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The purpose of this paper is to optimise the selective laser melting (SLM) process parameters for CMSX486 to produce a “void free” (fully consolidated) material, whilst reducing the cracking density to a minimum providing the best possible fabricated material for further post-processing. SLM of high temperature nickel base superalloys has had limited success due to the susceptibly of the material to solidification and reheat cracking.

Samples of CMSX486 were fabricated by SLM. Statistical design of experiments (DOE) using the response surface method was used to generate an experimental design and investigate the influence of the key process parameters (laser power, scan speed, scan spacing and island size). A stereological technique was used to quantify the internal defects within the material, providing two measured responses: cracking density and void per cent.

The analysis of variance (ANOVA) was used to determine the most significant process parameters and showed that laser power, scan speed and the interaction between the two are significant parameters when considering the cracking density. Laser power, scan speed, scan spacing and the interaction between power and speed, and speed and spacing were the significant factors when considering void per cent. The optimum setting of the process parameters that lead to minimum cracking density and void per cent was obtained. It was shown that the nominal energy density can be used to identify a threshold for the elimination of large voids; however, it does not correlate well to the formation of cracks within the material. To validate the statistical approach, samples were produced using the predicted optimum parameters in an attempt to validate the response surface model. The model showed good prediction of the void per cent; however, the cracking results showed a greater deviation from the predicted value.

This is the first ever study on SLM of CMSX486. The paper shows that provided that the process parameters are optimised, SLM has the potential to provide a low-cost route for the small batch production of high temperature aerospace components.

The purpose of this paper is to analyze the surface integrity, including recast layer thickness, surface crack density, X-ray diffractions study and microhardness for Ni53.49Ti46.51 shape memory alloy (SMA) during wire-spark erosion machining.

Four persuasive process parameters, that is, spark on time (SON), spark off time (SOFF), wire feed (WF) and spark gap voltage (SV), have been chosen for the current investigation. Efforts have been done to explore the effects of above said parameters on the machined surface of Ni-Ti SMA by embracing box Behnken design of response surface methodology (RSM). Cutting speed and ten-point mean roughness (Rz) has been taken into account as response variables. Analysis of variance test was also performed for both response parameters with the coefficient of determination (R²) 0.9610 for cutting speed and 0.9252 for ten-point mean Rz.

The recast layer thickness from 7.83 to 12.13 µm was developed near the machined surface at different parametric settings. The least surface crack density was found at the lowest value of ten-point mean Rz, while most surface crack density was identified at the highest value of cutting speed. The microhardness near the machined surface was increased by approximately 1.8 times bulk-hardness of Ni53.49Ti46.51 SMA.

Some researchers have done a study on average surface roughness, but very few investigators concentrated on ten-point mean Rz. Surface crack density is an essential aspect of machined parts; other researchers have seldom reported it. The novelty of this research work is that the influence of SON, SV, WF and SOFF on cutting speed, Rz, recast layer thickness, micro-hardness and surface crack density proximate the machined surface while machining workpiece material.

In this study, powder mixed electro discharge machining (PMEDM) has been performed for the machining of AISI 304 stainless steel by using the tungsten carbide electrode when silicon carbide (SiC) powder is mixed with kerosene. The purpose of this study is to find the optimal value and ascertain the effect of significant machining parameters on surface crack density (SCD) of a machined surface of AISI 304.

A face-centered central composite design-based response surface methodology has been adopted for designing this experiment.

An increase in peak current and powder concentration decreases SCD, which is the main goal of this investigation.

From this investigation, an optimal value has been achieved to minimize the SCD and prevent fatigue and corrosion resistance of the workpiece.

The purpose of this paper is to develop an efficient numerical method to study the complex crack initiation and propagation in linear elastic multiphase composites.

A phase field method is developed to study the complex fracture behavior in multiphase composites. A damage threshold is introduced for referring crack initiation in the proposed method. The damage threshold is assigned as a material property so that different composite components possess different thresholds. In this manner, smooth transition from crack initiation to propagation is revealed.

