm top sheet increases with the increase in yield stress of the bottom sheet, while a decreasing tendency is found for the joint with 1.6 mm top sheet. (iv) The minimum rivet length required for a successful joining increases with the increase in thickness ratio, while the opposite trend is observed for maximum rivet length.

关键词： joint quality numerical model pre-holed self-piercing riveting process parameters steel-aluminum hybrid sheets

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Influence of process parameters on joint characteristics in friction stir welding of Al/Cu dissimilar materials for lithium-ion battery

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2024年第3-4期130卷 1125-1139页

作者： Go, Bum-Su Park, Dong-Min Bang, Han-Sur Bang, Hee-Seon Chosun Univ Grad Sch Dept Welding & Joining Sci Engn 309 Pilmun Daero Gwangju 61452 South Korea Chosun Univ Dept Welding & Joining Sci Engn 309 Pilmun Daero Gwangju 61452 South Korea

The aluminum to copper dissimilar joining has great interest to industrial fields of lithium-ion battery, such as lead tab and busbar materials as a lap joint configuration. In this study, the dissimilar lap joining of the 1050 Al alloy with thickness of 0.5 mm and commercial pure copper with thickness of 1.0 mm has been carried out by friction stir welding (FSW) with three different rotation speeds (400, 500, and 600 rpm) and three different travel speeds (60, 120, and 180 mm/min). The influence of process parameters on Al-Cu dissimilar joint characteristics was investigated. From the results, a defect-free joint was achieved under the condition of rotation speed of 600 rpm and travel speed of 60 mm/min with a tensile-shear load of 913 N for the joint. In contrast, when the rotation speed is 400 rpm, the tensile-shear load reached only 646 N, where void and tunnel defects were observed, which results indicated that a higher heat input contributed to a higher tensile-shear load due to sufficient plasticization. The minimum hardness value in the TMAZ was 31 HV at a rotation speed of 600 rpm, which is a 36% decrease compared to the Al base material;this thermal softening is caused by low dislocation density. The intermetallic compounds formed in joints were Cu9Al4 and CuAl2 with a layer thickness of 0.64 mu m. According to the Al-Cu joint electrical resistance test, the minimum electrical resistance value was about 70 mu omega, which corresponded to the condition with the maximum tensile shear load. It can be inferred that the defect-free welded joint and sufficient joining area are crucial factors for ensuring smooth current flow compared to the thickness of the IMC layer in solid-state process.

关键词： process parameters Joint characteristics Friction stir welding Aluminum and copper Lithium-ion battery

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Effect of process parameters on Part Quality, Microstructure, and Mechanical Properties of a WC-Co-Hexagonal Boron Nitride Alloy Prepared by Laser Power Bed Fusion process

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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE 2024年第1期33卷 410-426页

作者： Agyapong, Joseph Czekanski, Aleksander Boakye-Yiadom, Solomon York Univ Lassonde Sch Engn Dept Mech Engn Toronto ON Canada

The WC-Co composite material is one of the most difficult materials to manufacture using a one-step additive manufacturing process such as Laser Powder Bed Fusion process (L-PBF). Recently, the addition of hexagonal boron nitride (hBN) has conferred good mechanical properties (hardness and wear) to WC-Co. However, comprehensive studies on the feasibility of adopting L-PBF for the composite are lacking. Thus, this study seeks to use L-PBF to prepare WC-Co-hBN (hBN: 3 vol.%) cemented carbide specimens by varying the processing parameters (laser power, scan speed and scan spacing). The effects of processing parameters on microstructural and mechanical properties on specimens are investigated using microstructural and chemical composition analysis, surface porosity analysis, microhardness and fracture toughness testing. The innovation of the study is that the hBN addition coupled with the varying printing parameters can regulate the resultant microstructure of the material and dictate very different mechanical properties. In detail, the findings of the experiments indicate that scan spacing was a significant factor in obtaining high densification. A highly dense specimen at 98% relative density (12.73 g/cm(3)) can be achieved at 0.04 mm scan spacing. We also recognized a reduction in the density generally linked to the low sinterability of BN, which resulted in a local volume increase of the specimen. Thus, hBN could be a good candidate for lightweight properties when added to materials, lowering the composite's effective density. The L-PBF procedure resulted in inhomogeneous and fast grain growth of WC, which was linked to the non-uniform temperature distribution and varying cooling rates of melt pools during processing. processed specimens were largely composed of polyangular WC carbides and WC platelets. The volume fraction of these two structures were influenced solely by the scan speed and laser power. The WC structure type has a significant effect on the strength

