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Additive manufacturing has the potential to repair high value components, saving significant time and resources; however, the level of reliability and performance of additive repairs is still relatively unknown. In this work, the structure–property and performance of laser wire additive manufacturing repairs in 1100 aluminum are investigated. Two types of intentional damage are inflicted on the samples and subsequently repaired with pulsed laser deposition additive manufacturing. Quasi-static (10 − 3 s − 1 ) and high strain-rate (10 − 3 s − 1 ) mechanical testing is carried out with in situ diagnostics and post-mortem imaging. The results show that while the quasi-static strength and ductility of samples with a repaired region are lower than a pristine sample, the dynamic strength under shock loading is comparable. This work highlights both the potential utility of additive manufacturing for repair purposes, the significant risk of compromised performance of additive parts under specific conditions, and the need to test at varying strain rates to fully characterize material performance. [ABSTRACT FROM AUTHOR]

Parts manufactured by wire arc additive manufacturing (WAAM) are characterized by a peculiar surface morphology, namely, surface waviness, that negatively affects the fatigue performance. To exploit the full potential of WAAM and minimize the need for postproduction work, it is crucial to utilize the components in the as‐built state. This is because conventional machining techniques, typically employed for postprocessing operations, severely curtail the freedom of geometry of the components. This study focuses on an experimental and numerical characterization of the notch effect of the surface waviness for an AISI 308 LSi stainless steel. This is done by quantifying the fatigue notch factor in a probabilistic fashion, considering the results of ad‐hoc designed fatigue tests. A finite element model is developed by considering a 3D scan of the geometry of WAAMed plates, allowing to determine the theoretical stress concentration factor. The fatigue notch factor is also estimated from the numerical model by making use of the gradient correction according to the FKM guidelines. To validate the numerical approach, test data produced for different testing conditions are correlated by using the local stress approach, showing that classical methods are also applicable to additive manufactured parts. Experimental determination of notch effect of as‐built surface in thick WAAMed plates. An FE model is formulated to estimate fatigue notch factor using FKM guidelines S‐N curves for WAAMed specimens of AISI308LSi steel at different load ratio. [ABSTRACT FROM AUTHOR]

The paper presents the findings of research on the production of wire from 850 and 585 platinum-based alloys intended for use in jewelry chains. The chemical compositions of two novel jewelry alloys of 585 platinum-containing modifying additives of rhodium and ruthenium are proposed and patented. An analysis was carried out to evaluate the existing section rolling and drawing schedules for the three platinum alloys to identify more efficient drafting methods, with a focus on reducing the labor intensity of metal deformation processes and minimizing the force parameters. A computer model of section rolling for the studied jewelry alloys, based on 850 and 585 platinum, was developed to analyze the shape variation and force parameters of the process and to propose a new deformation schedule for the studied alloys with the accepted reduction distribution per pass. The new deformation schedule was characterized by a more uniform reduction distribution per pass than that observed in the existing schedule, allowing the number of rolling passes to be reduced due to their redistribution. In order to determine the rolling force and to model the process, an approximation formula was used to calculate the time resistance, which is dependent on the total degree of compression. By using proprietary software and computer simulation, the parameters of wire drawing with a diameter of up to 0.25 mm from the studied alloys were calculated, which allowed the deformation and force parameters to be assessed when implementing the proposed drafting schedule. In addition, it was established that the drawing process exhibits a sufficiently high safety factor and low power consumption. It is therefore recommended that the process be subjected to industrial testing. The findings of this research can be recommended for improving the technology of wire manufacturing from the 850 and 585 platinum alloys intended for jewelry chains. [ABSTRACT FROM AUTHOR]

This paper takes the single-wall wall manufactured by wire arc additive manufacturing (WAAM) as the research object and compares it with the as-cast aluminum alloy with the same series. By using feed rate, cutting depth, spindle speed, etc., as single or compound parameters, the machinability of the sample is analyzed. The results indicate that the influence of varying parameters on the as-deposited aluminum alloy follows the order of feed rate > cutting depth > spindle speed. As the feed rate increases, the surface roughness initially decreases and then increases, with the optimal surface quality achieved at 12 mm/s (with a surface roughness of 2.013 μ m ). Different from the as-deposited alloy, the influence of the parameters on the as-cast alloys follows the order of spindle speed > cutting depth > feed rate. The experiments reveal that, for both as-deposited and as-cast states, the trends of the impact of cutting depth and spindle speed on surface quality are consistent. However, at low feed rates (2–12 mm/s), for as-deposited states, the surface quality of as-deposited samples becomes smoother as the feed rate increases (contrary to common knowledge). This result can be attributed to the elevated milling temperature, which softens the material, making it easier to remove and reducing the surface roughness. [ABSTRACT FROM AUTHOR]

