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A low-density wood fiber insulation panel (WIP) composite was developed with 100 % petrochemical-free, bio-based binder with high mechanical strength, water resistance and thermal insulation properties. This study investigated the manufacturing process of composite WIPs made with mechanical pulp fibers with cellulose nanofibrils (CNFs), lignin-containing CNFs (LCNFs), hybridized CNFs-LCNFs, and CNFs-starch as a binder on different scales and evaluated the effects of binder type and content on the panels’ physical, mechanical, and thermal properties. All panels had excellent thermal resistivity values, which increased with the decrease in density. The WIPs made with LCNFs as binder had lower mechanical properties, but it was possible to replace 20 % CNFs with LCNFs to obtain the same performance as neat CNFs as the binder. Untreated panels had poor water resistance but the water absorption properties were significantly improved with the addition wax. The WIPs made with 5 % and 7.5 % binder content and 2 % wax addition could fulfill the criteria of regular and structural wall sheathing applications, respectively. Overall, the results confirm the potential of CNFs and LCNFs to be used as 100 % bio-based adhesives to produce eco-friendly composite WIPs with excellent thermo-mechanical properties to be used for regular and structural wall sheathing applications.

Metal screw extrusion (MSE) is a continuous, solid-state forming method utilizing an inherently high degree of deformation to consolidate fragmented input materials into a solid bulk by breaking their oxide skins. Severe plastic deformation with equivalent strain in the range of 10–20 can be achieved depending on set process parameters. Rigorous mixing can be employed to form sophisticated materials like bulk composites, nanocomposites, particle-reinforced metals, and fine-grained materials. Furthermore, the inherent solid-state processing is well suited for recovery of difficult-to-recycle materials. A range of non-ferrous materials has been manufactured by MSE and further characterized in terms of microstructural evolution and mechanical and functional properties. Furthermore, MSE has been studied in terms of flow, accumulated strain, and environmental impact. The following review aims to critically highlight the existing work performed on MSE, compare it to existing and emerging technologies as well as explore future development and possible applications. MSE has the potential to be utilized for numerous commercial applications. To realize industrial use of MSE, key aspects of the process and the influence of processing parameters on the resulting product must be understood.

The increasing demands for better crashworthiness of vehicles require structural components with excellent energy absorption performance and anti-intrusion resistance. Here, we explored the potential of using a medium Mn steel with a 10 wt.% Mn content for hot/warm forming with the aim to produce automotive components with improved strength–ductility combination. The soaking temperature was varied from 670 to 870 °C for tuning the microstructure and the resultant mechanical properties. It is found that a duplex microstructure consisting of ferrite with a high dislocation density and retained austenite with a volume fraction of 53.5% is formed at 720 °C, leading to an exceptional strength–ductility combination (yield strength: 1016 MPa; ultimate tensile strength: 1407 MPa; total elongation: 32.7%). The energy absorbed before fracture is 39.8 GPa·%, which is four times more than that of the widely-used 22MnB5 boron steel. On basis of the experimental results, the effects of soaking temperature on austenite reverse transformation, ferrite recrystallization and martensitic transformation are discussed in depth to provide guidance for optimizing the strength–ductility combination of medium Mn steels processed by hot/warm forming.

In the aluminum industry, forming is an important process step that introduces dislocations in the material. To investigate the effect of dislocation retention after ageing on 6xxx-series alloys, a non-heat-treatable 5005 alloy was selected to measure the change in mechanical properties due to dislocation annihilation during dynamic recovery. However, the isothermal ageing treatment led to an unexpected and significant increase in mechanical properties after deformation. Increases in yield strength of 120% and tensile strength of 50% compared with the as-received material were achieved. However, this caused a significant decrease in elongation properties. The deformation start temperature did not have any impact on the final mechanical properties. TEM analysis attributed the increase in mechanical properties to an increased precipitation and dislocation density compared with the undeformed reference material. The precipitates are located along dislocation lines, showing that the solute elements are preferentially segregating to dislocations and precipitating. The precipitates were typical for the Al–Mg–Si(–Cu) system; therefore, the low amounts of Si and, to a lesser extent, Cu were responsible for the precipitation hardening in the 5005 alloy. [ABSTRACT FROM AUTHOR]

