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Journal of Manufacturing and Materials Processing, Volume 6, Issue 4

2022 August - 24 articles

Cover Story: The reduction in greenhouse gas emissions is fostering new challenges in the design of busbar power distribution systems for electric vehicles. The replacement of copper by aluminum leads to 32% mass and 84% cost savings, but gains in efficiency require substituting conventional bolting and welding by new processes that effectively diminish the electrical resistance of the busbar joints. Injection lap riveting is one of these processes that minimizes the electric current disturbance without having the assembly space and reliability problems of bolting and welding. The results show that the electric resistance of injection-lap-riveted joints is three times smaller than that of bolted joints, and that values increase only up to 6 μΩ (30%) when the service temperature approaches 105 °C. View this paper
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Articles (24)

  • Article
  • Open Access
10 Citations
4,519 Views
20 Pages

A Design of Experiment Approach for Development of Electron Beam Powder Bed Fusion Process Parameters and Improvement of Ti-6Al-4V As-Built Properties

  • Dor Braun,
  • Yaron Itay Ganor,
  • Shmuel Samuha,
  • Gilad Mordechai Guttmann and ,
  • Michael Chonin,
  • Nachum Frage,
  • Shmuel Hayun and
  • Eitan Tiferet
  • + 3 authors+ 0 author

Additive manufacturing is a novel and breakthrough technology by which parts can be manufactured for various purposes and services. As in any production process, the desired properties of additively manufactured components, particularly in electron b...

  • Article
  • Open Access
15 Citations
3,630 Views
15 Pages

2D Axisymmetric Modeling of Refill Friction Stir Spot Welding and Experimental Validation

  • Evan Berger,
  • Michael Miles,
  • Andrew Curtis,
  • Paul Blackhurst and
  • Yuri Hovanski

The development of the simulation of refill friction stir spot welding (RFSSW) is critical to be able to predict the behavior of aluminum in the process under specific parameters. A two-dimensional axisymmetric thermo-mechanical model of the RFSSW pr...

  • Article
  • Open Access
14 Citations
5,843 Views
23 Pages

Developing an Automated System to Control the Rolled Product Section for a Wire Rod Mill with Multi-Roll Passes

  • Andrey A. Radionov,
  • Olga I. Petukhova,
  • Ivan N. Erdakov,
  • Alexander S. Karandaev and ,
  • Boris M. Loginov and
  • Vadim R. Khramshin
  • + 1 author+ 0 author

The key priority of metallurgical industry development is expanding the range and improving the quality of bar products and their major component, steel wire. Continuous wire rod mills with multi-roll passes have been developed and implemented over t...

  • Article
  • Open Access
21 Citations
6,166 Views
17 Pages

Influences of Surface, Heat Treatment, and Print Orientation on the Anisotropy of the Mechanical Properties and the Impact Strength of Ti 6Al 4V Processed by Laser Powder Bed Fusion

  • Benjamin Meier,
  • Norica Godja,
  • Fernando Warchomicka,
  • Carlos Belei and ,
  • Sandra Schäfer,
  • Andreas Schindel,
  • Gregor Palcynski,
  • Reinhard Kaindl,
  • Wolfgang Waldhauser and
  • Christof Sommitsch
  • + 5 authors+ 0 author

The scope of this work is to provide an overview of the influences of process parameters, print orientation, and post-process treatments of Ti6AlV4 processed by laser powder bed fusion on its microstructure and physical and mechanical properties and...

(This article belongs to the Special Issue Metal Additive Manufacturing and Its Post Processing Techniques)
  • Article
  • Open Access
32 Citations
6,103 Views
23 Pages

Powder-bed binder jet 3D printing is a flexible method for producing magnesium oxychloride (MOC)-based articles. Despite the great potential of this additive manufacturing technology for producing free-form MOC cement-based components, the influence...

  • Feature Paper
  • Article
  • Open Access
25 Citations
8,604 Views
23 Pages

The microstructure, static, and fatigue mechanical properties of laser powder bed fused (LPBF) Ti-6Al-4V components subjected to three different post-processing treatments (PTs) are compared. The first treatment includes stress relief (SR) and beta-p...

(This article belongs to the Special Issue Metal Additive Manufacturing and Its Post Processing Techniques)
  • Article
  • Open Access
20 Citations
8,652 Views
11 Pages

This article presents a cost-effective and reliable method for welding 30 mm thick sheets of shipbuilding steel EH36. The method proposes to perform butt welding in a two-run technique using hybrid laser arc welding (HLAW) and submerged arc welding (...