Hybrid manufacturing combines the simultaneous benefits of additive manufacturing (complex geometries, part consolidation, and mass customization) with the advantages of subtractive manufacturing (superior surface finish and enhanced dimensional accuracies) by integrating a suite of complementary traditional processes into a base platform of additive manufacturing. The use of hybrid technology has grown in recent years given its capabilities on repairing metallic structures, producing parts with conformal cooling features, and manufacturing functionally graded products. These kinds of capabilities are of great interest to the medical implant, energy, automotive, maritime, and aerospace industry sectors, among many other fields. This work investigated the mechanical properties of stainless steel (SS) 316L as a function of different tool paths strategies using an integrated 5-axis CNC hybrid Mazak system with a laser hot wire deposition system (LHWDS). This study includes the evaluation of different printing parameters and their impact on the quality of the printed bead as well as the incorporation of a structure–property material relationship based on the mechanical performance of the manufactured coupons. [ABSTRACT FROM AUTHOR]

The revision of ceramic inlays of acetabular cups is a challenging surgical procedure. The mechanical impact during the inlay extraction process can damage the ceramic or metal cup rim. To avoid these risks, a concept for a new revision procedure was developed. It is based on an actuator system, which allows a non-destructive release of the ceramic inlay. To integrate the actuator system, different design concepts of acetabular cup components were investigated, and an actuator based on shape-memory alloy (SMA) wires was developed. The process chain for the actuator, starting from nickel-titanium wires manufactured into the actuator geometry by laser welding and thermo-mechanical treatment for the shape setting process up to the functionality evaluation of the actuator system, was implemented on a laboratory scale. The new revision procedure is based on a phase transformation of the SMA wire actuator, which was obtained through two methods—applying an electrical current by an instrument and rinsing the wire with heated water. The phase transformation of the actuator resulted in a contraction between 3.2% and 4.3% compared to its length after pre-stretching and was able to release the ceramic inlay from the cup. Therefore, the developed actuator design and process chain is a proof of concept towards a new revision procedure for modular acetabular cups. [ABSTRACT FROM AUTHOR]

In the single-pass multilayer deposition process of laser wire additive manufacturing, variations in process parameters significantly influence the morphology of the deposited layer. This study experimentally investigates how the main process parameters (laser power, scanning speed, and wire feeding speed) affect the morphology of the deposited layer. It was found that each parameter has distinct effects on the geometrical morphology of deposition. Simultaneously, aiming to enhance the surface topography of the deposited layer and its bonding with the substrate, three optimization objectives are defined. An optimization model is then constructed using experimental data to refine the process parameters. The optimal parameters are determined through experimentation, resulting in significant enhancement of the deposited layer's topography. [ABSTRACT FROM AUTHOR]

The main objective of this work was to propose and evaluate a methodology for shielding-gas selection in additive manufacturing assisted by wire arc additive manufacturing (WAAM) with an austenitic stainless steel as feedstock. To validate the proposed methodology, the impact of multi-component gases was valued using three different Ar-based blends recommended as shielding gas for GMA (gas metal arc) of the target material, using CMT (cold metal transfer) as the process version. This assessment considered features that potentially affect the building of the case study of thin walls, such as metal transfer regularity, deposition time, and geometrical and metallurgical characteristics. Different settings of wire-feed speeds were conceived to maintain a similar mean current (first constraint for comparison's sake) among the three gas blends. This approach implied different mean wire-feed speeds and simultaneously forced a change in the deposition speed to maintain the same amount of material deposited per unit of length (second comparison constraint). The composition of the gases affects the operational performance of the shielding gases. It was concluded that by following this methodology, shielding-gas selection decision-making is possible based on the perceived characteristics of the different commercial blends. [ABSTRACT FROM AUTHOR]

Traditional ACSR overhead wires, which consist of a high-strength steel core and several layers of aluminium wires, are currently the most popular overhead line conductor (OHL) design globally. Operating conditions, particularly operating under varying stresses from Karman vortices, lead to the fatigue cracking of wires of the outer layer, followed by wires of the inner layers. Karman vortices are formed by the detachment of a laminar wind stream flowing around the conductor, which causes vibrations in the conductor called wind or aeolian oscillations. Aluminium wires are manufactured using standard batch material drawing technology. Although the fatigue strength of such wires is not standardised, there are various criteria for evaluating this characteristic, as well as established limits on the number of cycles needed to break the first wires of the outer layer. Fatigue strength also strongly depends on the geometric structure of the wire and its operating conditions. The article analyses the influence of the mechanical condition of aluminium wires used in ACSR cables on their fatigue strength. We then present results from aluminium wire fatigue tests conducted on a specially constructed test rig. In addition, fatigue cracks were interpreted using scanning microscopy. [ABSTRACT FROM AUTHOR]

