Nanomanufacturing involves scaled-up, reliable, and cost-effective manufacturing of nanoscale materials, structures, devices, and systems. Nanomanufacturing methods can be classified into top-down and bottom-up approaches, including additive, subtractive, and replication/mass conservation processes. These include a cluster of various techniques such as nanomachining, nanofabrication, and nanometrology to produce nanotechnology components and conduct evaluation. This paper mainly focuses on the manufacturing methods for complex shapes or structures, such as textures on curves and hierarchical structures, and outlines the research perspectives and the current application status of nanomanufacturing fundamentals and key technologies.

https://orbit.dtu.dk/files/138286168/1_s2.0_S0007850617301439_main.pdf

Nanomanufacturing—Perspective and applications

Vibration coupling effects and machining behavior of ultrasonic vibration plate device for creep-feed grinding of Inconel 718 nickel-based superalloy

The service performance of the turbine blade root of an aero-engine depends on the microstructures in its superficial layer. This work investigated the surface deformation structures of turbine blade root of single crystal nickel-based superalloy produced under different creep feed grinding conditions. Gradient microstructures in the superficial layer were clarified and composed of a severely deformed layer (DFL) with nano-sized grains (48–67 nm) at the topmost surface, a DFL with submicron-sized grains (66–158 nm) and micron-sized laminated structures at the subsurface, and a dislocation accumulated layer extending to the bulk material. The formation of such gradient microstructures was found to be related to the graded variations in the plastic strain and strain rate induced in the creep feed grinding process, which were as high as 6.67 and 8.17×107 s-1, respectively. In the current study, the evolution of surface gradient microstructures was essentially a transition process from a coarse single crystal to nano-sized grains and, simultaneously, from one orientation of a single crystal to random orientations of polycrystals, during which the dislocation slips dominated the creep feed grinding induced microstructure deformation of single crystal nickel-based superalloy.

https://iopscience.iop.org/article/10.1088/2631-7990/ac1e05/pdf

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

Influence of the WEDM process on the fatigue behavior of Inconel® 718

The aerospace industry has experienced significant growth over the past decade and it is estimated that nearly 30,000 new commercial passenger aircraft will be required by 2030 to meet rising global demand. Abrasive machining is a key material removal process utilised in the production of aeroengine components. Current industrial practice and perspectives relating to grinding in the aerospace sector are presented including general workpiece surface integrity standards/requirements, fluid delivery systems, wheel preparation options and machine tool designs/configurations. Corresponding academic research on the machinability of aerospace alloys and composites are critically reviewed together with recent developments involving novel/innovative grinding processes.

Abrasive machining of advanced aerospace alloys and composites

The paper details experimental work on ultrasonic assisted creep feed grinding (UACFG) of γ-TiAl intermetallic alloy: Ti–45Al–2Mn–2Nb + 0.8 vol.%TiB2XD (wt%), using conventional SiC and electroplated diamond wheels. The majority of forces recorded were lower when using vibration assistance compared to conventional CFG by up to ∼35%, while grinding-ratios for the superabrasive wheel were substantially higher by a factor of 2–7. A reduction in workpiece surface roughness by up to ∼10% together with fewer defects and marginally increased subsurface microhardness by a maximum of ∼8%, was obtained when employing ultrasonic assistance. With uprated process parameters however, the effects of UACFG were less apparent.

/pdf/ultrasonic-assisted-creep-feed-grinding-of-gamma-titanium-2usn0wtiu1.pdf

John A. Webster

Papers

Abrasive machining of advanced aerospace alloys and composites

Ultrasonic assisted creep feed grinding of gamma titanium aluminide using conventional and superabrasive wheels