关键词： cemented carbides hexagonal boron nitride laser powder bed fusion (LPBF) porosity process parameters

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Neural Network-Based Optimization of the Electrical Discharge Drilling process parameters

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TEHNICKI VJESNIK-TECHNICAL GAZETTE 2024年第4期31卷 1101-1110页

作者： Van, An -Le Nguyen, Trung-thanh Huu, Phan Nguyen Dang, Xuan-Ba Nguyen Tat Thanh Univ Fac Engn & Technol Robot & Mechatron Res Grp 300A Nguyen Tat Thanh StWard 13Dist 4 Ho Chi Minh City 70000 Vietnam Le Quy Don Tech Univ Fac Mech Engn 236 Hoang Quoc Viet Hanoi 100000 Vietnam Hanoi Univ Ind 298 Cau Dien St Hanoi 100000 Vietnam Ho Chi Minh City Univ Technol & Educ Dept Automat Control 1 Vo Van Ngan St Ho Chi Minh City 70000 Vietnam

The current work aims to optimize process parameters, including the current (I), voltage (V), pulse on time (O), and pulse off time (F) of the electrical discharge drilling of the small hole (EDDH) to reduce the dilation of the drilled hole (DH) as well as the tapper of the drilled hole (HT) and enhance the material removal rate (MRR). The radial basis function network (RBFN) was used to develop EDDH responses, while the modified quantum-behaved particle swarm optimization algorithm (MQPSO) was applied to produce feasible solutions. The evaluation by an area-based method of ranking (EAMR) approach was used to select the best optimality. The obtained results indicated that the optimal I, V, O, and F are 5 A, 60 V, 40 mu s, and 45 mu s, respectively. The DH and TP are reduced by 32.8% and 28.0%, while the MRR is improved by 66.3%. The RBFN models could be effectively applied to present non-linear data. The DH and TP models were significantly affected by the O and F, while the I and V had effective influences on the MRR. The outcomes could be used to improve the drilled quality indicator and productivity in industrial EDDH applications.

关键词： dilation electrical drilling process parameters removal rate tapper

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Study on the effect of diamond wire saw-cutting process parameters on brittle cracks in monocrystalline silicon

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APPLIED PHYSICS A-MATERIALS SCIENCE & processING 2024年第10期130卷 1-11页

作者： Sun, Penglei Wei, Chen Zhang, Hui Zhang, Haiming Gao, Kun Wu, Jianhai Li, Kai Chen, Guifeng Hebei Univ Technol Shijiazhuang Innovat & Res Inst Shijiazhuang 050299 Peoples R China Hebei Univ Technol Sch Mat Sci & Engn Tianjin 300130 Peoples R China Hebei Univ Technol Hebei Engn Res Ctr Photoelect Funct Crystals Tianjin 300130 Peoples R China Tianjin Huanzhi New Energy Technol Co Ltd Tianjin 300384 Peoples R China

In this paper, based on the principle of wire saw cutting, the simulation model of scribing of monocrystalline silicon (100) planes has been established. The stress field distribution is obtained by applying loads, and the depth of crack damage is calculated. This enables the influence of different process parameters on the crack damage of silicon wafers to be analyzed. Furthermore, the effect of process parameters on crack damage is verified by observing the surface morphology of silicon wafers through cutting *** results indicate that as the particle half angle increases, the stress region under single-crystal silicon decreases and the stress value increases. The material crack length decreases with increasing wire speed and particle density and increases with increasing feed speed. The trend is approximately linear. The findings of this study are of value in optimizing the cutting process of brittle materials, such as monocrystalline silicon, and in reducing material damage.

