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Utilizing electrical discharge machining (EDM) to process micro-holes in superalloys may lead to the formation of remelting layers and micro-cracks on the machined surface. This work proposes a method of composite processing of EDM and ultrasonic vibration drilling for machining precision micro-holes in complex positions of superalloys.

A six-axis computer numerical control (CNC) machine tool was developed, whose software control system adopted a real-time control architecture that integrates electrical discharge and ultrasonic vibration drilling. Among them, the CNC system software was developed based on Windows + RTX architecture, which could process the real-time processing state received by the hardware terminal and adjust the processing state. Based on the SoC (System on Chip) technology, an architecture for a pulse generator was developed. The circuit of the pulse generator was designed and implemented. Additionally, a composite mechanical system was engineered for both drilling and EDM. Two sets of control boards were designed for the hardware terminal. One set was the EDM discharge control board, which detected the discharge state and provided the pulse waveform for turning on the transistor. The other was a relay control card based on STM32, which could meet the switch between EDM and ultrasonic vibration, and used the Modbus protocol to communicate with the machining control software.

The mechanical structure of the designed composite machine tool can effectively avoid interference between the EDM spindle and the drilling spindle. The removal rate of the remelting layer on 1.5 mm single crystal superalloys after composite processing can reach over 90%. The average processing time per millimeter was 55 s, and the measured inner surface roughness of the hole was less than 1.6 µm, which realized the  micro-hole machining without remelting layer, heat affected zone and micro-cracks in the single crystal superalloy.

The test results proved that the key techniques developed in this paper were suite for micro-hole machining of special materials.

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 paper is supposed to provide a critical review of current research progress on thermal management in grinding of superalloys, and future directions and challenges. By understanding the current progress and identifying the developing directions, thermal management can be achieved in the grinding of superalloys to significantly improve the grinding quality and efficiency.

The relevant literature is collected from Web of Science, Scopus, CNKI, Google scholar, etc. A total of 185 literature is analyzed, and the findings in the literature are systematically summarized. In this case, the current development and future trends of thermal management in grinding of superalloys can be concluded.

The recent developments in grinding superalloys, demands, challenges and solutions are analyzed. The theoretical basis of thermal management in grinding, the grinding heat partition analysis, is also summarized. The novel methods and technologies for thermal management are developed and reviewed, i.e. new grinding technologies and parameter optimization, super abrasive grinding wheel technologies, improved lubrication, highly efficient coolant delivery and enhanced heat transfer by passive thermal devices. Finally, the future trends and challenges are identified.

Superalloys have excellent physical and mechanical properties, e.g. high thermal stability, and good high-temperature strength. The superalloys have been broadly applied in the aerospace, energy and automobile industries. Grinding is one of the most important precision machining technologies for superalloy parts. Owing to the mechanical and physical properties of superalloys, during grinding processes, forces are large and a massive heat is generated. Consequently, the improvement of grinding quality and efficiency is limited. It is important to conduct thermal management in the grinding of superalloys to decrease grinding forces and heat generation. The grinding heat is also dissipated in time by enhanced heat transfer methods. Therefore, it is necessary and valuable to holistically review the current situation of thermal management in grinding of superalloys and also provide the development trends and challenges.

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 study aims to solve the problem of weld quality inspection, for the aluminum alloy profile welding structure of high-speed train body has complex internal shape and thin plate thickness (2–4 mm), the conventional nondestructive testing method of weld quality is difficult to implement.

In order to solve this problem, the ultrasonic creeping wave detection technology was proposed. The impact of the profile structure on the creeping wave detection was studied by designing profile structural test blocks and artificial simulation defect test blocks. The detection technology was used to test the actual welded test blocks, and compared with the results of X-ray test and destructive test (tensile test) to verify the accuracy of the ultrasonic creeping wave test results.

It is indicated that that X-ray has better effect on the inspection of porosities and incomplete penetration defects. However, due to special detection method and protection, the detection speed is slow, which cannot meet the requirements of field inspection of the welding structure of aluminum alloy thin-walled profile for high-speed train body. It can be used as an auxiliary detection method for a small number of sampling inspection. The ultrasonic creeping wave can be used to detect the incomplete penetration welds with the equivalent of 0.25 mm or more, the results of creeping wave detection correspond well with the actual incomplete penetration defects.

