Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects s...Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects such as porosity issues, significant deformation, surface cracks, and challenging control of surface morphology encountered during the selective laser melting(SLM) additive manufacturing(AM) process of specialized Micro Electromechanical System(MEMS) components, multiparameter optimization and micro powder melt pool/macro-scale mechanical properties control simulation of specialized components are conducted. The optimal parameters obtained through highprecision preparation and machining of components and static/high dynamic verification are: laser power of 110 W, laser speed of 600 mm/s, laser diameter of 75 μm, and scanning spacing of 50 μm. The density of the subordinate components under this reference can reach 99.15%, the surface hardness can reach 51.9 HRA, the yield strength can reach 550 MPa, the maximum machining error of the components is 4.73%, and the average surface roughness is 0.45 μm. Through dynamic hammering and high dynamic firing verification, SLM components meet the requirements for overload resistance. The results have proven that MEM technology can provide a new means for the processing of MEMS components applied in high dynamic environments. The parameters obtained in the conclusion can provide a design basis for the additive preparation of MEMS components.展开更多
The operation of deep-sea underwater vehicles relies entirely on onboard batteries.However,the extreme deep-sea conditions,characterized by ultrahigh hydraulic pressure,low temperature,and seawater conductivity,pose s...The operation of deep-sea underwater vehicles relies entirely on onboard batteries.However,the extreme deep-sea conditions,characterized by ultrahigh hydraulic pressure,low temperature,and seawater conductivity,pose significant challenges for battery development.These conditions drive the need for specialized designs in deep-sea batteries,incorporating critical aspects of power generation,protection,distribution,and management.Over time,deep-sea battery technology has evolved through multiple generations,with lithium(Li)batteries emerging in recent decades as the preferred power source due to their high energy and reduced operational risks.Although the rapid progress of Li batteries has notably advanced the capabilities of underwater vehicles,critical technical issues remain unresolved.This review first systematically presents the whole picture of deep-sea battery manufacturing,focusing on Li batteries as the current mainstream solution for underwater power.It examines the key aspects of deep-sea Li battery development,including materials selection informed by electro-chemo-mechanics models,component modification and testing,and battery management systems specialized in software and hardware.Finally,it discusses the main challenges limiting the utilization of deep-sea batteries and outlines promising directions for future development.Based on the systematic reflection on deep-sea batteries and discussion on deep-sea Li batteries,this review aims to provide a research foundation for developing underwater power tailored for extreme environmental exploration.展开更多
Large-aperture optical components are of paramount importance in domains such as integrated circuits,photolithography,aerospace,and inertial confinement fusion.However,measuring their surface profiles relies predomina...Large-aperture optical components are of paramount importance in domains such as integrated circuits,photolithography,aerospace,and inertial confinement fusion.However,measuring their surface profiles relies predominantly on the phase-shifting approach,which involves collecting multiple interferograms and imposes stringent demands on environmental stability.These issues significantly hinder its ability to achieve real-time and dynamic high-precision measurements.Therefore,this study proposes a high-precision large-aperture single-frame interferometric surface profile measurement(LA-SFISPM)method based on deep learning and explores its capability to realize dynamic measurements with high accuracy.The interferogram is matched to the phase by training the data measured using the small aperture.The consistency of the surface features of the small and large apertures is enhanced via contrast learning and feature-distribution alignment.Hence,high-precision phase reconstruction of large-aperture optical components can be achieved without using a phase shifter.The experimental results show that for the tested mirror withΦ=820 mm,the surface profile obtained from LA-SFISPM is subtracted point-by-point from the ground truth,resulting in a maximum single-point error of 4.56 nm.Meanwhile,the peak-to-valley(PV)value is 0.0758λ,and the simple repeatability of root mean square(SR-RMS)value is 0.00025λ,which aligns well with the measured results obtained by ZYGO.In particular,a significant reduction in the measurement time(reduced by a factor of 48)is achieved compared with that of the traditional phase-shifting method.Our proposed method provides an efficient,rapid,and accurate method for obtaining the surface profiles of optical components with different diameters without employing a phase-shifting approach,which is highly desired in large-aperture interferometric measurement systems.展开更多
The rapid evolution of laser micro/nano-manufacturing techniques has transformed precision manufacturing,enabling the creation of complex micro/nano-structures.These techniques are crucial for multiple industries,incl...The rapid evolution of laser micro/nano-manufacturing techniques has transformed precision manufacturing,enabling the creation of complex micro/nano-structures.These techniques are crucial for multiple industries,including electronics,photonics,and biomedical engineering,owing to their unmatched precision and versatility.The ability to manipulate materials at such scales has unlocked new possibilities for innovation,thereby facilitating the development of advanced components and devices with enhanced performance and functionalities.展开更多