关键词： Monocrystalline silicon Crack expansion process parameters Crack length Diamond wire saw

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INVESTIGATION OF THE INFLUENCE OF INDIRECT SQUEEZE CASTING process parameters ON THE SOLIDIFICATION MICROSTRUCTURE AND PROPERTIES OF A356.2 ALUMINUM ALLOY

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INTERNATIONAL JOURNAL OF METALCASTING 2024年第3期18卷 2579-2593页

作者： Jiang, Xiaolong Xing, Shuming Sun, Hongji Yan, Guangyuan Hu, Qian Beijing Jiaotong Univ Sch Mech Elect & Control Engn Beijing 100044 Peoples R China

Effects of indirect squeeze casting process parameters on the microstructure and mechanical properties of an A356.2 alloy engine hanger were studied. A 4-factor, 4-level orthogonal test was used to study the effects of applied pressure, punch velocity, pouring temperature and mold preheating temperature. The pressure, punch speed, pouring temperature and mold preheating temperature of the optimum process parameters were determined by range analysis (RA) as 100 MPa, 60 mm/s, 700 degrees C and 200 degrees C, respectively. The analysis of variance (ANOVA) showed that the only significant factor affecting the microstructure and mechanical properties was pouring temperature, while the other three factors were not significant. The specimens demonstrated mechanical characteristics akin to forged hangers, boasting a tensile strength of 297 MPa, 10.2% post-fracture elongation, and 105 HBW hardness. After T6 heat treatment, except the eutectic silicon morphology changed significantly, the microstructure basically maintained its as-cast characteristics. The samples' microstructure were categorized into three regions: coarse grain alpha-Al (A), eutectic structure (B), and fine grain structure (C). It was found that elevated pouring temperature could keep the pressure transmission channel open, which was helpful to improve the feeding ability and form a refined grain structure in zone C. However, with the excessive increase in casting temperature, alpha-Al grains in region A would be coarse, which would lead to the decline of mechanical properties. Therefore, 700 degrees C was determined as the best pouring temperature.

关键词： squeeze casting orthogonal test process parameters A356.2 alloy microstructure mechanical properties

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Effect of process parameters on CFRP/Steel Joints Using Self-Piercing Rivets

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INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING 2024年第4期25卷 811-818页

作者： Choi, Dong-Won Kang, Min-Seung Go, Bum-Su Bang, Hee-Seon Chosun Univ Grad Sch Dept Welding & Joining Sci Engn 309 Pilmun Daero Gwangju 61452 South Korea Chosun Univ Dept Welding & Joining Sci Engn 309 Pilmun Daero Gwangju 61452 South Korea

Self- piercing riveting (SPR) is an advanced process of the mechanical joining of two or more sheet metals by piercing a rivet into the sheets. SPR has been widely applied to join dissimilar materials that are difficult to join, such as aluminum alloys and steels, especially in automobile industries. In the present work, the Carbon Fiber Reinforced Plastics (CFRP) with thickness of 1.3 mm to SPFC 590DP steel with thickness of 1.2 mm was mechanical joined in lap configuration by the SPR process, and the effect of process parameters of force and shape of rivets on joints were investigated. The integrity of the joints was estimated by quality criteria in terms of the gap between the rivet head and the upper plate, remaining thickness of bottom plate and the length of interlock between the rivet and bottom plate. Furthermore, the tensile shear load, fatigue load and the fracture mode characteristics were investigated. From the result, maximum tensile-shear load of 1.94 kN was obtained at a force of 29 kN, which showed separation of CFRP due to fiber split phenomenon on interface of CFRP side in joints.