The utilization of diamond-like carbon (DLC) coatings has emerged as a promising strategy to enhance the performance, durability, and functionality of industrial tools and components. Recognized for their exceptional attributes such as hardness, wear resistance, low friction, and biocompatibility, DLC coatings have achieved widespread acclaim for their potential to improve the capabilities of tool steels for different applications. This present study shows a comprehensive investigation into the application of DLC coatings on a diverse range of tool steel substrates, encompassing 1.2379, 1.2358, Caldie, K340, HWS, and Vanadis 4. The main aim is to show the effects of DLC coatings on these substrates and to provide an in-depth analysis of their properties during forming processes. Furthermore, this study explores the practical utilization of DLC-coated tool steel components, with a particular focus on their role in cold forming dies. Additionally, the study reviews the application of duplex treatments involving plasma nitriding to enhance DLC coating performance. To sum up, this study pursues a threefold objective: to investigate DLC coatings' performance on diverse tool steel substrates; to assess the potential for improvement through nitriding; and to evaluate the behavior of DLC coatings in the cold stamping of S235 steel, which is of great technological and industrial interest to the cold forging sector. [ABSTRACT FROM AUTHOR]

Creasing and folding are fundamental steps in many manufacturing processes of multi-material paperboard packaging. The complex structure of these materials, which comprise layers of cellulose fibres, aluminium, and polyethylene, coupled with the growing complexity of packaging designs, make these process operations essential to ensure the required structural integrity for packaging as well as their functionality in daily life. This paper introduces an approach for modelling damage in paper-based sandwich materials by integrating fibre-based and cohesive numerical modelling techniques. The results prove the effectiveness of the proposed methodology, opening new possibilities for process design and optimization in packaging manufacturing. [ABSTRACT FROM AUTHOR]

With the growth of electric vehicle market, lithium-ion pouch battery is attracting great attention. In this work, the deformation and failure behavior of pouch film was investigated. A constitutive model from property characterization was also derived. Tensile testing and nanoindentation combined with optimization was introduced for identifying layered properties of the film. Nanoindentation predetermined yield stress and hardening coefficients for different layers enhances material characterization. The optimization accurately identified layered properties considering stress and strain directionalities. Applying the method to the Yoshida buckling test and battery pouch forming, the proposed multi-layered model proved more accurate than the single-layer model. [ABSTRACT FROM AUTHOR]

The formability of the ultra-thin (0.1 mm) titanium sheet is improved by introducing an intermediate electropulsing treatment in a two-step stamping process. This improvement is attributed to the enhancement in both the work hardening capability and total elongation. A short-duration electropulsing treatment (∼2 s) significantly reduces the twin density and dislocation pile-up, while also expediting the formation of equi-axed recrystallized grains in the pre-deformed titanium sheets. With its excellent time- and cost-efficiency, the proposed process has the potential to be seamlessly integrated into conventional multi-step stamping lines to extend the forming limits of ultra-thin titanium sheets. [ABSTRACT FROM AUTHOR]

The roll-slide-drawing process enables tailoring of profile cross-sections at arbitrary axial positions with short transition zones at high industrial throughput rates. The process combines rolling using rotating dies with non-axisymmetric complex geometries and subsequent drawing of a constant cross-section geometry. For initially round tubes, process limits of notches and transition lengths are derived analytically. These limits are removed through the novel approach of starting with oval or rectangular shaped profile cross-sections as demonstrated experimentally. Developed analytical models for the prediction of the profile thickness after forming and the prediction of the drawing forces are validated experimentally and numerically. [ABSTRACT FROM AUTHOR]

In Nordic kindergarten, activities with materials have had a significant position historically. The Norwegian term "forming" includes both the material-based craftwork and the art area. Research shows that creative activity with materials constitutes a smaller part of the content in the kindergarten than before. The aim of this article is 1) to provide a historical overview of the subject forming, 2) to put this retrospectively into an epistemological context that points towards 3) an actualization in relation to the UN Sustainability Goals and children's right to expression according to the UN Convention. The article is based on an ethnographic study in kindergarten and an article on the topic written in Norwegian (Carlsen, 2015, 2022). The discussion illuminates how the anchoring of forming in natural and cultural materials is lifted into a sustainability perspective and how a shift in theoretical perspectives opens new understandings and contributes to the kindergarten's content. [ABSTRACT FROM AUTHOR]

The vacuum vessel (VV) is one of the main components of the HL-2M tokamak device. It is a thin-shell, all-welded torus made of Inconel 625 material. Maintaining the welding quality and controlling welding distortion are the main manufacturing difficulties. Welding, forming, and assembly are the research focus. This technical note describes the fundamental manufacturing research and development (R&D) and the actual manufacturing procedure of the HL-2M VV. Three stages of R&D work are carried out. The weldability of Inconel 625 plate is studied. Partial and full-scale mock-ups are made. By optimizing the manufacturing process, the HL-2M VV was completed in 2019, and the measurement data meet the design requirements. HL-2M has good vacuum performance, the total leak rate reaches 6.0 × 10−8 Pa·m3/s at room temperature, and the ultimate vacuum pressure reaches 2.4 × 10−6 Pa after baking up to 100°C. [ABSTRACT FROM AUTHOR]