We employed a novel technique combining wire and powder co-delivery to fabricate a functionally gradient material (FGM) structure consisting of Al-based composites reinforced with alternating TiC and B4C particles. The TiC content increases from the bottom up and then decreases, while the B4C content gradually increases, resulting in a continuous gradient structure. Correspondingly, the grain size of the Al matrix also changes with the variation of ceramic particles, forming a dual-gradient change trend. This FGM structure exhibits a multi-performance balance of strength, ductility, anti-wear and damping properties, making it a promising candidate for the cost-effective application in multi-performance heterostructured components. This article reports a novel technique to manufacture FGM structures using a wire-and-powder co-delivery method. The resulting dual-gradient TiC-B4C/Al composite structure exhibits a balance of strength, ductility, anti-wear and damping. [ABSTRACT FROM AUTHOR]

Using neutron diffraction we determined internal residual stress in the stainless steel AISI 310S carrier tape with a thickness of 100 µm and a width of 4 mm after mechanical polishing and the ABAD deposition of the textured YSZ buffer layer. It is shown that mechanical polishing causes a slight distension of the tape in the rolling plane. After the deposition of the YSZ layer, uniform tensile stress of 70 MPa isotropic in the rolling plane was observed inside the tape. Calculations have shown that it results from relaxation of compressive stress acting on the surface of the tape in a layer several times thicker than the YSZ layer. It is assumed that the surface of the tape is plastically deformed during the YSZ deposition. [ABSTRACT FROM AUTHOR]

This paper discusses the mechanical failure analysis of Inconel 625 parts fabricated through the Wire and Arc Additive Manufacturing (WAAM) process. Three additive structures were manufactured with three inter-pass layer temperatures (IPT), such as 100, 200, and 300 °C. The tensile specimens were extracted from the additive structure in three principal orientations to evaluate the failure behavior concerning the deposition layer longitudinal (IN625-L), transversal (IN625-T), and diagonal orientations (IN625-D). Grain morphology and grain size varied with different inter-pass layer temperatures. An electromechanical tensile testing machine was used to conduct standardized testing to evaluate the tensile properties. The tensile curves were plotted to describe the tensile strength of the components in three orientations. The mechanical anisotropy and failure behavior of different orientations were defined with the grain boundaries and grain size. Compared to the other two orientations, IN625-D has a higher tensile strength. Because of their distinct orientations, the IN625-L and IN625-T specimens contain more elongated grains, and the IN625-D specimen has more grain boundaries. The strength obtained from grain boundaries is more significant than individual grains. [ABSTRACT FROM AUTHOR]

Due to its simplicity, accuracy, and adaptability, Crimp Force Monitoring (CFM) has long been the standard for fault detection in wiring harness manufacturing. However, it necessitates frequent reconfigurations based on the variability in materials, dependency on operator skill, and high costs of implementation, and thus reconfiguration presents significant challenges. To solve these problems, this paper introduces a fault detection system that employs an Artificial Intelligence (AI) classification model to enhance the performance and cost-efficiency of the quality control process of wiring harness manufacturing. Since there are no labeled data to train the classification model at the onset of manufacturing, a small number of normal data from each production run are manually extracted to train the model. To address the constraint of the limited available data, the system generates synthetic data from normal data, simulating potential defects by using Regional Selective Data Scaling (RSDS). This innovative method performs upscaling or downscaling on specific regions of the original data to produce synthetic abnormal data, which enables the fault detection system to efficiently train its classification model with a dataset consisting solely of normal operation data. [ABSTRACT FROM AUTHOR]

The article proposes the development of a layered process monitoring strategy based on multi-block kernel principal component analysis (MBKPCA). MBKPCA aids in the development of a distributed process monitoring strategy by taking into account the nonlinear relationships existing amongst the measured characteristics. A distributed process monitoring strategy stratifies the proposed process into a multi-layered structure comprising of blocks, sub-blocks etc. In this article, an MBKPCA-based monitoring strategy was devised for a wire rod manufacturing facility (WRMF) of an integrated steel plant (ISP). The proposed monitoring strategy stratified the entire process into 3 layers, with the first layer comprising the manufacturing stages, the next layer comprising the sub-stages and the third layer comprising the characteristics to be monitored within the respective sub-stages. The detection of the fault was carried out with the aid of kernel principal component analysis (KPCA) score–based Hotelling T2 chart. Fault detection was followed by fault diagnosis, for which new fault diagnostic statistics were proposed which took into account the contribution of the main and the auxiliary characteristics. The study also proposed the concept of cumulative percent contribution ratio (CPCR) to limit the number of parameters (stages/sub-stages/characteristics) that needs to be retained in fault diagnosis. [ABSTRACT FROM AUTHOR]