The results show that creeping wave detection results correspond well with the actual non-penetration defects and can be used for welding quality inspection of aluminum alloy thin-wall profile composite welding joints. It is recommended to use the echo amplitude of the 10 mm × 0.2 mm × 0.5 mm notch as the criterion for weld qualification.

This study aims to apply new modifications by changing the nonlinear logarithmic calculation steps in the method based on the removal effects of criteria (MEREC) method. Geometric and harmonic mean from multiplicative functions is used for the modifications made while extracting the effects of the criteria on the overall performance one by one. Instead of the nonlinear logarithmic measure used in the MEREC method, it is desired to obtain results that are closer to the mean and have a lower standard deviation.

The MEREC method is based on the removal effects of the criteria on the overall performance. The method uses a logarithmic measure with a nonlinear function. MEREC-G using geometric mean and MEREC-H using harmonic mean are introduced in this study. The authors compared the MEREC method, its modifications and some other objective weight determination methods.

MEREC-G and MEREC-H variants, which are modifications of the MEREC method, are shown to be effective in determining the objective weights of the criteria. Findings of the MEREC-G and MEREC-H variants are more convenient, simpler, more reasonable, closer to the mean and have fewer deviations. It was determined that the MEREC-G variant gave more compatible findings with the entropy method.

Decision-making can occur at any time in any area of life. There are various criteria and alternatives for decision-making. In multi-criteria decision-making (MCDM) models, it is a very important distinction to determine the criteria weights for the selection/ranking of the alternatives. The MEREC method can be used to find more reasonable or average results than other weight determination methods such as entropy. It can be expected that the MEREC method will be more used in daily life problems and various areas.

Objective weight determination methods evaluate the weights of the criteria according to the scores of the determined alternatives. In this study, the MEREC method, which is an objective weight determination method, has been expanded. Although a nonlinear measurement model is used in the literature, the contribution was made in this study by using multiplicative functions. As an important originality, the authors demonstrated the effect of removing criteria in the MEREC method in a sensitivity analysis by actually removing the alternatives one by one from the model.

Deployment of deep neural networks on embedded devices is becoming increasingly popular because it can reduce latency and energy consumption for data communication. This paper aims to give out a method for deployment the deep neural networks on a quad-rotor aircraft for further expanding its application scope.

In this paper, a design scheme is proposed to implement the flight mission of the quad-rotor aircraft based on multi-sensor fusion. It integrates attitude acquisition module, global positioning system position acquisition module, optical flow sensor, ultrasonic sensor and Bluetooth communication module, etc. A 32-bit microcontroller is adopted as the main controller for the quad-rotor aircraft. To make the quad-rotor aircraft be more intelligent, the study also proposes a method to deploy the pre-trained deep neural networks model on the microcontroller based on the software packages of the RT-Thread internet of things operating system.

This design provides a simple and efficient design scheme to further integrate artificial intelligence (AI) algorithm for the control system design of quad-rotor aircraft.

This method provides an application example and a design reference for the implementation of AI algorithms on unmanned aerial vehicle or terminal robots.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

Buildings use approximately 40% of global energy and are responsible for almost a third of the worldwide greenhouse gas emissions. They also utilise about 60% of the world’s electricity. In the last decade, stringent building regulations have led to significant improvements in the quality of the thermal characteristics of many building envelopes. However, similar considerations have not been paid to the number and activities of occupants in a building, which play an increasingly important role in energy consumption, optimisation processes, and indoor air quality. More than 50% of the energy consumption could be saved in Demand Controlled Ventilation (DCV) if accurate information about the number of occupants is readily available (Mysen et al., 2005). But due to privacy concerns, designing a precise occupancy sensing/counting system is a highly challenging task. While several studies count the number of occupants in rooms/zones for the optimisation of energy consumption, insufficient information is available on the comparison, analysis and pros and cons of these occupancy estimation techniques. This paper provides a review of occupancy measurement techniques and also discusses research trends and challenges. Additionally, a novel privacy preserved occupancy monitoring solution is also proposed in this paper. Security analyses of the proposed scheme reveal that the new occupancy monitoring system is privacy preserved compared to other traditional schemes.