The article summarizes information on the ceramic production of the Trypillya-Cucuteni culture. It covers all phases of Trypillya ceramic production, including clay preparation, modeling methods, structural component connection, and decoration. Special attention is given to the examination of engobe and pigment composition in the painted vessel areas. The composition of the clay body and petrographic studies are also addressed. At the Bodaki site, samples of painted pottery, traditional kitchenware, and ceramics classified as "western imports" were examined. Vessels were modeled from clay strips or slabs, with the strips often being diagonally connected to increase the bonding surface. There were various methods for creating vessel rims, and during the middle Trypillya culture, there was a tendency towards standardization of forms. The article describes various techniques and methods used in the ceramic production of the middle to late Trypillya culture. It also discusses the use of wooden sticks to connect parts of a vessel. Furthermore, various methods for treating vessel surfaces are described, such as scraping off excess clay and applying engobe. The study shows that surface treatment and handle production techniques were applied differently in various settlements of the Trypillia culture. The article describes the painting process, pigments, and binders used in the production of Trypillya ceramics. Painting covered about two-thirds of the surface of a vessel, with the lower part usually remaining undecorated. In the middle period, trichromatic painting with red, black, and white colors was common. Later, mainly monochrome painting was used. The colors consisted of a mixture of pyrolusite, ochre, and burnt bone. Organic binders were found in the paint layers, indicating that the ceramics were painted after firing. The surfaces of the painted ceramics were polished to make them more compact and water-resistant. [Extracted from the article]

Incremental forming is a rapid prototype production method, which can be used in different industrial applications. In this context, it can be used especially in forming of Titanium Grade 2 sheet as depending on the types of manufacture. The main problem of the incremental forming method is that the wall thickness of the piece obtained after the process is not homogeneous. In this study, Titanium Grade 2 sheet was formed 60° axially symmetrical cone geometry using the roller blank holder method (TPIF-RL), which is a new approach. This method provides bigger wall thickness than the conventional incremental forming method considering its results. In this study, it was aimed to investigate the effectiveness of the new roller blank holder method on titanium material. In the experiments, the axisymmetrical piece with a height of 40 mm was formed (the forming angle is 60° with the horizontal). Feedrate, clamping pressure, increment, and forming tool diameter were used as parameters. Forming force, surface roughness, and wall thickness distributions obtained as a result of experimental studies were examined statistically. The interactions of the parameters were evaluated, and optimum levels of forming parameters were determined for the roller blank holder method. In addition, by using gray relational analysis, parameter levels of three dependent variables (forming force, surface roughness, and sheet thickness) were defined to optimize at the same time. As a result, bigger wall thickness was obtained with a low clamping force considering roller blank holder method. It was determined the levels that optimize the three parameters together were 2 bar pressure, 500 mm/min feed rate, 0.25 mm increment, and 5 mm forming tool diameter. Bigger wall thickness was obtained with a low clamping force considering roller blank holder method. [ABSTRACT FROM AUTHOR]

The sustainability of the manufacturing industry is of special importance to increase the protection of the environment. The production of fasteners like self-piercing rivets, however, is costly, time-consuming and energy-intensive. The heat treatment and the coating, which are mandatory in conventional self-piercing rivets to achieve adequate strength, ductility and corrosion resistance, are especially crucial in this respect. Within this paper, an approach for an increase in the sustainability in fastener production is presented. The use of alternative, high strain hardening stainless steels as rivet material enables a shortening of the process chain, because post treatment of the rivets after they are formed can be omitted. As the change in rivet material and processing causes some issues along the process chain, the focus of this paper is on the holistic evaluation of the challenges within the forming of high strain hardening steel and the impact of the changed rivet properties on the joining result. [ABSTRACT FROM AUTHOR]

Solid-state electrolytes (SSEs) are vital components in solid-state lithium batteries, which hold significant promise for energy storage applications. This review provides an overview of solid-state batteries (SSBs) and discusses the classification of electrolytes, with a focus on the challenges associated with oxide- and sulphide-based SSEs, particularly concerning interfaces and chemical stability. This review also explores methods employed to form and sinter SSEs in large-scale manufacturing, including both established and novel techniques for producing dense oxide- and sulphide-based films. Additionally, the potential application of additive manufacturing (AM) in SSE production is discussed. Lastly, the paper summarises the mass manufacturing of SSEs and provides an outlook for sustainable SSB development goals. The insights presented in this review contribute to the understanding and progress of SSE technology for solid-state lithium batteries

