Table of Content

16 May 2025, Volume 13 Issue 2

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Role of interatomic potentials in molecular dynamics simulations of silicon nanomachining

Yi-Fan Li, Liang-Chi Zhang

2025, 13(2):  265-283.  doi:10.1007/s40436-024-00544-7

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This investigation examines the impact of diverse interatomic potentials on the molecular dynamics simulation results of deformation and microstructural evolution during nanomachining. The results revealed that the application of the Stillinger-Weber (SW) potential led to the occurrence of significant stacking faults and dislocations. Conversely, the Tersoff potential prevented the initiation of dislocations during the loading segment. The Tersoff potential adept representation of the high-pressure phase transformation of monocrystalline silicon throughout the nanoindentation more accurately predicted mechanical parameters when compared with experimental data. Analytical bond-order potential (ABOP) accurately delineated the deformation mechanisms, including dislocation nucleation and amorphization, during nanoscratching. In contrast, the SW potential tended to underestimate the generation of high-pressure phases, with dislocation nucleation predicted by the SW potential dominating the plastic deformation of monocrystalline Si, contradicting the experimental observations. Consequently, this study concludes that the Tersoff potential and ABOP are the preferred choices for investigating the behavior of monocrystalline Si under nanomachining conditions.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00544-7

Numerical/experimental investigation of the effect of the laser treatment on the thickness distribution of a magnesium superplastically formed part

Angela Cusanno, Pasquale Guglielmi, Donato Sorgente, Gianfranco Palumbo

2025, 13(2):  284-302.  doi:10.1007/s40436-024-00497-x

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The growing need for high-performance components in terms of shape and mechanical properties encourages the adoption of integrated technological solutions. In the present work, a novel methodology for affecting the superplastic behaviour and, in turn, the thickness distribution of magnesium alloy components is proposed. Through heat treatments using a CO₂ laser, the grain size was locally changed, thus modifying the superplastic behaviour in a predefined area of the blank. Both the grain coarsening produced by the laser heat treatment and the superplastic forming of the heat treated blank were simulated using a finite element model, which allowed to set the related process parameters for the manufacturing of the investigated case study (a truncated cone). The thermal finite element model of the laser heat treatment, calibrated using the experimental temperature evolutions acquired in specific areas during the heat treatment, was used to evaluate the influence of process parameters on the grain size evolution. The laser heat treatment was able to significantly promote the grain growth, increasing the mean grain size from about 8 μm to twice (about 17 μm). The resulting grain size distributions were implemented in the mechanical finite element model of the superplastic forming process and the combination of laser parameters which allowed to obtain the most uniform thickness distribution on the final component was finally experimentally reproduced and measured for validation purposes. Even in the case of the laboratory scale application, characterised by quite small dimensions, the proposed approach revealed to be effective, to improving the thinning factor (t_MIN/t_AVG) of the formed part from 0.85 to 0.89, and providing an increase in the thickness uniformity of about 4.7%.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00497-x

Cutting performance optimization and experimental research of indexable insert drill

Yun-Song Lian, Min Zhang, Xiao-Hui Chen, Shu-Wen Peng, Liang-Liang Lin, Chao Liu, Xu-Yang Chu, Wei Zhou

2025, 13(2):  303-321.  doi:10.1007/s40436-024-00507-y

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In this study, the entire process of entry-drilling cutting and steady-state cutting of indexable insert drills was investigated to address challenges, such as vibration, chipping, and poor machining quality, during the cutting process. The research involved the utilization of theoretical analysis and simulation to examine the three-stage force of entry drilling and steady-state force of drilling bodies with various lap structures. Different parameters of the lap structure were analyzed to understand their impact on the direction of the cutting force, emphasizing that the force direction was influenced more by lap structure than the size of the cutting force. Data on radial force, axial force, hole diameter, hole wall roughness, and drill scraping were obtained from experimental cutting of carbon and stainless steel. The performance of different lap structures was evaluated based on these parameters. The experimental results revealed that the radial force in the given environment was most significantly impacted by the height difference between the central and peripheral insert. This was followed by the central insert deflection angle α₂ and peripheral insert deflection angle α₁. A larger deflection angle β resulted in a skewed radial force direction toward the outermost end of the peripheral insert, minimizing drill body scraping and increasing radial force. Furthermore, a substantial increase in radial force and axial force was observed with an increase in feed, while these forces were not significantly affected by the increase in cutting speed. Additionally, the hole diameter and hole wall roughness after cutting increased with the rise in feed.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00507-y