China’s Dongfang Electric Machinery successfully completed the manufacturing of the first batch of embedded components for six turbines it is supplying for the Koysha Hydroelectric Dam project in Ethiopia.Transported...China’s Dongfang Electric Machinery successfully completed the manufacturing of the first batch of embedded components for six turbines it is supplying for the Koysha Hydroelectric Dam project in Ethiopia.Transported by land and sea,these parts will arrive on site in three months.Once completed,the power plant will generate more than 6 billion kwh of electricity annually,reducing carbon dioxide emissions by 1 million tonnes per year.展开更多
Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex ...Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery manufacturing.To address this problem,the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles,improve machining qualities,and reduce costs.This paper summarises the research status on the material removal mechanism,precision control of structure shape,machined surface integrity control and intelligent process control technology of complex thin-walled components.Numerous solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall components.The development status,challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.展开更多
Combining dissimilar materials in a single component is an effective solution to integrate diverse material properties into a single part.Copper-stainless steel hybrid components are attracting more and more attention...Combining dissimilar materials in a single component is an effective solution to integrate diverse material properties into a single part.Copper-stainless steel hybrid components are attracting more and more attention since the high thermal conductivity of copper can greatly enhance the thermal performance of stainless steel,which benefits its applications in many industries.However,direct joining of copper and stainless steel such as SS316 L is challenging since they preserve significant dissimilarities in physical,chemical,and thermo-mechanical properties.This paper aims to fabricate well-bonded copper-SS316 L hybrid parts using a laser-aided directed energy deposition(DED) process.A nickel-based alloy Deloro22(D22) is introduced between copper and SS316 L to address the detrimental issues in copper-SS316 L direct joints.Using this technique,defect-free interfaces are achieved at both the D22-SS316 L and copper-D22 transition zones.Tensile testing of Cu-D22-SS316 L and D22-SS316 L hybrid parts shows the fracture occurs at pure copper and SS316 L region,respectively,indicating an excellent bonding at the interfaces.Ascending in the building direction,a transition of grain structure is observed.A significant diffusion zone is obtained at both the D22-SS316 L and the Cu-D22 interfaces.The large diffusion distance results in a smooth variation in microhardness over the dissimilar materials.The microhardness increases from SS316 L to D22 with the highest value of 240 HV and then decreases from D22 to Cu with the lowest value of 63 ± 4 HV.Testing of thermophysical properties of the Cu-D22-SS316 L system indicates there is a ~300 % increase in thermal diffusivity and a ~200 % increase in thermal conductivity when compared to pure SS316 L.The significant increase in thermal diffusivity and conductivity validates the enhanced thermal performance of SS316 L when it is joined with pure copper.展开更多
To cope with various unpredictable changes in large scale parts,the concept of reconfigurable manufacturing system (RMS) for machining these components is presented.Considering with large-size space measurement and th...To cope with various unpredictable changes in large scale parts,the concept of reconfigurable manufacturing system (RMS) for machining these components is presented.Considering with large-size space measurement and the fixed-free manufacture mode,an automatically localizing machining method for large scale part is studied in this paper,and the architecture of the RMS for machining large scale parts is proposed.According to the method and structure,the automatically localizing model is established.The theoretical analysis and simulation examples demonstrate the feasibility and validity of the proposed method,and the results indicate that the method is suitable and effective for machining large scale components in significant scientific projects.展开更多
Logistics network design influences the efficiency and cost of Logistics directly.Some manufacturing enterprises not only have warehouse hubs,but also build component processing workshops which are usually located in ...Logistics network design influences the efficiency and cost of Logistics directly.Some manufacturing enterprises not only have warehouse hubs,but also build component processing workshops which are usually located in those places where the costs of materials and workforce are lower.This paper establishes a logistics network design model for the manufacturing enterprises with component processing workshops based on 0-1 mixture integer programming.The model optimizes the logistics network in an integrated view,by which the selection of the nodes,the manufacturing plan,and transportation plan can be obtained.An example is given to verify its feasibility.The approach is helpful for designing of the logistics network in manufacturing enterprises.展开更多