The use of ultra-short pulse lasers in the kW range, combined with an appropriate beam engineering approach, enables the achievement of high-throughput production of laser-functionalised surfaces. However, the manufacturing of complex parts still faces various challenges, such as difficulties in accessing regions with high aspect ratio shapes or intricate profiles, which often leads to the necessity of adapting the laser processing workstation to specific geometries. The forming process is a well-established technique for producing parts of any shape from metallic foils by imposing specific constraints. In this study, we aimed to assess the feasibility of producing laser-functionalised 3D complex products by the forming of laser-treated flat thin metallic sheets. Two-hundred micrometre-thick stainless-steel foils were textured with laser-induced periodic surface structures (LIPSS) through a roll-to-roll pilot line. First, we optimized the morphology of LIPSS. Subsequently, we conducted three types of mechanical tests on both laser-treated and untreated foils: standard tensile tests, fatigue tests, and cruciform specimen tests. We measured and compared parameters such as ultimate tensile strength, breaking strength, maximum elongation, and area reduction between specimens with and without LIPSS, all obtained from the same foil. Additionally, we utilized scanning electron microscopy (SEM) to compare the LIPSS morphology of laser-treated samples before and after mechanical tests. [ABSTRACT FROM AUTHOR]

In order to study the influence of technological factors on the nature of forming and the risk of metal fracture, problems of computer modeling of the process of continuous pipe rolling on the Fine Quality Mill (FQM) are formulated and solved. The solution of the problems has made it possible to assess the nature of the influence of deviation of rolling axes of the continuous mill and the extracting mill. The results of the research have made it possible to formulate and propose technical solutions to minimize the probability of risk defect. [ABSTRACT FROM AUTHOR]

In this paper, the influence of ultrasonic vibration on the forming forces and surface quality of products formed using an ultrasonic-assisted incremental sheet forming (UISF) method was investigated and compared with an incremental sheet forming (ISF) method. The elements and parameters used for research include a sheet of Al 5052 aluminum alloy with thickness of 1.0 mm, a lathe with a feed rate of 70-130-225 rpm, and step size of 1.0-1.5-2.0 mm. The results show that ultrasonic vibration significantly reduces the forming forces, of which the main forming force Fzmax is reduced by about 20%. Besides, the results also show that the surface quality of products formed via UISF is significantly improved compared to that formed by ISF. [ABSTRACT FROM AUTHOR]

In scientific studies, sheet metal is usually considered as a two-dimensional body. Thus, it is accepted that material properties are in most cases regarded homogeneous in thickness direction. However, a gradation of certain properties becomes apparent when going beyond the standard characterization methods for sheet metals, which can for example, influence the springback behavior and the thinning of the sheet after forming. Thus, the aim of this work is to further improve the prediction accuracy of springback after forming in simulations, by implementing several inhomogeneous properties over the sheet thickness in an existing material model. For this purpose, the entire procedure from the identification of the inhomogeneous properties for describing the gradation to the implementation in a numerical model and its validation by comparing experimental and simulated bending operations is carried out on a DC04 cold-forming steel in order to prove its influence on the springback behavior. It is shown that including graded material properties in simulations does indeed have an impact on the prediction quality of springback and that the information about inhomogeneous properties can be provided by existing characterization methods with a high local resolution like electron backscatter diffraction or X-ray stress analysis. In a further step, it was possible to validate the improvement in numerical accuracy by comparing the prediction of the springback angle from both the existing and the extended model with experimental bending results. Both the initial model as well as the model supplemented with the 3D properties provide a good prediction accuracy in the solution heat treated material state. For the predeformed material, however, the initial numerical model predicts a springback angle of about 13°, which deviates remarkably from the experimentally obtained mean value of about 17°. The extended model delivers a significantly improved accuracy in springback prediction in relation to the initial prediction (deviation of 4°) with a minor deviation of only about 0.8°, which proves the importance of considering the gradation of material properties in thickness direction for an overall higher dimensional accuracy of sheet metal products. [ABSTRACT FROM AUTHOR]