(This article belongs to the Special Issue Advances in Welding Technology)
  • Article
  • Open Access
10 Citations
4,632 Views
19 Pages

Areal Analysis Investigation of Selective Laser Melting Parts

  • Alberto Boschetto,
  • Luana Bottini and
  • Nahal Ghanadi

Selective laser melting is an additive manufacturing technology used to fabricate metal parts characterized by complex geometries that are difficult or impossible to produce with conventional production methods. One of the major drawbacks of laser me...

(This article belongs to the Special Issue Laser-Based Manufacturing II)
  • Article
  • Open Access
27 Citations
6,282 Views
12 Pages

Prediction of Surface Roughness of SLM Built Parts after Finishing Processes Using an Artificial Neural Network

  • Daniel Soler,
  • Martín Telleria,
  • M. Belén García-Blanco,
  • Elixabete Espinosa and ,
  • Mikel Cuesta and
  • Pedro José Arrazola
  • + 1 author+ 0 author

A known problem of additive manufactured parts is their poor surface quality, which influences product performance. There are different surface treatments to improve surface quality: blasting is commonly employed to improve mechanical properties and...

(This article belongs to the Special Issue Metal Additive Manufacturing and Its Post Processing Techniques)
  • Article
  • Open Access
2 Citations
3,263 Views
11 Pages

Analysis of Surface Grinding of Thermoplastics Specimens with Inline Measurements

  • Roberto Spina,
  • Bruno Melo Cavalcante,
  • Maria Grazia Guerra and
  • Marco Massari

This paper analyzes the surface grinding of unfilled and glass-filled polyamides. The process is performed by varying the workpiece velocities to evaluate applied practical applications in the industry while being energy efficient. During the machini...

  • Article
  • Open Access
16 Citations
5,448 Views
14 Pages

A Generalized Method for In-Process Defect Detection in Friction Stir Welding

  • Johnathon B. Hunt,
  • Brian A. Mazzeo,
  • Carl D. Sorensen and
  • Yuri Hovanski

Friction stir welding (FSW) is an advantageous solid-state joining process that is suitable for many materials in multiple industries. In an industrial setting, manufacturers are actively seeking faster welding speeds to increase throughput. Increasi...

  • Article
  • Open Access
5 Citations
3,576 Views
12 Pages

Fabrication of Highly Compacted Green Body Using Multi-Sized Al Powder under a Centrifugal Force

  • Bakytzhan Sariyev,
  • Abilkhairkhan Aldabergen,
  • Dulat Akzhigitov,
  • Boris Golman and
  • Christos Spitas

This study investigates the application of centrifugal force for the compaction of metal powder. Previous studies using the centrifugal force for manufacturing the green bodies were focused on fine powders with narrow particle size distribution or bi...

  • Article
  • Open Access
6 Citations
4,771 Views
32 Pages

To verify the mathematical model of the water-jet cooling of steel plates developed by the authors, previously performed experimental studies of the temperature of the test plates in a roller-quenching machine (RQM) were used. The calculated temperat...

  • Article
  • Open Access
22 Citations
4,893 Views
15 Pages

In this work, the expansion of friction stir welding (FSW) in parts made via material extrusion (MEX) 3D printing was investigated. Poly(methyl methacrylate) (PMMA) plates were joined in a full factorial experimental design. The effects of three FSW...

(This article belongs to the Special Issue Frontiers in Friction Stir Welding and Processing)
  • Article
  • Open Access
24 Citations
11,146 Views
19 Pages

Flange wrinkling is often seen in deep-drawing process when the applied blankholding force is too small. This paper investigates the plastic wrinkling of flange under a constant blankholding force. A series of deep-drawing experiments of AA1100-O bla...

(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
  • Article
  • Open Access
31 Citations
6,851 Views
17 Pages

Pallet racking is a fundamental component within the manufacturing, storage, and distribution centers of companies around the World. It requires continuous inspection and maintenance to guarantee the protection of stock and the safety of personnel. A...