Sensitivity analysis of near solidus forming (NSF) process with digital twin using Taguchi approach

Muhammad Sajjad, Javier Trinidad, Gorka Plata, Jokin Lozares, Joseba Mendiguren

2025, 13(2):  322-336.  doi:10.1007/s40436-024-00482-4

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Forging at near solidus material state takes advantage of the high ductility of the material at the semi solid or soft-solid state while keeping most of the mechanical properties of a forged part. The technology is at maturity level ready for its industrial implementation. However, to implement the process for complex cases the development of an appropriate digital twin (DT) is necessary. While developing a material model, a strong experimental and DT is necessary to be able to evaluate the accuracy of the model. Aimed at having a reliable DT under control, for future material model validations, the main objective of this work is to develop a sensitivity analysis of three NSF industrial cases such as Hook, R spindle and H spindle to develop an adequate DT calibration procedure. Firstly, the benchmark experimentation process parameter noise and experimentation boundary conditions (BCs) parameter uncertainty are identified. Secondly, the three industrial benchmark DTs are constructed, and a Taguchi design of experiments (DoEs) methodology is put in place to develop the sensitivity analysis. Finally, after simulations the results are critically evaluated and the sensitivity of each benchmark to the different inputs (process parameter noise and BC parameter uncertainty) is studied. Lastly, the optimum DT calibration procedure is developed. Overall, the results stated the minimum impact of the material model in terms of dies filling. Nevertheless, even if the material model is the highest impacting factor for the forging forces other inputs, such as heat transfer and friction must be under control first.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00482-4

Laser welding monitoring techniques based on optical diagnosis and artificial intelligence: a review

Yi-Wei Huang, Xiang-Dong Gao, Perry P. Gao, Bo Ma, Yan-Xi Zhang

2025, 13(2):  337-361.  doi:10.1007/s40436-024-00493-1

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Laser welding is an efficient and precise joining method widely used in various industries. Real-time monitoring of the welding process is important for improving the quality of the weld products. This study provides an overview of the optical diagnostics of the laser welding process. The common welding defects and their formation mechanisms are described, starting with an introduction to the principles of laser welding. Optical signal sources are divided into radiated and external active lights, and different monitoring systems are summarized and classified. Also, the applications of artificial intelligence techniques in data processing, weld defect prediction and classification, and adaptive welding control are summarized. Finally, future research and challenges in real-time laser welding monitoring technology based on optical diagnostics are discussed. This study demonstrated that optical diagnostic techniques could acquire substantial information about the laser welding process and help identify welding defects.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00493-1

Blockchain-enabled platform for the quality management of the ready-mixed concrete supply chain

Wen Wang, Hao Hu, Xiao-Wei Luo, Shi-Shu Ding

2025, 13(2):  362-376.  doi:10.1007/s40436-024-00524-x

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Currently quality information management of the ready-mixed concrete (RMC) is manually operated, facing risks like poor traceability, information tampering, and fragmentation in the RMC supply chain. To this end, this study proposes a Blockchain-IPFS (interplanetary file system)-enabled information management platform for improving transparency, traceability, and effectiveness of RMC quality management. Specifically, through a semi-structured interview investigating the potential benefits and applications of Blockchain, a transformative Blockchain-based management mode for RMC quality management is constructed. Based on that, a novel Blockchain-based architecture is further proposed by integrating with IPFS and cloud service for addressing its data storage limitation. Furthermore, the information flows and smart contracts representing physical and cyber interactions among multiple supply chain stakeholders are illustrated in detail. Finally, a real-world case study is presented to verify the feasibility of the proposed model. A prototype system is established with solutions for client-cloud collaboration, multi-source data fusion, and enterprise privacy protection, detailing the practical application of proposed model in actual projects. The evaluation results indicate that the proposed model can improve the quality management of RMC supply chain from three aspects: transparency, traceability, and information sharing. This paper contributes to the body of knowledge by offering a novel architecture leveraging both Blockchain and IPFS in storing small-sized and large-sized information. Meanwhile, this research moves beyond conceptual framework and implements the theoretical benefits of Blockchain into engineering practice. Technical components in this paper can be adapted for multiple applications in the construction industry, providing valuable references for future search efforts.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00524-x