The production of high-performance composite parts with non-crimp fabrics (NCFs) requires a profound understanding of the material’s behavior during draping to prevent forming defects such as wrinkling and gapping. Simulation methods can be used to model the complex material behavior of NCFs and predict their deformation during the draping process. However, NCFs do not intrinsically deform under pure shear like most woven fabrics, but often under superimposed shear, transverse tension and in-plane roving compaction. Therefore, non-standard characterization methods have to be applied besides typical picture frame tests or bias-extension tests. Off-axis-tension tests (OATs) utilize a simple setup to characterize a fabric’s membrane behavior under different ratios of superimposed shear, transverse tension and in-plane compaction. OATs at three different bias angles (30 ∘ , 45 ∘ and 60 ∘ ) are conducted to investigate a unidirectional and a bidirectional NCF. A method is presented to measure the fiber curvatures in addition to the occurring strains. The investigations reveal a relatively symmetrical, shear-dominated behavior with limited roving slippage for the Biax-NCF. The behavior of the UD-NCF strongly depends on the stitching load during tests and is characterized by an asymmetric shear behavior as well as significant roving slippage. The off-axis-tension test results can be used as the basis for the development and validation of new simulation methods to model the complex membrane behavior of NCFs. [ABSTRACT FROM AUTHOR]

Spring back compensation is essential for accurate geometry of sheet metal components. In this paper the effect of process parameters namely sheet thickness, bend angle and tool travel rate on spring back in SS304 and C80 material sheets under V-bending is predicted by using finite element method and artificial neural network approaches. Total nine experiments were designed considering three process parameters, each with three levels, by using Taguchi's L9 orthogonal array. The results obtained by ANN model are in good agreement with FEM model. This establish the robustness of ANN model for predicting spring back value and may be used an alternative to FEM model as the latter is more expensive and time consuming. The optimized value of sheet thickness, bend angle and tool travel rate are 2 mm, 80° and 6 mm ms–1 respectively for SS 304 material and 2 mm, 80° and 2 mm ms–1 for C80 material. [ABSTRACT FROM AUTHOR]

This study presents an experimental investigation on Al matrix composites (AMCs) reinforced titanium carbide (TiC) nano-particles produced by five accumulative roll bonding cycles and three cryorolling (CR) cycles. The microstructures and mechanical properties of composites were studied. The results exhibited consequentially improved mechanical properties for processed Al/TiC AMCs as the number of rolling cycles increased. The presence of TiC in Al matrix showed the combination of elastic modulus, hardness, yield, and ultimate tensile stress of 84 ± 2GPa, 86 ± 3HV, 240 ± 12MPa, and 308 ± 15MPa, respectively. The dispersion of TiC particles was improved with increasing in the number of rolling cycles, resulting in a decrease in porosity between the matrix and reinforcement. This phenomenon was attributed to the breakup of particle clusters and their subsequent uniform dispersion within the Al matrix under CR. The composite microstructure shows uniform TiC particle distribution and grain refinement in the Al matrix, which all contribute to the enhanced mechanical properties. [ABSTRACT FROM AUTHOR]

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During the thermoforming of fibre-reinforced thermoplastic (FRTP) organosheets, the desire to minimise tool temperatures leads to non-isothermal temperature profiles through the laminate thickness. The aim of this study was to understand the influence of these non-isothermal conditions on FRTP intra-ply shearing. Novel non-isothermal bias extension tests were conducted, revealing that an average between the isothermal shear curves of both laminate faces approximately represented the respective non-isothermal condition. However, these findings were irrespective of FRTP thickness, and only applied to laminates that wholly remained above the crystallisation onset temperature. Upon the onset of crystallisation in a single ply, the non-isothermal shear resistance skewed heavily towards that (within 5%) of the crystallised ply and inhomogeneous shear angles were observed. Non-isothermal thermoforming validated these findings with the presence of wrinkles on non-isothermal hemispheres in which a single ply had reached crystallisation. This reaffirms the importance of accurate thermal monitoring during FRTP processing. [ABSTRACT FROM AUTHOR]

Fatigue of cold formed parts is an important consideration especially in the automotive industry. Methods exist for predicting the fatigue of parts where the plastic deformation during forming is less than the uniform elongation. Nevertheless, many stamped parts include areas where forming strain exceeds uniform elongation. These areas are also very important in terms of high cyclic fatigue. Fatigue tests were carried out on these highly formed bodies. The results are presented in this paper. Also, a simple method is proposed for avoiding some common mistakes in fatigue evaluation. [ABSTRACT FROM AUTHOR]

A vacuum-assisted sheet former was used for analyzing water removal from refined bleached hardwood kraft pulp furnishes. The Schopper Riegler (SR) values of the studied furnishes ranged from 43 to 97. Water removal time increased significantly with increasing SR value; the water removal time for SR97 furnish was two orders of magnitude longer than for SR43. Retention behaved differently with different SR levels. Retention was approximately constant for SR43 and SR72, for SR85 retention was initially slightly lower, and for SR97 retention was initially very low. The clogging of the wire due to the fines was very strong for SR97. A simple model of flow resistance of the filtered sheet worked very well for SR43 and SR72, and the model worked reasonably well for SR85. However, for higher SR levels, a retention model is needed to predict accurately the water removal in real-life applications.

