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The purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.

No methodology was used because the paper is a review article.

no fundings.

Herein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the controllable and fixed build parameters of metallic parts. The authors discuss the effect and interplay between process parameters, including: laser power, scan speed and powder feed rate. Further, the authors show the interplay between process parameters is pivotal in achieving the desired microstructure, macrostructure, geometrical accuracy and mechanical properties.

In this manuscript, the authors review current research examining the process inputs and their influences on the final product when manufacturing with the LENS process. The authors also discuss how these parameters relate to important build aspects such as melt-pool dimensions, the volume of porosity and geometry accuracy.

The authors conclude that studies have greatly enriched the understanding of the LENS build process, however, much studies remains to be done. Importantly, the authors reveal that to date there are a number of detailed theoretical models that predict the end properties of deposition, however, much more study is necessary to allow for reasonable prediction of the build process for standard industrial parts, based on the synchronistic behavior of the input parameters.

This paper intends to raise questions about the possible research areas that could potentially promote the effectiveness of this LENS technology.

The purpose of this paper is to investigate the effect of remelting each layer on the homogeneity of nickel-titanium (NiTi) parts fabricated from elemental nickel and titanium powders using laser powder bed fusion (LPBF). In addition, the influence of manufacturing parameters and different melting strategies, including multiple cycles of remelting, on printability and macro defects, such as pore and crack formation, have been investigated.

An LPBF process was used to manufacture NiTi alloy from elementally blended powders and was evaluated with the use of a remelting scanning strategy to improve the homogeneity of fabricated specimens. Furthermore, both single melt and up to two remeltings were used.

The results indicate that remelting can be beneficial for density improvement as well as chemical and phase composition homogenization. Backscattered electron mode in scanning electron microscope showed a reduction in the presence of unmixed Ni and Ti elemental powders in response to increasing the number of remelts. The microhardness values of NiTi parts for the different numbers of melts studied were similar and ranged from 487 to 495 HV. Nevertheless, it was observed that measurement error decreases as the number of remelts increases, suggesting an increase in chemical and phase composition homogeneity. However, X-ray diffraction analysis revealed the presence of multiple phases regardless of the number of melt runs.

For the first time, to the best of the authors’ knowledge, elementally blended NiTi powders were fabricated via LPBF using remelting scanning strategies.

The purpose of this paper is to artificially construct a functional surface with self-propulsion flow characteristics for the directional transportation of propellant in surface tension tanks.

In this study, a method to enhance the propulsion efficiency by using functional surfaces of self-propulsion performance was proposed. Superhydrophilic wedged-groove with the superhydrophobic background was fabricated and the self-propulsion capacity was verified.

It is found that the self-propulsion capacity is related to the divergence angle of the wedged-groove in the hydrophilic area, and the velocity of the droplets on the deflector plate is the largest with the divergence angle of 4°; the temperature gradient field formed by the condensing device at the nozzle can accelerate the droplet outflow from the tank.

Realization of this idea provides an accurate control strategy for the complex flow process of propellant in plate surface tension tanks, which could enhance the efficiency of the tension tank significantly.

The purpose of this study is to verify how the carbon doping of the WC-Co cemented carbide (CC) affected their structure before their processing by hot isostatic pressing (HIP) technology.

The samples for this experiment were fabricated by selective laser melting technology (SLM) using a YAG fiber laser with a power of P = 40 W and a scanning speed of 83 mm/s. The subsequent carbon doping process was performed in a chamber furnace at 900 0 C for 1, 4 and 12 h. The HIP was performed at 1,390°C and pressures of 40 MPa, 80 MPa and 120 MPa. The changes induced in the structures were evaluated using X-ray diffraction and various microscopic methods.

X-ray diffraction analysis showed that the structure of the samples after SLM consisted of WC, W₂C, Co₄W₂C and Co phases. As a result of the increase in the carbon content in the structure of the samples, the transition carbide W₂C and structural phase Co₄W₂C decayed. Their decay was manifested by the coarsening of the minor alpha phase (WC), which occurred both during the carburizing process and during the subsequent processing using HIP. In the samples in which the structure was carburized prior to HIP, only the structural phases WC and Co were observed in most cases.

The results confirm that it is possible to increase the homogeneity of the CC structure and thus its applicability in practice by additional carburization of the sample structure with subsequent processing by HIP technology.