Investigation of control method on blade shape accuracy of blisk in vibration finishing

Chang-Feng Yao, Yun-Qi Sun, Liang Tan, Min-Chao Cui, Ding-Hua Zhang, Jun-Xue Ren

2025, 13(2):  377-394.  doi:10.1007/s40436-024-00505-0

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Vibration finishing can effectively reduce the surface roughness of blisks and change blade shape accuracy. This study investigates the influence of vibration finishing on the shape accuracy of the blade part of the blisk. The influence of the fixed attitude of the blisk on the position accuracy and profile accuracy of different measuring sections of the blade is analyzed. The changes in the blade geometry before and after vibration finishing are analyzed. The adjustment method of blade disc attitude in the machining process is developed, and the tooling used to fix the blade disc in the vibration finishing is improved. By controlling the deformation in different time periods to offset each other, the contact between the abrasive and the blade edge is reduced, effectively reducing the displacement of the blade section and the excessive wear of the edge.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00505-0

Cutting performance and effectiveness evaluation on organic monolayer embrittlement in ductile metal precision machining

Chao-Jun Zhang, Song-Qing Li, Pei-Xuan Zhong, Fei-Fan Zhang, Wen-Jun Deng

2025, 13(2):  395-412.  doi:10.1007/s40436-024-00513-0

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In the traditional machining field, the addition of cutting fluid can appropriately reduce cutting forces, dissipate cutting heat, and facilitate the machining process. However, the use of cutting fluids has environmental implications. Recently, a phenomenon known as organic monolayer embrittlement (OME) has been proposed, which could address this issue. OME can reduce cutting forces, enhance surface quality, and improve machining performance without the need for cutting fluids, particularly noticeable in ductile metals like pure copper. This study conducted micro-cutting experiments on pure copper to investigate the microstructural features, cutting performance, chip flow patterns, and the effectiveness of OME. The results indicate that OME alters chip flow patterns from sinuous flow to segmented quasi-periodic micro-fracture flow, resulting in a 42% and 63% reduction in cutting forces for copper materials with different initial hardness. This phenomenon significantly improves surface quality, diminishes surface defects caused by adhesion, and effectively reduces work hardening layers. The study also demonstrates that OME is a physical phenomenon closely related to the adsorption properties of organic catalytic agents and van der Waals interactions. Materials with higher initial hardness exhibit less pronounced OME due to a sufficiently high grain boundary density, impeding dislocation movement during shear deformation and causing a local stress increase at the free surface of the chip. This leads to a change in chip flow patterns, improving machining performance, analogous to the adsorption effect of organic catalytic agents.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00513-0

Structural design and simulation of PDMS/SiC functionally graded substrates for applications in flexible hybrid electronics

Jian-Jun Yang, Yin-Bao Song, Zheng-Hao Li, Luo-Wei Wang, Shuai Shang, Hong-Ke Li, Hou-Chao Zhang, Rui Wang, Hong-Bo Lan, Xiao-Yang Zhu

2025, 13(2):  413-429.  doi:10.1007/s40436-024-00510-3

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Flexible hybrid electronics possess significant potential for applications in biomedical and wearable devices due to their advantageous properties of good ductility, low mass, and portability. However, they often exhibit a substantial disparity in elastic modulus between the flexible substrate and rigid components. This discrepancy can result in damage to the rigid components themselves and detachment from the substrate when subjected to tensile, bending, or other loads. Consequently, it diminishes the lifespan of flexible hybrid electronics and restricts their broader-scale application. Therefore, this paper proposes a polydimethylsiloxane (PDMS)/SiC functionally graded flexible substrate based on variable stiffness properties. Initially, ABAQUS simulation is employed to analyze how variations in stiffness impact the stress-strain behavior of PDMS/SiC functionally graded flexible substrates. Subsequently, we propose a multi-material 3D printing process for fabricating PDMS/SiC functionally graded flexible substrates and develop an advanced multi-material 3D printing equipment to facilitate this process. Tensile specimens with the functional gradient of PDMS/SiC are successfully fabricated and subjected to mechanical testing. The results from the tensile tests demonstrate a significant enhancement in the tensile rate (from 21.6% to 35%) when utilizing the PDMS/SiC functionally graded flexible substrate compared to those employing only PDMS substrate. Furthermore, the application of PDMS/SiC functional gradient flexible substrate exhibits remarkable bending and tensile properties in stretchable electronics and skin electronics domains. The integrated fabrication approach of the PDMS/SiC functionally graded flexible substrate structure presents a novel high-performance solution along with its corresponding 3D printing methodology for stretchable flexible electronics, skin electronics, and other related fields.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00510-3