In order to build a ceramic component by inkjet printing, the object must be fabricated through the interaction and solidification of drops, typically in the range of 10–100 p L. In order to achieve this goal, stable...In order to build a ceramic component by inkjet printing, the object must be fabricated through the interaction and solidification of drops, typically in the range of 10–100 p L. In order to achieve this goal, stable ceramic inks must be developed. These inks should satisfy specific rheological conditions that can be illustrated within a parameter space defined by the Reynolds and Weber numbers. Printed drops initially deform on impact with a surface by dynamic dissipative processes, but then spread to an equilibrium shape defined by capillarity. We can identify the processes by which these drops interact to form linear features during printing, but there is a poorer level of understanding as to how 2D and 3D structures form. The stability of 2D sheets of ink appears to be possible over a more limited range of process conditions that is seen with the formation of lines. In most cases, the ink solidifies through evaporation and there is a need to control the drying process to eliminate the "coffee ring" defect. Despite these uncertainties, there have been a large number of reports on the successful use of inkjet printing for the manufacture of small ceramic components from a number of different ceramics. This technique offers good prospects as a future manufacturing technique. This review identifies potential areas for future research to improve our understanding of this manufacturing method.展开更多
Component sequence preservation is an intrinsic requirement in typical engineering applications, such as deployable chain-likestructures, 3D printing structures with contour-parallel toolpaths, additive manufacturing ...Component sequence preservation is an intrinsic requirement in typical engineering applications, such as deployable chain-likestructures, 3D printing structures with contour-parallel toolpaths, additive manufacturing of continuous fibre-reinforcedpolymer structures, customized stents, and soft robotics parts. This study presents a feature-driven method that preservescomponent sequences accounting for engineering requirements. The chain-of-bars design variables setting scheme is developedto realize the sequential component’s layout, which sets the current bar’s end point as the next bar’s start point. The total lengthof the printing path is constrained to reduce the consumption of material accurately. Also, the angle between adjacent bars isconstrained to avoid sharp angles at the turning point of the 3D printing path. Next, the sensitivity analysis considering theinter-dependence of substructures is performed. Several numerical examples are given to demonstrate the validity and merits ofthe proposed method in designing structures preserving component sequences.展开更多
基金funded by the National Natural Science Foundation of China Youth Fund(Grant No.62304022)Science and Technology on Electromechanical Dynamic Control Laboratory(China,Grant No.6142601012304)the 2022e2024 China Association for Science and Technology Innovation Integration Association Youth Talent Support Project(Grant No.2022QNRC001).
文摘Metal Additive Manufacturing(MAM) technology has become an important means of rapid prototyping precision manufacturing of special high dynamic heterogeneous complex parts. In response to the micromechanical defects such as porosity issues, significant deformation, surface cracks, and challenging control of surface morphology encountered during the selective laser melting(SLM) additive manufacturing(AM) process of specialized Micro Electromechanical System(MEMS) components, multiparameter optimization and micro powder melt pool/macro-scale mechanical properties control simulation of specialized components are conducted. The optimal parameters obtained through highprecision preparation and machining of components and static/high dynamic verification are: laser power of 110 W, laser speed of 600 mm/s, laser diameter of 75 μm, and scanning spacing of 50 μm. The density of the subordinate components under this reference can reach 99.15%, the surface hardness can reach 51.9 HRA, the yield strength can reach 550 MPa, the maximum machining error of the components is 4.73%, and the average surface roughness is 0.45 μm. Through dynamic hammering and high dynamic firing verification, SLM components meet the requirements for overload resistance. The results have proven that MEM technology can provide a new means for the processing of MEMS components applied in high dynamic environments. The parameters obtained in the conclusion can provide a design basis for the additive preparation of MEMS components.
基金support provided by National Key Research and Development Program of China(2023YFE0203000 and 2016YFC0300200)the NSAF(Grant No.U2330205)+3 种基金Full-Sea-Depth Battery Project(2020-XXXX-XX-246-00)Open project of Shaanxi Laboratory of Aerospace Power(2022ZY2-JCYJ-01-09)Fundamental Research Funds for the Central Universities,ND Basic Research Funds(G2022WD)the Innovation Team of Shaanxi Province。
文摘The operation of deep-sea underwater vehicles relies entirely on onboard batteries.However,the extreme deep-sea conditions,characterized by ultrahigh hydraulic pressure,low temperature,and seawater conductivity,pose significant challenges for battery development.These conditions drive the need for specialized designs in deep-sea batteries,incorporating critical aspects of power generation,protection,distribution,and management.Over time,deep-sea battery technology has evolved through multiple generations,with lithium(Li)batteries emerging in recent decades as the preferred power source due to their high energy and reduced operational risks.Although the rapid progress of Li batteries has notably advanced the capabilities of underwater vehicles,critical technical issues remain unresolved.This review first systematically presents the whole picture of deep-sea battery manufacturing,focusing on Li batteries as the current mainstream solution for underwater power.It examines the key aspects of deep-sea Li battery development,including materials selection informed by electro-chemo-mechanics models,component modification and testing,and battery management systems specialized in software and hardware.Finally,it discusses the main challenges limiting the utilization of deep-sea batteries and outlines promising directions for future development.Based on the systematic reflection on deep-sea batteries and discussion on deep-sea Li batteries,this review aims to provide a research foundation for developing underwater power tailored for extreme environmental exploration.