The proposed method is used to investigate complex crack evolution in mesoscale cementitious composite, which consists of aggregates, matrix and void pores. From a mesoscale point of view, it is found that cracks prefer to evolve within the matrix phase. As a crack encounters an aggregate, it tends to bypass the aggregate and evolve along the interface. Cracks tend to avoid to penetrate through aggregates. Also, cracks tend to be attracted by void pores. From a mesoscale point of view, it is revealed that the elastic modulus and strength of concrete models are closely related to porosity.

A criterion with a damage threshold is introduced to the proposed method. The criterions with and without a damage threshold are compared with each other in details. The proposed method is proven to be a useful tool to study mechanical behavior and crack evolution of brittle multiphase composites.

To develop a new method for estimation of damage configuration in composite laminate structure using acoustic wave propagation signal and a reduction‐prediction neural network to deal with high dimensional spectral data.

A reduction‐prediction network, which is a combination of an independent component analysis (ICA) and a multi‐layer perceptron (MLP) neural network, is proposed to quantify the damage state related to transverse matrix cracking in composite laminates using acoustic wave propagation model. Given the Fourier spectral response of the damaged structure under frequency band‐selective excitation, the problem is posed as a parameter estimation problem. The parameters are the stiffness degradation factors, location and approximate size of the stiffness‐degraded zone. A micro‐mechanics model based on damage evolution criteria is incorporated in a spectral finite element model (SFEM) for beam type structure to study the effect of transverse matrix crack density on the acoustic wave response. Spectral data generated by using this model is used in training and testing the network. The ICA network called as the reduction network, reduces the dimensionality of the broad‐band spectral data for training and testing and sends its output as input to the MLP network. The MLP network, in turn, predicts the damage parameters.

Numerical demonstration shows that the developed network can efficiently handle high dimensional spectral data and estimate the damage state, damage location and size accurately.

Only numerical validation based on a damage model is reported in absence of experimental data. Uncertainties during actual online health monitoring may produce errors in the network output. Fault‐tolerance issues are not attempted. The method needs to be tested using measured spectral data using multiple sensors and wide variety of damages.

The developed network and estimation methodology can be employed in practical structural monitoring system, such as for monitoring critical composite structure components in aircrafts, spacecrafts and marine vehicles.

A new method is reported in the paper, which employs the previous works of the authors on SFEM and neural network. The paper addresses the important problem of high data dimensionality, which is of significant importance from practical engineering application viewpoint.

In accord with the literature reviews, there is not a promising examination regarding the several straight and curved cracks interaction with arbitrary arrangement in the rectangular FGP plane. The purpose of this paper is to consider the effect of crack length, position of the point load, material non-homogeneity constant and also the arrangement of cracks on the resulting field intensity factors.

First of all, in order to obtain a set of Cauchy singular integral equations, both the dislocation method and the finite Fourier cosine transform technique are applied. Using the corresponding solution to these equations, the dislocation densities on the crack surfaces are then obtained. Considering the results, both the stress intensity factors (SIFs) and electric displacement intensity factors (EDIFs) for a vertical crack and the interaction between two straight and curved cracks, which have an arbitrary configuration, are determined.

The numerical examples are represented in order to illustrate the interesting mechanical and electrical coupling phenomena induced by multi-crack interactions. At the end, the effects of the material non-homogeneity constant, the crack length and the cracks arrangements on the SIFs and EDIFs are investigated.

The solutions are obtained in series expansion forms which may be considered as Green’s functions in an FGP rectangular plane possessing multiple cracks. The technique of Green’s function provides the ability to analyze multiple cracks having any smooth configuration.

The purpose of this paper is to investigate prediction and optimization of multiple performance characteristics in the wire electrical discharge machining (wire-EDM) process of SKD 61 (AISI H13) tool steel.

The experimental studies were conducted under varying wire-EDM process parameters, which were arc on time, on time, open voltage, off time and servo voltage. The optimized responses were recast layer thickness (RLT), surface roughness (SR) and surface crack density (SCD). Arc on time was set at two different levels, whereas the other four parameters were set at three different levels. Based on Taguchi method, an L18 mixed-orthogonal array was selected for the experiments. Further, three methods, namely grey relational analysis (GRA), backpropagation neural network (BPNN) and genetic algorithm (GA), were applied separately. GRA was performed to obtain a rough estimation of optimum drilling parameters. The influences of drilling parameters on multiple performance characteristics were determined by using percentage contributions. BPNN architecture was determined to predict the multiple performance characteristics. GA method was then applied to determine the optimum wire-EDM parameters.