Most manufactured electrical cables suffer from reductions in their physical, mechanical and electrical properties. These setbacks are mainly attributed to the improper control of wire tension during the cable manufacturing process. Hence, this paper systematically reviewed different control algorithms involved in controlling tension in moving webs, which include conventional control, advanced control, observer-based control, artificial intelligence-based control and hybrid control techniques. Thus, the review provided information about existing tension control techniques in moving webs, including their strengths and weaknesses. It was observed in this review that although a significant research effort has been made on web tension control systems, a thorough literature review is still lacking. It was concluded that controller optimisation using hybrid control algorithms is gaining popularity in web tension control due to their improved control response. Hence, its application in wire tension control can better help cable manufacturers improve the quality of manufactured cables. [ABSTRACT FROM AUTHOR]

Micro-tools comprising difficult-to-machine materials have seen widespread application in micro-manufacturing to satisfy the demands of micro-part processing and micro-device development. Taking micro-shafts as an example, the related developmental technology, based on wire electric discharge grinding (WEDG) as the core method, is one of the key technologies used to prepare high-precision micro-shafts. To enable efficient and high-precision machining of micro-shafts with target diameters, instead of performing multiple repeated on-machine measurements and reprocessing, a geometric constraint strategy is proposed based on the previously introduced twin-mirroring-wire tangential feed electrical discharge grinding (TMTF-WEDG). This strategy encompasses the tool setting method, tangential feed distance compensation, and an equation that establishes the relationship between tangential distance and diameter variation. These components are derived from a key points analysis of the geometric constraints. The micro-shafts with diameters of 50 µm and consistencies of ±1.5 µm are repeatedly processed. A series of micro-shafts with diameters ranging from 30 µm to 120 µm achieve geometric constraints with a diameter accuracy of ±2 µm, accompanied by the complete continuous automation of the entire process. Accordingly, it can be concluded that the geometric constraint strategy is flexible and stable and can be controlled with high precision in the TMTF-WEDG process. [ABSTRACT FROM AUTHOR]

The replacement of gold bonding wire with silver bonding wire can significantly reduce the cost of wire bonding. This paper provides a comprehensive overview of silver wire bonding technology. Firstly, it introduces various types of silver-based bonding wire currently being studied by researchers, including pure silver wire, alloy silver wire, and coated silver wire, and describes their respective characteristics and development statuses. Secondly, the development of silver-based bonding wire in manufacturing and bonding processes is analyzed, including common silver wire manufacturing processes and their impact on silver wire performance, as well as the impact of bonding parameters on silver wire bonding quality and reliability. Subsequently, the reliability of silver wire bonding is discussed, with a focus on analyzing the effects of corrosion, electromigration, and intermetallic compounds on bonding reliability, including the causes and forms of chlorination and sulfurization, the mechanism and path of electromigration, the formation and evolution of intermetallic compounds, and evaluating their impact on bonding strength and reliability. Finally, the development status of silver wire bonding technology is summarized and future research directions for silver wire are proposed. [ABSTRACT FROM AUTHOR]

Form-cutting tools are an economical choice for turning parts with defined profiles in mass production. The effects of the form contour of these tools—produced by the wire electrical discharge machining (WEDM) process—on tool quality were investigated in this research. This study focuses on reducing the adverse effects of the recast layer induced by WEDM on form-cutting tools. The basic component types of profile forms in form-cutting tools can be summarized by a combination of four modes, i.e., concave and convex arcs and flat and oblique surfaces. Hence, sample cutting tools with three different radii of convex and concave arcs and a flat surface were produced. During the WEDM operation, one-pass mode was used for roughing, two passes for semi-finishing, and three passes for finishing. Furthermore, the difference between the percentage of oxygen and carbon elements on the recast layer in the two areas above the workpiece or wire entry point and the bottom area of the workpiece or wire exit point was investigated. Finally, the influences of the direction, size of the curvature, and the number of passes in the wire electric discharge process on the recast layer were analyzed. It was observed that the recast layer thickness could be reduced by increasing the number of WEDM process. Additionally, the uniformity of the cutting contour was superior in the entry region of the wire going into the workpiece compared with the exit region of the wire. [ABSTRACT FROM AUTHOR]

A model for controlling the electrolytic phosphating process was established based on related theories. A general empirical formula for calculating the process condition i.e. electrical current for electrolytic phosphating during steel wire manufacturing with an independent power supply for single wire was derived and verified according to the actual production. [ABSTRACT FROM AUTHOR]