关键词： Self-piercing riveting Carbon fiber reinforced plastics High strength steel Dissimilar materials process parameters

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A framework for optimizing process parameters in fused deposition modeling using predictive modeling coupled response surface methodology

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INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 2024年第1期131卷 447-466页

作者： Deka, Angshuman Hall, John F. SUNY Buffalo Dept Mech & Aerosp Engn Univ Buffalo Buffalo NY USA Univ North Carolina Charlotte Mech Engn & Engn Sci Dept Charlotte NC 28223 USA

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) process due to its simplicity, cost-effectiveness, and low waste generation. The mechanical properties of FDM products are greatly influenced by the process parameters. Thus, it is important to use optimal process parameters to achieve desired mechanical properties. One way to determine the optimal process parameters is using response surface methodology (RSM) which has been widely implemented for determining optimal manufacturing process parameters. For RSM, experimental investigations are performed in a systematic way using design of experiments (DOE). However, in some cases, experimental data is not collected in a systematic manner using DOE. Additionally, it is expensive and time consuming to conduct experimental investigations of a well-designed DOE to acquire data. This results in generating insufficient experimental data for developing response surface models using RSM. To address these challenges, this study presents a streamlined five-step framework to optimize FDM process parameters for achieving desired mechanical properties of products. In this process, once experimental data is collected, it is analyzed and preprocessed to remove or repair any missing data. Next, this data is used to develop an artificial neural network (ANN) predictive model to predict the systematic DOE data necessary for developing response surface models. Finally, these models are used to optimize the process parameters for maximizing mechanical properties of FDM products. The efficacy of this framework is demonstrated in detail for a real-world FDM application with limited experimental data. This framework determines the four optimal process parameters for simultaneously maximizing three mechanical properties. By utilizing ANN and genetic algorithm-based optimization, this approach minimizes the need for extensive experiments. Thus, unlike any other work in the literature, this framework not only determine

关键词： Fused deposition modeling process parameters Response surface methodology Artificial neural network Genetic algorithm

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Effect of process parameters on the synthesis and lead ions removal performance of novel porous hydroxyapatite sheets prepared via non-aqueous precipitation method

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CERAMICS INTERNATIONAL 2024年第7期50卷 10897-10905页

作者： Zheng, Entao Feng, Guo Jiang, Feng Shao, Chuan Fu, Huiqun Hu, Zi Wu, Qian Yang, Qing Liu, Jianmin Jingdezhen Ceram Univ Dept Mat Sci & Engn Jingdezhen 333000 Peoples R China Jingdezhen Ceram Res Inst Jingdezhen 333000 Peoples R China Minist Civil Affairs Inst 101 Beijing 333000 Peoples R China

Herein, porous hydroxyapatite sheets with high lead ions removal performance are synthesized via self-assembly non-aqueous precipitation method, and the effects of process parameters on the synthesis and lead ions removal performance are systematically investigated. The optimized precursors concentration, the molar ratio of calcium to phosphorus and the calcination temperature are 0.25 mol/L, 1.67 and 650 degrees C, respectively. The refinement XRD, FE-SEM and EDS tests of the optimized samples show that the samples have a porous sheet structure with uniform pore size and wall thickness. The lead ions removal rate of hydroxyapatite sheets has the maximum value of 99.6% when the hydroxyapatite addition amount is 1 g/L. The lead ions removal content is the maximum of 1303.6 mg/g when the initial lead ions concentration is 9 mmol/L. The removal mechanism of lead ions by porous hydroxyapatite sheets prepared in this work is the composite mechanisms of surface adsorption, surface complexation and ions exchange. The hydroxyapatite porous sheet material prepared by optimizing the process parameters in this study has the advantages of high removal capacity and wide adaptability, so it is expected to become a novel adsorbent to solve lead-containing wastewater.

关键词： Porous hydroxyapatite sheets Nonaqueous precipitation method Lead ions removal performance process parameters

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