The minimum RLT, SR and SCD could be obtained by setting arc on time, on time, open voltage, off time and servo voltage at 2 ms, 3 ms, 90 volt, 10 ms and 38 volt, respectively. The experimental confirmation results showed that BPNN-based GA optimization method could accurately predict and significantly improve all of the responses.

There were no publications regarding multi-response optimization using a combination of GRA and BPNN-based GA methods during wire-EDM process available.

A mesoscopic phase field (PF) model is proposed to simulate the meso-failure process of lightweight concrete.

The PF damage model is applied to the meso-failure process of lightweight concrete through the ABAQUS subroutine user-defined element (UEL). And the improved staggered iteration scheme with a one-pass procedure is used to alternately solve the coupling equations.

These examples clearly show that the crack initiation of the lightweight concrete specimens mainly occurs in the ceramsite aggregates with weak strength, especially in the larger aggregates. The crack propagation paths of the specimens with the same volume fraction of light aggregates are completely different, but the crack propagation paths all pass through the ceramsite aggregates near the cracks. The results also showed that with the increase in the volume fractions of the aggregates, the slope and the peak loads of the force-deflection (F-d) curves gradually decrease, the load-bearing capacity of the lightweight concrete specimens decreases, and crack branching and coalescence are less likely during crack propagation.

The mesostructures with a mortar matrix, aggregates and an interfacial transition zone (ITZ) are generated by an automatic generation and placement program, thus incorporating the typical three-phase characteristics of lightweight concrete into the PF model.

Concrete is a widely used construction material which can be prepared using locally available resources (aggregates, cement and water) by following relevant standard guidelines. The residual properties of concrete determined by heating in an electric furnace may not produce a similar effect of fire. The purpose of this paper is to compare the effect of a fire with that coming from the exposure of normal strength concrete to predetermined reference temperatures, for which two sets of specimens were heated in a fire furnace provided with gas burners and an electric furnace.

The concrete cubes and cylinders were subjected to 200^oC, 400^oC, 600oC and 800^oC temperature in a gas-controlled fire furnace and an electric furnace for 2 h. The physical properties and mechanical properties of concrete were determined after cooling the specimens in air. The quality of concrete specimens was determined using the ultrasonic pulse velocity test, and surface hardness of the heat-exposed cubes was recorded using the Schmidt rebound hammer.

The fire-exposed specimens were found to have lower residual compressive strength, tensile strength and higher porosity/voids/internal cracks than the specimens heated in an electric furnace at the same temperature. Further, a good agreement with compressive strength and rebound numbers was observed for each of the two heating systems (flames coming from gas burners and electric furnace).

Normal strength concrete specimens exposed to heat in an electric furnace will not give the same effect of fire having the same maximum temperature. Further, it is noticed that concrete subjected to elevated temperature is sensitive to heating modalities, be it the flames of a gas furnace or the radiation of an electric furnace.

The purpose of this paper is to study the functionality of additively manufactured (AM) parts, mainly depending on their dimensional accuracy and surface finish. However, the products manufactured using AM usually suffer from defects like roughness or uneven surfaces. This paper discusses the various surface quality improvement techniques, including how to reduce surface defects, surface roughness and dimensional accuracy of AM parts.

There are many different types of popular AM methods. Unfortunately, these AM methods are susceptible to different kinds of surface defects in the product. As a result, pre- and postprocessing efforts and control of various AM process parameters are needed to improve the surface quality and reduce surface roughness.

In this paper, the various surface quality improvement methods are categorized based on the type of materials, working principles of AM and types of finishing processes. They have been divided into chemical, thermal, mechanical and hybrid-based categories.

The review has evaluated the possibility of various surface finishing methods for enhancing the surface quality of AM parts. It has also discussed the research perspective of these methods for surface finishing of AM parts at micro- to nanolevel surface roughness and better dimensional accuracy.

This paper represents a comprehensive review of surface quality improvement methods for both metals and polymer-based AM parts.