The superconducting joints of superconducting in situ MgB2 wires have been of great interest since the first MgB2 wires were manufactured. The necessity of joining fully reacted wires in applications such as NMR brings complexity to the methodology of connecting already reacted wires sintered under optimised conditions via a mixture of Mg + 2B and subsequential second heat treatment to establish fully superconducting MgB2 joints. Some of the data in the literature resolved such a procedure by applying high cold pressure and sintering at a low temperature. A topical review publication did not address in depth the question of whether cold sintering is a potential solution, suggesting that hot pressing is the way forward. In this paper, we discuss the potential joint interfacial requirements, suggesting a thermo-mechanical procedure to successfully form a superconductive connection of two in situ reacted wires in the presence of Mg + 2B flux. The critical current at 25 K of the researched junction achieved 50% Ic for an individual in situ wire. [ABSTRACT FROM AUTHOR]

Wire harness manufacturing in the aeronautic sector is highly manual work, with production defined by multiple references and small batches. Although complete automation of the production process is not feasible, a robot-assisted approach could increase the efficiency of the existing production means. This paper presents a novel dual-arm robotic solution for workbench configuration and cable routing during the initial steps of wire harness manufacturing. Based on the CAD information of the wire harness, the proposed framework generates trajectories in real-time to complete the initial manufacturing tasks, dividing automatically the whole job between both robots. The presented approach has been validated in a production environment using different wire harness references, obtaining promising results and metrics. [ABSTRACT FROM AUTHOR]

In this research, a comparison between two methods of grinding and WEDM and the chip formation of each form tool was studied through a set of designs of experiments. A multi-functional form tool with different cutting-edge shapes was designed to compare different production methods, and a grinding machine and a five-axis wire-cutting machine were made. The form tools by the wire cutting method were made with three different machining states, rough, semi-finish, and finish. The results of the experimental test showed that the chip formation of the finished surface of the wire cut tool was close to the ground tools. Additionally, the tool life in wear generation was assessed, revealing that the tool generated through the wire-cutting method with three passes exhibited superior performance compared to alternative approaches. Furthermore, employing the wire-cutting technique with high surface finishing yielded optimal outcomes for producing form-cutting tools featuring complex profiles. [ABSTRACT FROM AUTHOR]

Microstructure and mechanical properties of in situ Cu-7.7Nb microcomposite (MC) wires manufactured by cold drawing with intermediate heat treatment (HT) have been studied. The evolution of Nb filaments morphology under various steps of deformation and modes of intermediate HT have been studied by the SEM and TEM methods. According to X-ray analysis, internal microstresses accumulate in the niobium filaments of the drawn MC, leading to a decrease in ductility. After heat treatment, the ductility of the wire increases significantly, since the microstresses in the niobium decrease even at the lowest HT temperature. The strength of the composite decreases under the HT because of negative changes in morphology and interface density of Nb filaments. The <110>Nb texture is stable under the HT up to 800 °C. The Nb filaments morphology and semi-coherent boundaries at Cu/Nb interfaces are restored under the post-HT cold drawing, leading to a sharp increase in the strength of the MC wire. Reducing the niobium concentration to 7.7%Nb relative to the traditional MC with 16–20%Nb and the recovery of the wire ductility under the HT makes it possible to obtain long-scale high-strength microwires with an extremely small diameter of 0.05 mm and high ultimate tensile strength of 1227 MPa. [ABSTRACT FROM AUTHOR]

A significant increase in roughness of dieless-drawn wires due to the strain-induced roughness phenomenon has been documented. For small-diameter wires, even a slight surface relief creates stress concentrations that may contribute to the wire breakage during cold drawing. This, in turn, significantly limits the achievable diameter of the product and the efficiency of drawing process. The present study, however, demonstrates that reducing the wire roughness is possible by combining the dieless and conventional drawing methods. Thus, it is possible to improve the process workability threefold when compared to dieless drawing alone, and the product quality is simultaneously improved. In addition, the surface defects typical to the dieless-drawn wires have been significantly reduced, resulting in an increase in the wire strength. This new combined technology enables a significant reduction in the wire diameter and facilitates an economical large-scale production of ultra-thin wires. In addition, based on the classic drawing and dieless drawing process, a brass wire with a diameter of 0.017 mm has been manufactured. Six times thinner than a human hair, it is believed to be the thinnest long brass wire currently manufactured in the world. [ABSTRACT FROM AUTHOR]

