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Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This study presents finite element (FE) and generalized regression neural network (GRNN) approaches for modeling multiple crack growth problems and predicting crack-growth directions under the influence of multiple crack parameters.

To determine the crack-growth direction in aluminum specimens, multiple crack parameters representing some degree of crack propagation complexity, including crack length, inclination angle, offset and distance, were examined. FE method models were developed for multiple crack growth simulations. To capture the complex relationships among multiple crack-growth variables, GRNN models were developed as nonlinear regression models. Six input variables and one output variable comprising 65 training and 20 test datasets were established.

The FE model could conveniently simulate the crack-growth directions. However, several multiple crack parameters could affect the simulation accuracy. The GRNN offers a reliable method for modeling the growth of multiple cracks. Using 76% of the total dataset, the NN model attained an R2 value of 0.985.

The models are presented for static multiple crack growth problems. No material anisotropy is observed.

In practical crack-growth analyses, the NN approach provides significant benefits and savings.

The proposed GRNN model is simple to develop and accurate. Its performance was superior to that of other NN models. This model is also suitable for modeling multiple crack growths with arbitrary geometries. The proposed GRNN model demonstrates its prediction capability with a simpler learning process, thus producing efficient multiple crack growth predictions and assessments.

This study provides an analysis of patch repair for cracked aircraft structures. Delamination is a type of damage that affects the patch's behavior. The purpose of this study is to assess the influence of delamination on repair performance.

An analytical and numerical study using the finite element method was conducted for a cracked plate repaired with a patch containing a pre-existing delamination defect. The method for defining the contact pair surfaces and modeling the delamination interaction within the patch interface is specified using the virtual crack closure technique (VCCT) approach.

The efficiency of the repair is measured in terms of the J-integral. The effects of delamination initiation, mechanical loading, crack length and patch stacking sequences are presented. It is noted that in mode I, delamination propagation is only significant at node A. The numerical results are in good agreement with those of the analytical solution found in the literature. It is observed that the patch's behavior is strongly dependent on loading, crack size and stacking sequences in terms of reducing the structure's lifespan, especially in the presence of delamination.

The numerical modeling presented by the VCCT approach is highly valuable for studying delamination evolution. The influence of loading, crack size and stacking sequences on repair performance is discussed in this work.

This paper aims to study the interfacial delamination found in the boundary of the copper/copper-epoxy layers of a multi-layer ceramic capacitor.

The thermal reflow process of the capacitor assembly and the crack propagation from the initial micro voids presented in the boundary, and later manifested into delamination, were numerically simulated. Besides, the cross section of the capacitor assembly was inspected for delamination cracks and voids using a scanning electronic microscope.

Interfacial delamination in the boundary of copper/copper-epoxy layers was caused by the thermal mismatch and growth of micro voids during the thermal reflow process. The maximum deformation on the capacitor during reflow was 2.370 µm. It was found that a larger void would induce higher vicinity stress, mode I stress intensity factor, and crack elongation rate. Moreover, the crack extension increased with the exerted deformation until 0.3 µm, before saturating at the peak crack extension of around 0.078 µm.

The root cause of interfacial delamination issues in capacitors due to thermal reflow has been identified, and viable solutions proposed. These can eliminate the additional manufacturing cost and lead time incurred in identifying and tackling the issues; as well as benefit end-users, by promoting the electronic device reliability and performance.

To the best of the authors’ knowledge, the mechanism of delamination occurrence in a capacitor during has not been reported to date. The parametric variation analysis of the void size and deformation on the crack growth has never been conducted.

Engineering composite laminates/structures are usually subjected to complex and variable loads, which result in interlayer delamination damage. However, damaged laminate may cause the whole structure to fail before reaching the design level. Therefore, the purpose of this paper is to develop an equivalent model to effectively evaluate compressive residual strength.

In this paper, taking carbon fiber reinforced composite T300/69 specimens as the study object, first, the compressive residual strength under different impact energy is obtained. Then, zero-thickness cohesive elements, Hashin failure criteria and Camanho nonlinear degradation scheme are used to simulate the full-process simulation for compression after edge impact (CAEI). Lastly, based on an improved Whitney–Nuismer criterion, the equation of edge hole stress distribution, characteristic length and compressive residual strength is used to verify the correctness of the equivalent model.

An equivalent relationship between the compressive residual strength of damaged laminates and laminates with edge hole is established. For T300/69 laminates with a thickness of 2.4 mm, the compressive residual strength after damage under an impact energy of 3 J is equivalent to that when the hole aperture R = 2.25 mm and the hole aperture R = 9.18 mm when impact energy is 6 J. Besides, the relationship under the same size and different thickness is obtained.

The value of this study is to provide a reference for the equivalent behavior of damaged laminates. An equivalent model proposed in this paper will contribute to the research of compressive residual strength and provide a theoretical basis for practical engineering application.

