Advances in Manufacturing

Foreword for the Inaugural Issue

Kuang-di Xu

2013, 1(1): 0.

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Progress of remanufacturing engineering and future technology

Bin-Shi Xu

2013, 1(1): 8-12. doi:10.1007/s40436-013-0003-8

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After development for decades, abroad remanufacturing has formed a complete industrial system. At present, the research emphases are on marking logistics management and market cultivation theory of remanufacturing products, and so on. The Chinese remanufacturing starts fairly late. After 10 years of development, it formed a remanufacturing mode with Chinese characteristics that is sustained by high-tech industries, using the surface engineering
technology to restore the size and improve properties, and combining manufacturing, study and research together. The remanufacturing mode is not only circular but also economic. With the development of science and technology, future remanufacturing technology will break the previous limits, explore and understand the limits of micro machining. It will carry out the waste product remanufacturing in the micro-nano scale, and extend the remanufacturing industry to a more broad space.

Carbon nanotubes for electronics manufacturing and packaging:from growth to integration

Johan Liu, Di Jiang, Yifeng Fu, Teng Wang

2013, 1(1): 13-27. doi:10.1007/s40436-013-0007-4

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Carbon nanotubes (CNTs) possess excellent electrical, thermal and mechanical properties. They are light in weight yet stronger than most of the other materials. They can be made both highly conductive and semi-conductive. They can be made from nano-sized small catalyst particles and extend to tens of millimeters long. Since CNTs emerged as a hot topic in the early 1990s, numerous research efforts have been spent on the study of the various properties of this new material. CNTs have been proposed as alternative materials of potential excellence in a lot of applications such as electronics, chemical sensors, mechanical sensors/actuators and composite materials, etc. This paper reviews the use of CNTs particularly in electronics manufacturing and packaging
field. The progresses of three most important applications, including CNT-based thermal interface materials, CNT-based interconnections and CNT-based cooling devices are reviewed. The growth and post-growth processing of CNTs for specific applications are introduced and the tailoring of CNTs properties, i.e., electrical resistivity, thermal conductivity and strength, etc., is discussed with regard to specific application requirement. As the semiconductor industry is still driven by the need of getting smaller and faster, CNTs and the related composite systems as emerging new materials are likely to provide the solution to the future challenges as we make more and more complex electronics devices and systems.

Reverse metallurgical engineering towards sustainable manufacturing of vehicles using Nb and Mo alloyed high performance steels

Hardy Mohrbacher

2013, 1(1): 28-41. doi:10.1007/s40436-013-0002-9

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Steel is the dominant construction material for most industrial goods such as equipments, structures, buildings or vehicles. Although there have been great
advances in steel technology over the last 4 decades, the industry currently faces serious sustainability challenges with regard to energy conservation, reduction of CO₂ emission and a generally more efficient use of resources. The principal connotation in this respect is increasing steel strength allowing to reduce component weight. However, it is also necessary considering in how far the modified steel properties interfere with typical manufacturing techniques
established in the processing chain. A feasible method in this sense is a reverse approach starting from detailed knowledge of the manufacturing process and translating it back into the most suitable metallurgical and microstructural design of steel. Modifying steels towards better manufacturing performance typically involves innovative alloying and metallurgical processing concepts. Niobium and molybdenum are two of the most powerful alloying elements in helping to adapt microstructures and properties with regard to downstream manufacturing processes. This paper will highlight several examples how a reverse metallurgical engineering approach can be successfully applied to optimize the efficiency of subsequent manufacturing processes with a focus on the automotive industry.

Making aviation green

Zuo-Ming Lin

2013, 1(1): 42-49. doi:10.1007/s40436-013-0008-3

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With rapid economic progress and tremendous advances of science and technology, awareness of environmental protection has become worldwide consensus. Saving energy, reducing emission and dealing with climate changes are global objectives. The aviation industry belongs to the manufacturing industry. Air transportation is a major consumer of natural resources and energy. Development of green technology in aviation manufacturing will have significant impacts on air transportation. On the basis of the international situation, this article focuses on the current development of green aviation manufacturing in China, depicting AVIC’s objectives and commitments to achieving this.

Thermal plasma synthesis of SiC

Muralidharan Ramachandran, Ramana G. Reddy

2013, 1(1): 50-61. doi:10.1007/s40436-013-0011-8

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Synthesis of silicon carbide has been carried out using thermal plasma processing technique using SiO₂ as the solid feed and CH4 as the gaseous reducing agent. Thermochemical calculations have been performed varying the molar ratio of silicon dioxide and methane to determine the feasibility of the reaction. Experiments using a molar ratio of SiO2:CH4 equal to 1:2 produced maximum yield of SiC of about 65 mol % at a solid feed rate of 5 g/min.
Mostly spherical morphology with some nanorods has been observed. The presence of Si had been observed and was quantified using XRD, HRTEM, Raman spectroscopy and X-ray photoelectron microscopy (XPS). Si acts as a nucleating agent for SiC nanorods to grow.