基金funded by the National Natural Science Foundation of China Instrumentation Program(52327806)Youth Fund of the National Nature Foundation of China(62405020)China Postdoctoral Science Foundation(2024M764131).
文摘Large-aperture optical components are of paramount importance in domains such as integrated circuits,photolithography,aerospace,and inertial confinement fusion.However,measuring their surface profiles relies predominantly on the phase-shifting approach,which involves collecting multiple interferograms and imposes stringent demands on environmental stability.These issues significantly hinder its ability to achieve real-time and dynamic high-precision measurements.Therefore,this study proposes a high-precision large-aperture single-frame interferometric surface profile measurement(LA-SFISPM)method based on deep learning and explores its capability to realize dynamic measurements with high accuracy.The interferogram is matched to the phase by training the data measured using the small aperture.The consistency of the surface features of the small and large apertures is enhanced via contrast learning and feature-distribution alignment.Hence,high-precision phase reconstruction of large-aperture optical components can be achieved without using a phase shifter.The experimental results show that for the tested mirror withΦ=820 mm,the surface profile obtained from LA-SFISPM is subtracted point-by-point from the ground truth,resulting in a maximum single-point error of 4.56 nm.Meanwhile,the peak-to-valley(PV)value is 0.0758λ,and the simple repeatability of root mean square(SR-RMS)value is 0.00025λ,which aligns well with the measured results obtained by ZYGO.In particular,a significant reduction in the measurement time(reduced by a factor of 48)is achieved compared with that of the traditional phase-shifting method.Our proposed method provides an efficient,rapid,and accurate method for obtaining the surface profiles of optical components with different diameters without employing a phase-shifting approach,which is highly desired in large-aperture interferometric measurement systems.
文摘The rapid evolution of laser micro/nano-manufacturing techniques has transformed precision manufacturing,enabling the creation of complex micro/nano-structures.These techniques are crucial for multiple industries,including electronics,photonics,and biomedical engineering,owing to their unmatched precision and versatility.The ability to manipulate materials at such scales has unlocked new possibilities for innovation,thereby facilitating the development of advanced components and devices with enhanced performance and functionalities.
文摘China’s Dongfang Electric Machinery successfully completed the manufacturing of the first batch of embedded components for six turbines it is supplying for the Koysha Hydroelectric Dam project in Ethiopia.Transported by land and sea,these parts will arrive on site in three months.Once completed,the power plant will generate more than 6 billion kwh of electricity annually,reducing carbon dioxide emissions by 1 million tonnes per year.
基金supported by the National Natural Science Foundation of China(Nos.51921003,92160301,52175415 and 52205475)the Science Center for Gas Turbine Project(No.P2022-A-IV-002-001)Natural Science Foundation of Jiangsu Province(No.BK20210295).
文摘Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery manufacturing.To address this problem,the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles,improve machining qualities,and reduce costs.This paper summarises the research status on the material removal mechanism,precision control of structure shape,machined surface integrity control and intelligent process control technology of complex thin-walled components.Numerous solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall components.The development status,challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.