Structural strengthening is vital to improve the load-carrying capacity of partially or severely damaged Reinforced Concrete (RC) elements. Fiber Reinforced Polymers (FRPs) are widely used for strengthening purposes. In this study, use of Stainless-Steel Wire Mesh (SSWM) is explored, as FRPs are having limitations like high cost, less fire resistance, and brittle behavior. The experimental studies are conducted to evaluate the mechanical properties of the SSWM, to explore its feasibility as a strengthening material. Three different variants of SSWM i.e., 30x32, 40x32 and 50x34 are considered for the study. SSWM used in present study is a woven mesh made from stainless-steel wires manufactured in India. Important mechanical properties such as tensile strength and bond strength with concrete surface is experimentally evaluated in this study. Response of test specimens are evaluated with respect to ultimate load carrying capacity, corresponding deformations, rupture strain, and failure pattern. SSWM exhibits a tensile strength of 489.134-658.375 MPa which is comparable to tensile strength of various types of fibers used for strengthening. Based on experimental studies, it is found that SSWM 40x32 performs better in different aspects, so it can be a good alternative for strengthening of RC elements compared to other FRP materials. [ABSTRACT FROM AUTHOR]

In this paper, the authors introduce the reader to the state of the art of Metal Wire Additive Manufacturing (MWAM) and provide a comparison between Wire Arc Additive Manufacturing (WAAM), Wire Laser Additive Manufacturing (WLAM), and Laser Arc Hybrid Wire Deposition (LAHWD) based on their characteristics and potential future applications, since MWAM is expected to have a promising future in various areas, such as aerospace, automotive, biomedical, and energy fields. A detailed discussion of the benefits and drawbacks of each Metal Wire Additive Manufacturing process can help to improve our understanding of the unique characteristics of metal wire application. Therefore, this paper offers a comprehensive analysis that can serve as a reference for upcoming industrial projects and research initiatives, with the aim of helping industries choose the most appropriate WAM technique for their specific applications. [ABSTRACT FROM AUTHOR]

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This paper describes research on the influence the technology of zinc-coated steel wire manufacturing has on the energy and force parameters of the drawing process, energy consumption and zinc expenditure. In the theoretical part of the paper, the theoretical work and drawing power were calculated. Calculations of the electric energy consumption have shown that usage of the optimal wire drawing technology results in a 37% drop in energy consumption, which in the course of a single year translates to savings equal to 13 TJ. This, in turn, results in the decrease of CO2 emissions by tons and a total decrease of the eco-costs by approximately EUR 0.5 mln. Drawing technology also influences the losses of the zinc coating and CO2 emissions. Properly adjusted parameters of the wire drawing technology allow obtaining a zinc-coating that is 100% thicker, translating to 265 tons of zinc, whose production generates 900 tons of CO2 and incurs eco-costs equal to EUR 0.6 mln. Optimal parameters for drawing, from the perspective of decreased CO2 emissions during the zinc-coated steel wire manufacturing, are as follows: usage of the hydrodynamic drawing dies, angle of the die reducing zone α = 5°, and drawing speed of 15 m/s. [ABSTRACT FROM AUTHOR]

This paper presents a detailed study on the dimensional accuracy of Ti6Al4V parts manufactured by the wire feed laser directed energy deposition process as compared to the design data before any postprocessing, as the majority of the reported research is focused on the mechanical and microstructural properties of the manufactured parts. Due to the large layer thickness (1.2 mm) and high material deposition rate (15 mm/s), smaller rectangular samples were susceptible to more dimensional inaccuracies. Most of the samples have larger dimensions than the design data, which is favorable for postprocessing. Special consideration should be given to the Z axis as the top layer has the most curves on the periphery of the samples due to shrinkage upon cooling. Depositing the material along the periphery of the present layer at the start of each layer minimized the overflow of the molten alloy when the laser is near the edges of the model in each layer. Upon further inspection using an optical microscope and scanning electron microscope analysis, surfaces voids were observed. Only ∼0.5 mm was required to remove from each side to obtain a minimal crack-free flat surface. The microhardness of the samples ranged from 313.64 to 346.17 HV. [ABSTRACT FROM AUTHOR]

The demand for high-strength steels has continued to increase in various fields of industry due to the advancement in technology. The wire arc additive manufacturing (WAAM) enables the fabrication of high-strength structures from different materials by controlling the raw wire in layers. This study focuses on the fabrication of high-strength steel by WAAM using the gas metal arc welding + cold wire feeding (GMAW + CWF) technique. A new alloy was formed by simultaneously adding 316LSi stainless steel from the CWF to the low alloyed ER70S-6 steel from the GMAW torch. In this way, three different new alloyed structures were produced with varied 316LSi ratios ranging from 10 %, 20 % and 25 % respectively. Besides, their metallurgical and mechanical properties were compared with each other and with single material WAAMed structures. In the macrostructure examinations, no defects due to the mixture of both materials were found and both materials melted properly to create the new alloy. Due to the alloying elements transferred from 316LSi, the microstructure of the new material parts were completely changed compared to the single material WAAMed components and bainite and martensite phases were found in the new alloys. The hardness increased significantly compared to the single-material WAAMed structures and increased up to 139 % and 84 % compared to the single-material WAAMed ER70S-6 and 316LSi, respectively. The tensile strength showed a great improvement and reached almost 1200 MPa, increased by 142 % compared to the single-material WAAMed structure. The fabricated new alloys have the potential to be a candidate material for industries that use high-strength steel. • GMAW + cold wire feeding approach was implemented in the WAAM process. • New alloy parts were successfully fabricated from different two wires. • The tensile strength of the new alloys reached almost 1200 MPa. [ABSTRACT FROM AUTHOR]