Towards zero-defect manufacturing (ZDM)—a data mining approach

Ke-Sheng Wang

2013, 1(1): 62-74. doi:10.1007/s40436-013-0010-9

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The quality of a product is dependent on both facilities/equipment and manufacturing processes. Any error or disorder in facilities and processes can cause a catastrophic failure. To avoid such failures, a zero- defect manufacturing (ZDM) system is necessary in order to increase the reliability and safety of manufacturing systems and reach zero-defect quality of products. One of the major challenges for ZDM is the analysis of massive raw datasets. This type of analysis needs an automated and self-organized decision making system. Data mining (DM) is an effective methodology for discovering interesting knowledge within a huge datasets. It plays an important role in developing a ZDM system. The paper presents a general framework of ZDM and explains how to apply DM approaches to manufacture the products with zero-defect. This paper also discusses 3 ongoing projects demonstrating the practice of using DM approaches for reaching the goal of ZDM.

Advances of physics-based precision modeling and simulation for manufacturing processes

Gang Wang 1, Yi-Ming Rong 1,2

2013, 1(1): 75-81. doi:10.1007/s40436-013-0005-6

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The development of manufacturing process concerns precision, comprehensiveness, agileness, high efficiency and low cost. The numerical simulation has
become an important method for process design and optimization. Physics-based modeling was proposed to promote simulations with a high accuracy. In this paper, three cases, on material properties, precise boundary conditions, and micro-scale physical models, have been discussed to demonstrate how physics-based modeling can improve manufacturing simulation. By using this method, manufacturing process can be modeled precisely and optimized
for getting better performance.

Dynamic characteristics of ultra-precision aerostatic bearings

Xue-Dong Chen, Jin-Cheng Zhu, Han Chen

2013, 1(1): 82-86. doi:10.1007/s40436-013-0013-6

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With high acceleration and ultra-precision requirements, the design of aerostatic bearings has been gradually focused on their dynamic performances. In this paper, the dynamic stiffness and damping coefficients of aerostatic bearings are investigated. Due to compressibility of the gas, the dynamic characteristics of aerostatic bearings show nonlinear frequency dependence. Particularly, their nonlinear dynamic behaviors are quite remarkable for
ultra-precision aerostatic bearings with small air gap heights and high supply pressure.

Robotic GMAW forming remanufacturing technology

Sheng Zhu

2013, 1(1): 87-90. doi:10.1007/s40436-013-0001-x

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Robotic GMAW forming process with the advantages of high productivity and high bond strength has become an important forming remanufacturing technology. In this paper, our recent research achievements are introduced and our development prospect on robotic GMAW forming remanufacturing is declared.

Development of remaining life prediction of crankshaft remanufacturing core

Li-Hong Dong, Bin-Shi Xu, Nan Xue,Hui-Peng Wang, Hao-Yu Li

2013, 1(1): 91-96. doi:10.1007/s40436-013-0004-7

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This paper reviewed the main research work in the field of remaining life prediction of crankshaft remanufacturing core by Science and Technology on Remanufacturing Laboratory. Based on the results of finite element analysis, the R angle zone of crankshaft was determined as a major measuring position. A special measuring probe is developed, and bending fatigue bench tests were carried out to collect electromagnetic damage information during
fatigue process. A neural network model was established to identify damage degree of crankshaft core, and a damage evaluation equipment for crankshaft core was developed.

Research on automatic high velocity arc spraying technique and metastable coating materials

Xiu-Bing Liang, Yong-Xiong Chen,Zhi-Bin Zhang,Shi-Cheng Wei,Yong-Ming Guo

2013, 1(1): 97-101. doi:10.1007/s40436-013-0012-7

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Into the 21st century, remanufacturing engineering has been accepted by more and more people in China. Remanufacturing is an industrial maintenance
technology for worn or waste electro-mechanical products using advanced technology, which means the high-level stage for the maintenance and surface engineering. In this paper, a new automotive high velocity arc spraying system was introduced. And three kinds of advanced amorphous and nanocrystalline metastable coatings were developed, including Fe, Ni and Al-based amorphous and nanocrystalline composite coatings. Their research development and
applications were introduced. And the development trends of high velocity arc spraying system and advanced metastable surface protective coating materials on the remanufacturing engineering were indicated.

Technology of self-repairing and reinforcement of metal worn surface
surface

Yi Xu 1, Fei Gao 1, Bo Zhang 1, Feng Nan 1, 2, Bin-Shi Xu

2013, 1(1): 102-105. doi:10.1007/s40436-013-0009-2

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Researches on self-repairing material (serpentine phyllosilicate) of our team in the past few years, such as ultrafining treatment, surface modification, self-repairing mechanism, the effect of rare metal on the self-repairing performance of serpentine, were introduced summarily. The phyllosilicate of serpentine shows excellent tribological and self-repairing performance for metal worn surface as additive in lubricant.

Smart technology renders high-end manufacturing possible

Bing-Heng Lu

2013, 1(1): 107-111. doi:10.1007/s40436-013-0028-z

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