Dissimilar metals welding processes realized by vaporizing metal foils

Sheng Cai, Zhi-Chao Deng, Jia-Nan Wang, Nan Zhang

2025, 13(2):  430-443.  doi:10.1007/s40436-024-00506-z

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In high-velocity impact welding (HVIW), vaporizing foil actuator welding (VFAW) can be utilized to join dissimilar metals. In comparison with conventional welding processes, the VFAW process minimizes energy loss, enhances weld strength, and effectively mitigates issues of overheating or material deformation associated with traditional welding methods. In this study, VFAW was utilized to successfully weld three different metal materials (Cu, Al6061-T6, Q235). An accurate smoothed particle hydrodynamics (SPH) model was established based on the experimental results. The impacts of collision angle and velocity of the flyer on the interface morphology of Cu/Al6061-T6 weld were investigated using the SPH method. The experimental results show that with an increase in the collision angle from 0° to 20°, both the wavelength and amplitude of the welding interface significantly increase. The tail vortex phenomenon also becomes more pronounced with the angle of tail rotation caused by particle motion gradually increasing. But when the collision angle exceeds 20°, the wavelength and amplitude of the welding interface tend to stabilize while its influence on tail vortex phenomenon decreases. The tail rotation angle induced by particle motion continues to increase, although at a decreasing rate. When the initial collision angle is kept constant, both the wavelength and amplitude of the welding interface continue to rise with increasing collision velocity up to 900 m/s. The wake vortex phenomenon becomes more pronounced as the number of particles in the jet gradually increases.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00506-z

Prototype pipeline modelling using interval scanning point clouds

Toa Pečur, Frédéric Bosché, Gabrielis Cerniauskas, Frank Mill, Andrew Sherlock, Nan Yu

2025, 13(2):  444-461.  doi:10.1007/s40436-024-00515-y

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With the aid of computer aided design (CAD) and building information modelling (BIM), as-built to as-designed comparison has seen many developments in improving the workflow of manufacturing and construction tasks. Recently, evolution has been centred around automation of scene interpretation from three-dimensional (3D) scan data. The scope of this paper is to assess assemblies as the installation process progresses and inferring if arising deviations are problematic (complex task). The adequacy of utilising unorganised point clouds to compliance check are trialled with a real life down-scaled prototype model in conjunction with a synthetic dataset. This work aims to highlight areas where large rework could be avoided, in part by the detection of potential clashes of components early in the pipeline installation process. With the help of an extracted model in the form of a point cloud generated from a scanned physical model and a 3D CAD model representing the nominal geometry, an operator can be made visually aware of potential deviations and component clashes during a pipeline assembly process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00515-y

Combining 3D printing of copper current collectors and electrophoretic deposition of electrode materials for structural lithium-ion batteries

Ana C. Martinez, Alexis Maurel, Bharat Yelamanchi, A. Alec Talin, Sylvie Grugeon, Stéphane Panier, Loic Dupont, Ana Aranzola, Eva Schiaffino, Sreeprasad T. Sreenivasan, Pedro Cortes, Eric MacDonald

2025, 13(2):  462-475.  doi:10.1007/s40436-024-00514-z

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Serving as a proof of concept, additive manufacturing and electrophoretic deposition are leveraged in this work to enable structural lithium-ion batteries with load-bearing and energy storage dual functionality. The preparation steps of a complex 3D printed copper current collector, involving the formulation of a photocurable resin formulation, as well as the vat photopolymerization process followed by a precursors-based solution soaking step and thermal post-processing are presented. Compression and microhardness testing onto the resulting 3D printed copper current collector are shown to demonstrate adequate mechanical performance. Electrophoretic deposition of graphite as a negative electrode active material and other additives was then performed onto the 3D printed copper collector, with the intention to demonstrate energy storage functionality. Half-cell electrochemical cycling of the 3D multi-material current collector/negative electrode versus lithium metal finally demonstrates that structural battery components can be successfully obtained through this approach.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00514-z