This study shows that the hot wire is an effective way to reduce the amount of undesirable Laves phase during the repair of 718Plus components, which are detrimental to the mechanical properties. The complex relationship between microstructure and hotwire was studied in detail. Five damaged components were repaired by depositing the melted 718Plus wire onto the wrought substrate using directed energy deposition-arc (DED-arc). A finite element model was used to provide clues for the thermal process analysis. The hot-wire method enhanced the cooling rate of the molten pool and suppressed the remelting behaviour of secondary dendritic arms (SDA) in the reheated zone. The resultant microstructure contained refined dendrites with more obvious SDA, which allows the production of tiny reticular Nb-rich liquid spots between dendrites during final solidification stage. These spots beyond a threshold of Nb could cause eutectic reaction, leading to the morphologic transformation from long-stripped to granular Laves phase and a lower volume fraction. Moreover, the hot-wire method hindered the dynamic precipitation of γ' phase due to the shortened precipitation time, which was responsible for the inferior mechanical properties. The heat-treatment re-optimized the precipitation of γ' phase and further dissolved Laves phase to release more Nb for γ' phase, which leads to the improvement of strength about 10 %. [ABSTRACT FROM AUTHOR]

Al–Cu alloy components fabricated by laser wire additive manufacturing (LWAM) generally present coarse columnar grains and poor mechanical properties. This study proposes a new strategy, integrating an 8-shaped beam oscillation and laser directed energy deposition, to solve these issues. The impacts of oscillation frequencies and amplitudes on the energy flux distribution and macro morphology of the single-bead deposited layer are investigated. The influences of beam oscillation on the microstructural characteristics and tensile properties of Al–Cu alloys fabricated by oscillating laser wire additive manufacturing (O-LWAM) are revealed. A high-frequency oscillating laser achieves a uniform energy flux distribution and improves the surface quality of the deposited layer. The <100> texture in the O-LWAM specimen decreases markedly owing to the columnar to equiaxed transition. The Cu element content at grain boundaries in the O-LWAM specimen is reduced by 52.6 %. The ultimate tensile strength of O-LWAM specimens in the horizontal and vertical orientations reach 334.2 and 327.3 MPa, respectively, which increased by 40.7 % and 64.6 % compared to those of the LWAM specimen. The substantial enhancement in strength and plasticity is attributed to fine-grain strengthening. [ABSTRACT FROM AUTHOR]

In this study, we propose a technological system designed to provide machine vision-based automatic inspection and autonomous operation services for an entire process related to product inspection in wire harness manufacturing. The smart factory paradigm is a valuable and necessary goal, small companies may encounter steep barriers to entry. Therefore, the best approach is to develop towards this approach gradually in stages starting with the relatively simple improvement to manufacturing processes, such as replacing manual quality assurance stages with machine vision-based inspection. In this study, we consider design issues of a system based on the proposed technology and describe an experimental implementation. In addition, we evaluated the implementation of the proposed technology. The test results show that the adoption of the proposed machine vision-based automatic inspection and operation service system for multi-wire harness production may be considered justified, and the effectiveness of the proposed technology was verified. [ABSTRACT FROM AUTHOR]

The fatigue behavior of continuous wire polymer composite (CWPC) fabricated by fused filament fabrication (FFF) was investigated. Four compositions were examined: polylactic acid (PLA), PLA with copper wire (Cu), thermoplastic polyurethane (TPU), and TPU with Cu wire. Residual properties were measured after different sets of number of cycles (102, 104, 105). Residual strengths were 89.7% and 70.5% of the ultimate tensile strength of the original material after 105 cycles for PLA CWPC and TPU CWPC, respectively. A one‐way analysis of variance (ANOVA) statistical tests showed insignificant changes in the residual strengths of PLA‐based materials after an increasing number of cycles and significant changes for the TPU‐based materials. CWPC electromechanical properties under fatigue test demonstrated reverse piezoresistance behavior. A strain‐controlled fatigue life analytical model was compared with the experimental results showing good agreement. This study demonstrates the applicability of FFF technique to print sensors with continuous integrated wire with tunable properties. [ABSTRACT FROM AUTHOR]