Understanding the thermoforming process for thermoplastic composites is of great importance to ensure the quality of the composite product but is difficult because of the complex material constitutive models and thermo-mechanical coupling in the thermoforming process. In this study, a woven fabric thermoplastic composite consisting of glass fiber and polyetherimide resin was thermoformed under one-sided cooling conditions. After the effective material properties are homogenized with newly developed, two-step asymptotic homogenization methods, and the temperature and pressure boundary conditions are measured experimentally, a 3D composite laminate sandwiched by interfacial layers and metal molds was finite element simulated in the macroscale. The simulated warpage, which was caused by the in-plane residual stresses, was consistent with the experimental results when reasonable tool–part interactions were considered. Subsequently, the temperature, displacement, strain, and stress were comprehensively discussed in terms of their spatial distribution, temporal evolution, and correlations with the others. [ABSTRACT FROM AUTHOR]

The demands on joining technology are constantly increasing due to the consistent lightweight construction and the associated increasing material mix. To meet these requirements, the adaptability of the joining processes must be improved to be able to process different material combinations and to react to challenges caused by deviations in the process chain. One example of a highly adaptable process due to the two-step process sequence is thermomechanical joining with Friction Spun Joint Connectors (FSJCs) that can be individually adapted to the joint. In this paper, the potentials of the adaption in the two-stage joining process with aluminium auxiliary joining elements are investigated. To this end, it is first investigated whether a thermomechanical forming process can be used to achieve a uniform and controlled manufacturing regarding the process variable of the temperature as well as the geometry of the FSJC. Based on the successful proof of the high and good repeatability in the FSJC manufacturing, possibilities, and potentials for the targeted influencing of the process and FSJC geometry are shown, based on an extensive variation of the process input variables (delivery condition and thus mechanical properties of the raw parts as well as the process parameters of rotational speed and feed rate). Here it can be shown that above all, the feed rate of the final forming process has the strongest influence on the process and thus also offers the strongest possibilities for influencing it. [ABSTRACT FROM AUTHOR]

According to the need of a certain gas transmission pipeline project, a Φ610 mmxl8 mm L290M SAWH pipe with ultra large SDR is researched and developed by a certain domestic company. Described here in the paper are the difficulties as concerned with the formation and welding operations which are encountered during the trial production process of the said SAWH pipe, and relevant adjustment and control measures as taken. Also analyzed are the physiochemical properties, the welding quality and the welding difficulties, etc. of the pipe. The results of the tests and inspections as made to the pipe show that all the technical indexes of the pipe are up to the applicable technical requirements. [ABSTRACT FROM AUTHOR]

Significant fluid–structure interaction is present in fiber metal laminate forming with a low viscous matrix. A modular, process-inspired test setup is presented for one-dimensional saturated and unsaturated infiltration experiments for fiber metal laminates. Permeability measurements for different fabric orientations, fabric layers, and fiber volume contents show low scatter and good repeatability for fiber volume contents up to 65%. Fiber metal laminate specimens were formed by exchanging the mid-segment of the test setup with a punch and die. The stiffness differences between metal and fabric lead to remarkably high compactions in the bending radii, significantly reducing the flow during infiltration. Contrary to resin transfer molding processes, no formation of resin-rich zones along bending edges occurs due to the high normal pressures from metal forming. A numerical forming simulation was developed to predict the local fiber volume content. Comparing the experimental results with the numerical simulation shows that the high fiber volume content in the radii almost exclusively impacts the overall permeability. Implications for fiber metal laminate processing and modeling are outlined. [ABSTRACT FROM AUTHOR]