This study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.

Specimens of the capacitor assembly were subjected to JEDEC level 1 preconditioning (85 °C/85%RH/168 h) with 5× reflow at 270°C peak temperature. Then, they were inspected using a 2 µm scanning electron microscope to investigate the evidence of defects. The reliability test was also numerically simulated and analyzed using the extended finite element method implemented in ABAQUS.

Excellent agreements were observed between the SEM inspections and the simulation results. The findings showed evidence of discontinuities along the Cu and the Cu-epoxy layers and interfacial delamination crack at the Cu/Cu-epoxy interface. The possible root causes are thermal mismatch between the Cu and Cu-epoxy layers, moisture contamination and weak Cu/Cu-epoxy interface. The maximum crack length observed in the experimentally reflowed capacitor was measured as 75 µm, a 2.59% difference compared to the numerical prediction of 77.2 µm.

This work's contribution is expected to reduce the additional manufacturing cost and lead time in investigating reliability issues in MLCCs.

Despite the significant number of works on the reliability assessment of surface mount capacitors, work on crack growth in soft-termination MLCC is limited. Also, the combined experimental and numerical investigation of reflow-induced reliability issues in soft-termination MLCC is limited. These cited gaps are the novelties of this study.

The purpose of this study was to introduce three-dimensional printing (3DP) of functionally graded sandwich foams (FGSFs). This work was continued by predicting the mechanical buckling and free vibration behavior of 3DP FGSFs using experimental and numerical analyses.

Initially, hollow glass microballoon-reinforced high-density polyethylene-based polymer composite foams were developed, and these materials were extruded into their respective filaments. These filaments are used as feedstock materials in fused filament fabrication based 3DP for the development of FGSFs. Scanning electron microscopy analysis was performed on the freeze-dried samples to observe filler sustainability. Furthermore, the density, critical buckling load (P_cr), natural frequency (f_n) and damping factor of FGSFs were evaluated. The critical buckling load (P_cr) of the FGSFs was estimated using the double-tangent method and modified Budiansky criteria.

The density of FGSFs decreased with increasing filler percentage. The mechanical buckling load increased with the filler percentage. The natural frequency corresponding to the first mode of the FGSFs exhibited a decreasing trend with an increasing load in the pre-buckling regime and an increase in post-buckled zone, whereas the damping factor exhibited the opposite trend.

The current research work is valuable for the area of 3D printing by developing the functionally graded foam based sandwich beams. Furthermore, it intended to present the buckling behavior of 3D printed FGSFs, variation of frequency and damping factor corresponding to first three modes with increase in load.

The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed.

Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes.

The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants.

This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

The industrial application of continuous glass fabric-reinforced polymer composites (GFRPCs) is growing; however, the manufacturing boundedness of complex structures and the high cost of molds restrict their use. This research proposes a three-dimensional (3 D) printing process for GFRPCs that allows low-cost and rapid fabrication of complex composite parts.

The composite is manufactured using a digital light processing (DLP) based Vat-photopolymerization (VPP) process. For the composites, suitable resin material and glass fabrics are chosen based on their strength, stiffness, and printability. Jacob's working curve characterizes the curing parameters for adequate adhesion between the matrix and fabrics. The tensile and flexural properties were examined using UTM. The fabric distribution and compactness of the cured resin were analyzed in scanning electron microscopy.

The result showed that the object could print at a glass fabric content of 40 volume%. In DLP-based VPP printing technology, the adequate exposure time was found to be 30 seconds for making a GFRPC. The tensile strength and Young's modulus values were increased by 5.54 and 8.81 times, respectively than non-reinforced cured specimens. The flexural strength and modulus were also effectively increased to 2.8 and 3 times more than the neat specimens. In addition, the process is found to help fabricate the functional component.

The experimental procedure to fabricate GFRPC specimens through DLP-based AM is a spectacular experimental approach.

To explore the influence of various factors on the adhesion strength of 3D printing materials and chiffon fabrics, and to develop an original design clothing prototype with an extended functionality that would be compatible with the specifics of the circular design.

Four different chiffon fabrics and four 3D printed materials were chosen as the research subjects to determine the influence of various factors on the adhesion strength and ductility. The uniaxial tensile test was used to determine pull-out force and the pull-out elongation from the interlayer.

3D printed TPU elements can be used to join clothing parts made from low-elasticity chiffon fabrics to improve wearing comfort. In order to comply with the circular economy concept, it is important to select such adhesion parameters of the 3D printed elements and the material system that would ensure wear comfort and withstand wear-level loads; and at the end of the life cycle of a garment, the 3D printed elements could be separated from the product and recycled.

The systems developed can be used to renew and repair products, adding originality, individual touch or additional decorative features, while extending the functional possibilities of clothing items in accordance with circular design principles.