Laser Wire Additive Manufacturing (LWAM) is a flexible and fast manufacturing method used to produce variants of high metal geometric complexity. In this work, a physics-based model of the bead geometry including process parameters and material properties was developed for the LWAM process of large-scale products. The developed model aimed to include critical process parameters, material properties and thermal history to describe the relationship between the layer height with different process inputs (i.e., the power, the standoff distance, the temperature, the wire-feed rate, and the travel speed). Then, a Model Predictive Controller (MPC) was designed to keep the layer height trajectory constant taking into consideration the constraints faced in the LWAM technology. Experimental validation results were performed to check the accuracy of the proposed model and the results revealed that the developed model matches the experimental data. Finally, the designed MPC controller was able to track a predefined layer height reference signal by controlling the temperature input of the system. [ABSTRACT FROM AUTHOR]

The susceptibility to deep processing in the industrial wire drawing process has been investigated in the research paper regarding the copper grade influence on the process. The conducted research included the identification of the mechanical and electrical properties of wires manufactured from Electrolytic Tough Pitch Copper (Cu-ETP) wire rod and Oxygen-Free Copper (Cu-OF) cast rod in terms of the applied deformation. In particular, as main contribution of this research to the scientific and industrial community a mathematical model describing the wire strengthening and softening characteristics was determined. [ABSTRACT FROM AUTHOR]

• The heat transfer and flow of laser wire additive manufacturing process are analyzed in detail.. • The deposition process of single pass multi-layers under different process parameters was simulated. • The single pass multi-layer deposition process was optimized by a laser power attenuation strategy. In the process of single track multi-layer aluminum alloy laser wire additive manufacturing, there is a lack of in-depth understanding of the heat transfer and dynamics within the melt pool, and it is difficult to characterize the flow behavior inside the melt pool. This paper introduces the numerical simulation of single-track multi-layer aluminum alloy laser wire additive manufacturing. Through numerical simulation methods, the continuous feeding of the wire is realized in the form of mass source terms. The results show that as the specific energy K increases, the length and depth of the molten pool gradually increase, the Marangoni force and thermal buoyancy are enhanced, and the flow speed of the molten pool gradually increases. As the number of layers increases, the heat accumulation between layers increases linearly. Finally, the laser attenuation strategy was adopted, and the laser power of each layer was decreased by 100 W. The flow mode in the molten pool transformed from non-rotational to rotational, and the flow velocity of the molten pool was reduced to 0.187 m/s, and the sedimentary layer with excellent geometric morphology was obtained. [ABSTRACT FROM AUTHOR]

The electroplated diamond wire saw has been widely used in the production of semiconductors, photovoltaic devices, etc. Composite electroplating is an important process in the production of electroplated diamond wire saws. The utilization of nickel (Ni)-coated diamonds is a widely adopted approach to enhance the efficiency of the composite electroplating process employed in the manufacturing of wire saws. However, the pristine diamond does not chemically react with Ni, and the interfacial bonding strength between the Ni coating and the diamond is relatively weak. This frequently results in the detachment of diamonds from the Ni coating during the cutting process. To solve this problem, titanium (Ti)-coated diamonds were used in the preparation of wire saws. We had specially developed a vacuum slow evaporation technology to produce diamond micro-powder (8 μm) with uniform conductive Ti coatings that were firmly bonded with diamond through the interfacial product TiC. A series of electrochemical test results were used to demonstrate the effect of Ti coating on the composite electroplating process. The linear scanning voltammetry curves showed that the addition of Ti-coated diamond shifted the overpotential of composite electroplating in a positive direction, so it promoted the electrodeposition reaction more than diamond powder. The electrochemical impedance spectroscopy revealed that the conductive Ti-coated diamond reduced the charge transfer resistance during composite electroplating. The Ti-coated diamond micro-powder was completely enveloped by an electroplated Ni layer, and TiC formed between the Ti coating and the diamond provided a stronger interfacial bonding force compared to that of the Ni-coated diamond micro-powder. After cutting, the Ti-coated diamond was found not to fall off the wire saw. The use of Ti-coated diamond micro-powder as an abrasive will significantly improve the product quality of mass-produced electroplating diamond wire saws. [Display omitted] • Ti-coated diamond was prepared by vacuum slow evaporation technology. • Uniform Ti coating was chemically bonded to diamond by interfacial product TiC. • Ti-coated diamond wires exhibited superior resistance to abrasives fall off. [ABSTRACT FROM AUTHOR]