The design of structures using advanced composite materials such as fiber metal laminate requires an in‐depth understanding of their deformation behavior and response to the discontinuities in the structures. In the present study, a GLARE kind of fiber metal laminate in 2/1 configuration was fabricated in the form of conical frustum. Three cut‐outs of two different shapes such as circular and square were intentionally made at the center of the frustum at an angular distance of 120°. The quasi‐static compression test was conducted to determine the crashworthiness characteristics of laminate frustums with cut‐out and the results were compared with perfect frustum. The study showed that the laminate with cut‐out undergone for inward buckling near the discontinuities. Apart from that, the delamination and outward buckling were noted in the edges of the cut‐outs. The energy absorption of laminate frustum with circular cut‐outs was observed to be better than square cut‐outs. The performance of laminate frustums with cut‐outs was ranked using Technique for Order Preference by Similarity to an Ideal Solution technique. A finite element analysis was carried out to simulate the deformation behavior of laminate frustum with cut‐outs and the numerical results of deformation mode closely represented the experimental results. [ABSTRACT FROM AUTHOR]

In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of a DED-LB/M process using a laser power of 600 W and a feed rate of 400 mm/min and a subsequent forming process, in which the structure is upset with a hydraulic press using a constant forming force of 500 kN in order to smooth the surface and influence the accuracy of the components. For the generation of a fundamental process understanding, a cuboid, basic shape was chosen as geometry for the investigations. The aim is to improve part properties by applying the process steps to generate part properties, which are superior to solely additive manufactured material. It is shown that the geometry of additive manufactured structures can be adapted, and the top surface can be smoothed due to the forming operation. The mean roughness value Rz decreases up to 50% after the forming operation. The hardness can be increased by work hardening. Of special interest is that the higher hardness can be kept up even though a further DED-LB/M process step and forming operation are applied to the additively manufactured and formed structure again. Finally, an analysis of the new manufacturing approach regarding its potential is given. [ABSTRACT FROM AUTHOR]

In this work, a new welding method, AC-DC hybrid TIG welding, is used to weld 304 stainless steel. Research on the formation, microstructure, and properties of 304 stainless-steel welded joints are studied by using optical microscope and microhardness. The results show that the weld with AC/DC hybrid welding is a fish-scale pattern, and the density of the fish-scale pattern increases with the increase of AC proportion. Both the weld penetration and the ratio of weld penetration to weld width are the highest when AC accounts for 30%. At this point, the weld penetration is 0.83 mm larger than DC mode, an increase of 93.26%, and the ratio of weld penetration to weld width is 1.6, which is 76.19% higher than DC mode. When the proportion of AC is increased, the microstructure of the weld is equiaxed or columnar, and the microstructure of the heat-affected zone is ferrite in the form of lath. The hardness of the weld is greater than that of the base metal, and the hardness of the heat-affected zone is the lowest. The microhardness distribution of the weld with AC 50% is the most uniform. When AC accounts for 20% and 30%, the average weld hardness is the highest, which are 196.7 HV and 198.1 HV, respectively. [ABSTRACT FROM AUTHOR]

This paper is focused on investigating the mechanisms associated with different failure modes of copper (C101) sandwich panels with honeycomb cores of different heights subjected to flexural loading. Honeycomb core is made up of copper strips which were formed to required shapes using Dies fabricated by Electric Discharge Wire cut machining technique. All the joints in the sandwich panel were established through Brazing technique. Three-point bending test was conducted as per ASTM standard C-393. It was observed that increase in height of the core resulted in panels with higher strength to weight ratio. It also exhibited higher stiffness to weight ratio and very high strain energy absorption ability. An increase in flexural strength was reported with a maximum of 43% improvement for 10.9 mm core compared to 6.9 mm core. Further, 81.75% increase in absorbed strain energy was reported for 10.9 mm thick panel compared to 6.9 mm. The Optical and scanning electron microscope (SEM) analysis confirmed the establishment of good bonding between the filler and the substrate. Energy-dispersive Spectroscopic (EDS) analysis revealed the presence of Cu, Al, Zn, SiO2 and CaCO3 in the substrate. Further it also revealed the presence of Cu, CaCO3 and GaP in the filler material. The failure mode map was constructed which can be used for predicting different types of failures more likely to occur for specific parameters of copper sandwich panel. The dominant failures occurred during testing was in good agreement with the prediction done through failure mode map. The appreciable results in the proposed research may be supportive in construction of cooling system. The structure development and process control are convenient in mass production in automobile industries.