  • Article
  • Open Access
15 Citations
7,667 Views
16 Pages

Injection Lap Riveting of Aluminum Busbars—A Thermo-Electro-Mechanical Investigation

  • João P. M. Pragana,
  • Rui F. V. Sampaio,
  • Ivo M. F. Bragança,
  • Carlos M. A. Silva and
  • Paulo A. F. Martins

This paper presents a new mechanical joining process to assemble aluminum busbars in energy distribution systems. The process is based on the extension of injection lap riveting to the connection of busbars made from the same material as the rivets a...

  • Article
  • Open Access
2 Citations
3,391 Views
19 Pages

Additive Manufacturing (AM) appears to be the best candidate to manufacture random architected materials, as it offers significant freedom in the design of hollowed parts with complex geometry. However, when these structures are needed with thins wal...

  • Article
  • Open Access
34 Citations
7,255 Views
20 Pages

Laser Additive Manufacturing of Duplex Stainless Steel via Powder Mixture

  • Chengsong Cui,
  • Louis Becker,
  • Eric Gärtner,
  • Johannes Boes and ,
  • Jonathan Lentz,
  • Volker Uhlenwinkel,
  • Matthias Steinbacher,
  • Sebastian Weber and
  • Rainer Fechte-Heinen
  • + 4 authors+ 0 author

Laser additively manufactured duplex stainless steels contain mostly ferrite in the as-built parts due to rapid solidification of the printed layers. To achieve duplex microstructures (ferrite and austenite in roughly equal proportions) and, thus, a...

(This article belongs to the Special Issue Laser-Based Manufacturing II)
  • Article
  • Open Access
8 Citations
5,239 Views
21 Pages

Non-destructive testing (NDT) is a quality control measure designed to ensure the safety of products according to established variability thresholds. With the development of advanced technologies and a lack of formalised knowledge of the state-of-the...

(This article belongs to the Special Issue Selected Papers from the 30th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2020-2021))
  • Article
  • Open Access
12 Citations
4,267 Views
19 Pages

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

  • Derek Vaughan,
  • Christopher Saldana,
  • Thomas Kurfess and
  • Andrzej Nycz

Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machin...

(This article belongs to the Special Issue Hybrid Manufacturing)
  • Review
  • Open Access
37 Citations
10,726 Views
35 Pages

Photocatalytic Materials Obtained from E-Waste Recycling: Review, Techniques, Critique, and Update

  • Ashkan Bahadoran,
  • Jeffrey Roshan De Lile,
  • Saeid Masudy-Panah,
  • Behzad Sadeghi and ,
  • Jiaxin Li,
  • Mohammad Hosein Sabzalian,
  • Seeram Ramakrishna,
  • Qinglei Liu,
  • Pasquale Cavaliere and
  • Arun Gopinathan
  • + 5 authors+ 0 author

Waste-derived materials obtained from the recovery and recycling of electronic waste (e-waste) such as batteries and printed circuit boards have attracted enormous attention from academia and industry in recent years, especially due to their eco-frie...

  • Article
  • Open Access
20 Citations
5,421 Views
14 Pages

Numerical Simulation of the Thermo-Mechanical Behavior of 6061 Aluminum Alloy during Friction-Stir Welding

  • Vasiliy Mishin,
  • Ivan Shishov,
  • Alexander Kalinenko,
  • Igor Vysotskii and ,
  • Ivan Zuiko,
  • Sergey Malopheyev,
  • Sergey Mironov and
  • Rustam Kaibyshev
  • + 3 authors+ 0 author

In this work, a finite-element model was elaborated to simulate the thermomechanical behavior of 6061 aluminum alloy during friction-stir welding (FSW). It was shown that FSW-induced deformation is a two-stage process. In addition to the stirring act...

  • Article
  • Open Access
15 Citations
6,500 Views
15 Pages

Processability and Physical Properties of Compatibilized Recycled HDPE/Rice Husk Biocomposites

  • Andrés Rigail-Cedeño,
  • Miriam Lazo,
  • Julio Gaona,
  • Joshua Delgado and ,
  • Clotario V. Tapia-Bastidas,
  • Ana L. Rivas,
  • Estephany Adrián and
  • Rodrigo Perugachi
  • + 3 authors+ 0 author

The circular economy promotes plastic recycling, waste minimization, and sustainable materials. Hence, the use of agricultural waste and recycled plastics is an eco-friendly and economic outlook for developing eco-designed products. Moreover, new alt...

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J. Manuf. Mater. Process. - ISSN 2504-4494