基金supported by National Science Foundation Grants CMMI-1547042 and CMMI 1625736Intelligent Systems Center,Center for Aerospace Manufacturing TechnologiesMaterial Research Center at Missouri S&T。
文摘Combining dissimilar materials in a single component is an effective solution to integrate diverse material properties into a single part.Copper-stainless steel hybrid components are attracting more and more attention since the high thermal conductivity of copper can greatly enhance the thermal performance of stainless steel,which benefits its applications in many industries.However,direct joining of copper and stainless steel such as SS316 L is challenging since they preserve significant dissimilarities in physical,chemical,and thermo-mechanical properties.This paper aims to fabricate well-bonded copper-SS316 L hybrid parts using a laser-aided directed energy deposition(DED) process.A nickel-based alloy Deloro22(D22) is introduced between copper and SS316 L to address the detrimental issues in copper-SS316 L direct joints.Using this technique,defect-free interfaces are achieved at both the D22-SS316 L and copper-D22 transition zones.Tensile testing of Cu-D22-SS316 L and D22-SS316 L hybrid parts shows the fracture occurs at pure copper and SS316 L region,respectively,indicating an excellent bonding at the interfaces.Ascending in the building direction,a transition of grain structure is observed.A significant diffusion zone is obtained at both the D22-SS316 L and the Cu-D22 interfaces.The large diffusion distance results in a smooth variation in microhardness over the dissimilar materials.The microhardness increases from SS316 L to D22 with the highest value of 240 HV and then decreases from D22 to Cu with the lowest value of 63 ± 4 HV.Testing of thermophysical properties of the Cu-D22-SS316 L system indicates there is a ~300 % increase in thermal diffusivity and a ~200 % increase in thermal conductivity when compared to pure SS316 L.The significant increase in thermal diffusivity and conductivity validates the enhanced thermal performance of SS316 L when it is joined with pure copper.
基金Funded by the National Natural Science Foundation of Chinathe Development Program for Outstanding Young Teachers in Harbin Institute of Technology
文摘To cope with various unpredictable changes in large scale parts,the concept of reconfigurable manufacturing system (RMS) for machining these components is presented.Considering with large-size space measurement and the fixed-free manufacture mode,an automatically localizing machining method for large scale part is studied in this paper,and the architecture of the RMS for machining large scale parts is proposed.According to the method and structure,the automatically localizing model is established.The theoretical analysis and simulation examples demonstrate the feasibility and validity of the proposed method,and the results indicate that the method is suitable and effective for machining large scale components in significant scientific projects.
基金Supported by the National High Technology Research and Development Program of China (863 Program) (2007AA04Z105)the Innovation Action Project from Science and Technology Commission of Shanghai Municipality (08170511300)
文摘Logistics network design influences the efficiency and cost of Logistics directly.Some manufacturing enterprises not only have warehouse hubs,but also build component processing workshops which are usually located in those places where the costs of materials and workforce are lower.This paper establishes a logistics network design model for the manufacturing enterprises with component processing workshops based on 0-1 mixture integer programming.The model optimizes the logistics network in an integrated view,by which the selection of the nodes,the manufacturing plan,and transportation plan can be obtained.An example is given to verify its feasibility.The approach is helpful for designing of the logistics network in manufacturing enterprises.
文摘In order to build a ceramic component by inkjet printing, the object must be fabricated through the interaction and solidification of drops, typically in the range of 10–100 p L. In order to achieve this goal, stable ceramic inks must be developed. These inks should satisfy specific rheological conditions that can be illustrated within a parameter space defined by the Reynolds and Weber numbers. Printed drops initially deform on impact with a surface by dynamic dissipative processes, but then spread to an equilibrium shape defined by capillarity. We can identify the processes by which these drops interact to form linear features during printing, but there is a poorer level of understanding as to how 2D and 3D structures form. The stability of 2D sheets of ink appears to be possible over a more limited range of process conditions that is seen with the formation of lines. In most cases, the ink solidifies through evaporation and there is a need to control the drying process to eliminate the "coffee ring" defect. Despite these uncertainties, there have been a large number of reports on the successful use of inkjet printing for the manufacture of small ceramic components from a number of different ceramics. This technique offers good prospects as a future manufacturing technique. This review identifies potential areas for future research to improve our understanding of this manufacturing method.
基金supported by the Chinese Studentship Council(Grant No.201908060224)the Young Talent Fund of Association for Science and Technology in Shaanxi,China(Grant No.20230240)+1 种基金the National Natural Science Foundation of China(Grant No.11972308)Queen Mary University of London with the PhD fee waiver.
文摘Component sequence preservation is an intrinsic requirement in typical engineering applications, such as deployable chain-likestructures, 3D printing structures with contour-parallel toolpaths, additive manufacturing of continuous fibre-reinforcedpolymer structures, customized stents, and soft robotics parts. This study presents a feature-driven method that preservescomponent sequences accounting for engineering requirements. The chain-of-bars design variables setting scheme is developedto realize the sequential component’s layout, which sets the current bar’s end point as the next bar’s start point. The total lengthof the printing path is constrained to reduce the consumption of material accurately. Also, the angle between adjacent bars isconstrained to avoid sharp angles at the turning point of the 3D printing path. Next, the sensitivity analysis considering theinter-dependence of substructures is performed. Several numerical examples are given to demonstrate the validity and merits ofthe proposed method in designing structures preserving component sequences.