Bio Forming in Nature to Create Textile Printing Design for Hospitalization HouseResearch SummaryThe vast universe around us always pushes us to think, contemplate and learn. Nature is the basis on which all sciences and arts are based, and from this standpoint, the inspiration the structural and forming systems of all the vital forms of living creatures around us will enrich the field of textile printing design, especially if our destination is design for psychological support and resisting the repercussions of disease for the recovered and sick to improve their visual environment in the places of receiving treatment ( hospitalization) by applying the requirements of the healing environment and resisting disease through communicating with nature and its aesthetic values, which are derived and inspired by micro and ultrafine morphological details of cells of living organismswith interest in using color that has a positive impact on Human health to design psychologically which supports recoverees from illness . The design aims to meet all human requirements, which vary between functional and psychological requirements, and ignoring one of these requirements is a deficiency in the design process itself. The research problem is summarized in the use of the biological structure of living organisms to find innovative design solutions for textile printing fabrics for hospitalization rooms, which in turn contribute to Psychological support for recovered and sick people.The importance of the research is summarized in the development of a methodology to take advantage of the aesthetic values of biological forms under the microscope as one of the sources of creativity and psychological support for the recovered and sick people, inspiration for the biosynthesis of nature is an important moral message for the recovered and the sick. It is also an important trend for a textile printing designer, in-depth study enables us to understand the laws and relationships that are govern the natural systems around us, so attention must be paid to the designer's role towards his community in its various categories with attention to the psychological aspect of the users and the need to study in depth the modern trends of design and combine them with the design of textile printing.Key words : Bio formation - Hospitalization House

The main idea behind “Quilted Stratum Process” (QSP®) is to create a flat blank made of unidirectional/woven thermoplastic prepreg patches instead of using uniformly shaped prepreg stack as is the case with standard thermostamping process. Thus, using QSP®; one can manufacture components with complex geometries by using nearly rectangular patches while still maintaining a short cycle time similar to the standard thermostamping process. The use of near-rectangular patches results in a significant material saving which is a necessity for a sustainable product development. During standard thermostamping and/or QSP®; the consolidation phase plays a key role in the strength and quality of the final product. This becomes even more important in the case of unidirectional thermoplastic prepregs where mechanisms such as transverse squeeze flow can impact not only the in-plane dimensions of the prepreg but also the fibre orientations within the prepreg. This work presents a unified modeling approach that combines a novel pinching shell element, a new elasto-plastic constitutive model for pinching shell in order to provide a unified solution to simulate both forming and consolidation-flow using a shell-based approach. This unique unified approach of simulating forming and consolidation provides a set of additional outputs such as the through-thickness stress, final deformed shape of the plies including the squeeze flow effect and the changes in the orientation of fibres within the plies during and after the process. This work finally demonstrates how this information can help the manufacturers to design better tooling based on the outcomes of the numerical process simulation in order to achieve a desired product quality. Additionally, one can also steer the final fibre orientation which results from the initial position of the patch, its forming and squeeze flow.

The automotive industry has undergone significant advancements and changes over time, resulting in the use of more complex parts in modern vehicles. As a consequence, the parts used in the manufacturing process are subject to higher stress levels, which reduce their service life. To mitigate this issue, surface treatments can be applied to improve the mechanical properties of the tools. In this study, we examined the impact of surface treatments on reducing tool stress during a cold forming process. The process involved reducing the thickness of a sheet from 6 mm to 2.5 mm, which generated high stresses in the tooling. We used finite element stress calculations to analyze the process and found that by reducing the friction coefficient to 0.1, tool stresses can be reduced by 20%, leading to an increase in tool life. Moreover, the press force and tool wear were also reduced by 18%. To validate the theoretical calculations, we performed field tests in a real manufacturing process. [ABSTRACT FROM AUTHOR]

This study reports a counterintuitive antisymmetric deformation behavior during the electrohydraulic sheet-forming process, which is induced by the positional eccentricity of the electrical explosion. The novelty lies in the antisymmetry between the explosion eccentricity and the position of maximum deformation. When the explosion position is eccentric, the sheet metal becomes naturally eccentric; however, herein the position of maximum deformation was found to be far away from the position of the eccentric explosion, instead of being close to it. Herein, a series of simulations was performed to understand the dynamics involved in such behavior. It was found that the shockwave pressure and the inertial force of water medium are two dominant mechanisms for such an antisymmetric phenomenon. The former tends to accelerate the explosion-side sheet region, and the latter tends to accelerate the explosion-opposite-side sheet region. The much longer duration of the inertial force of water finally results in the observed antisymmetric phenomenon. The experimental results of the high-velocity deformation process obtained by using a high-speed camera confirmed the abovementioned findings. This study may aid in better understanding of the process dynamics in the eccentric explosion electrohydraulic forming, and may also help in the process and equipment design. [ABSTRACT FROM AUTHOR]