This paper aims to present an investigation into the variation of scan vector hatch rotation strategies in selective laser melting (SLM), focussing on how it effects density, surface roughness, tensile strength and residual stress.

First the optimum angle of hatch vector rotation is proposed by analysing the effect of different increment angles on distribution of scan vectors. Sectioning methods are then used to determine the effect that the chosen strategies have on the density of the parts. The top surface roughness was analysed using optical metrology, and the tensile properties were determined using uni-axial tensile testing. Finally, a novel multi-support deflection geometry was used to quantify the effects of rotation angles on residual stress.

The results of this research showed that the hatch rotation angle had little effect on the density, top surface roughness and strength of the parts. The greatest residual stress deflection was measured parallel to unidirectional scan vectors. The use of hatch rotations other than alternating 90° showed little benefit in lowering the magnitude of residual stresses. However, the use of rotation angles with a good suitability measure distributes stresses in all directions more evenly for certain part geometries.

All samples produced in this work were made from commercially pure titanium, therefore care must be taken when applying these results to other materials.

This paper serves to increase the understanding of SLM scanning strategies and their effect on the properties of the material.

The purpose of this paper is to show that the droplet impact phenomenon is important for the advancement of industrial technologies in many fields such as spray cooling and ink jet printing. Droplet bouncing on the nonwetting surfaces is a special phenomenon in the impact process which has attracted lots of attention.

In this work, the authors fabricated two kinds of representative nonwetting surfaces including superhydrophobic surfaces (SHS) and a slippery liquid-infused porous surface (SLIPS) with advanced UV laser processing.

The droplet bouncing behavior on the two kinds of nonwetting surfaces were compared in the experiments. The results indicate that the increasing Weber number enlarges the maximum droplet spreading diameter and raises the droplet bounce height but has no effect on contact time.

In addition, the authors find that the topological SHS and SLIPS with the laser-processed microwedge groove array produce asymmetric droplet bouncing with opposite offset direction. Microdroplets can be continuously transported without any additional driving force on such a topological SLIPS. The promising method for manipulating droplets has potential applications for the droplet-based microfluidic platforms.

The purpose of this paper is to report on the developments in manufacturing soft magnetic materials using laser powder bed fusion (L-PBF).

Ternary soft magnetic Fe-49Co-2V powder was produced by gas atomization and used in an L-PBF machine to produce samples for material characterization. The L-PBF process parameters were optimized for the material, using a design of experiments approach. The printed samples were exposed to different heat treatment cycles to improve the magnetic properties. The magnetic properties were measured with quasi-static direct current and alternating current measurements at different frequencies and magnetic flux densities. The mechanical properties were characterized with tensile tests. Electrical resistivity of the material was measured.

The optimized L-PBF process parameters resulted in very low porosity. The magnetic properties improved greatly after the heat treatments because of changes in microstructure. Based on the quasi-static DC measurement results, one of the heat treatment cycles led to magnetic saturation, permeability and coercivity values comparable to a commercial Fe-Co-V alloy. The other heat treatments resulted in abnormal grain growth and poor magnetic performance. The AC measurement results showed that the magnetic losses were relatively high in the samples owing to formation of eddy currents.

The influence of L-PBF process parameters on the microstructure was not investigated; hence, understanding the relationship between process parameters, heat treatments and magnetic properties would require more research.

The relationship between microstructure, chemical composition, heat treatments, resistivity and magnetic/mechanical properties of L-PBF processed Fe-Co-V alloy has not been reported previously.

This paper aims to gain an understanding of the behaviour of iron ore when melted by a laser beam in a continuous manner. This fundamental knowledge is essential to further develop additive manufacturing routes such as production of low cost parts and in-situ reduction of the ore during processing.

Blown powder directed energy deposition was used as the processing method. The process was observed through high-speed imaging, and computed tomography was used to analyse the specimens.

The experimental trials give preliminary results showing potential for the processability of iron ore for additive manufacturing. A large and stable melt pool is formed in spite of the inhomogeneous material used. Single and multilayer tracks could be deposited. Although smooth and even on the surface, the single layer tracks displayed porosity. In case of multilayered tracks, delamination from the substrate material and deformation can be seen. High-speed videos of the process reveal various process phenomena such as melting of ore powder during feeding, cloud formation, melt pool size, melt flow and spatter formation.

Very little literature is available that studies the possible use of ore in additive manufacturing. Although the process studied here is not industrially useable as is, it is a step towards processing cheap unprocessed material with a laser beam.