Journal Description
Journal of Manufacturing and Materials Processing
Journal of Manufacturing and Materials Processing
is an international, peer-reviewed, open access journal on the scientific fundamentals and engineering methodologies of manufacturing and materials processing published bimonthly online by MDPI.
- Open Access— free for readers, with article processing charges (APC) paid by authors or their institutions.
- High Visibility: indexed within Scopus, ESCI (Web of Science), Inspec, CAPlus / SciFinder, and other databases.
- Journal Rank: CiteScore - Q1 (Mechanical Engineering)
- Rapid Publication: manuscripts are peer-reviewed and a first decision is provided to authors approximately 14.2 days after submission; acceptance to publication is undertaken in 2.9 days (median values for papers published in this journal in the second half of 2023).
- Recognition of Reviewers: reviewers who provide timely, thorough peer-review reports receive vouchers entitling them to a discount on the APC of their next publication in any MDPI journal, in appreciation of the work done.
Impact Factor:
3.2 (2022);
5-Year Impact Factor:
3.6 (2022)
Latest Articles
High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation
J. Manuf. Mater. Process. 2024, 8(2), 60; https://doi.org/10.3390/jmmp8020060 - 15 Mar 2024
Abstract
A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed
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A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed hollow tube and help us to find an optimal process design. Experimental trials show the significant effect of the axial material flow and the number of tools on the rotary swaging process. By taking these effects into account, successful form- and force-fit joining of the sensor carrying discs into the tube can be achieved. Successful joining of an optical sensor for bending force and torque measurement shows hysteresis-free sensory behavior and thus backlash-free joining of the sensor carrier discs. The paper concludes with a presentation of the results of a numerical study on a potential closed-loop approach to the joining process.
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(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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Minimizing Dimensional Defects in FFF Using a Novel Adaptive Slicing Method Based on Local Shape Complexity
by
Ahmed Elayeb, Mehdi Tlija, Ameni Eltaief, Borhen Louhichi and Farhat Zemzemi
J. Manuf. Mater. Process. 2024, 8(2), 59; https://doi.org/10.3390/jmmp8020059 - 11 Mar 2024
Abstract
Additive Manufacturing (AM) has emerged as an innovative technology that gives designers several advantages, such as geometric freedom of design and less waste. However, the quality of the parts produced is affected by different design and manufacturing parameters, such as the part orientation,
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Additive Manufacturing (AM) has emerged as an innovative technology that gives designers several advantages, such as geometric freedom of design and less waste. However, the quality of the parts produced is affected by different design and manufacturing parameters, such as the part orientation, the nozzle temperature and speed, the support material, and the layer thickness. In this context, the layer thickness is considered an important AM parameter affecting the part quality and accuracy. Thus, in this paper, a new adaptative slicing method based on the cusp vector and the surface deviation is proposed with the aim of minimizing the dimensional defects of FFF printed parts and investigate the impact on the dimensional part tolerancing. An algorithm is developed to automatically extract data from the STL file, select the build orientation, and detect intersection points between the initial slicing and the STL mesh. The innovation of this algorithm is exhibited via adapting the slicing according to the surface curvature based on two factors: the cusp vector and the surface deviation. The suggested slicing technique guarantees dimensional accuracy, especially for complex feature shapes that are challenging to achieve using a uniform slicing approach. Finally, a preview of the slicing is displayed, and the G-code is generated to be used by the FFF machine. The case study consists of the dimensional tolerance inspection of prototypes manufactured using the conventional and adaptive slicing processes. The proposed method’s effectiveness is investigated using RE and CMM processes. The method demonstrates its reliability through the observed potential for accuracy improvements exceeding 0.6% and cost savings of up to 4.3% in specific scenarios. This reliability is substantiated by comparing the resulting dimensional tolerances and manufacturing costs.
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(This article belongs to the Topic Additive Manufacturing of Architected Metallic Materials)
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Open AccessArticle
AA5754–Al2O3 Nanocomposite Prepared by Friction Stir Processing: Microstructural Evolution and Mechanical Performance
by
Moustafa M. Mohammed, Mahmoud E. Abdullah, M. Nafea M. Rohim, Andrzej Kubit and Hamed Aghajani Derazkola
J. Manuf. Mater. Process. 2024, 8(2), 58; https://doi.org/10.3390/jmmp8020058 - 08 Mar 2024
Abstract
The utilization of Al2O3 nanopowder to reinforce AA5754 aluminum alloy through blind holes employing the friction stir processing (FSP) technique to produce an aluminum matrix nanocomposite is explored in this paper. Motivated by the necessity to enhance the strength and
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The utilization of Al2O3 nanopowder to reinforce AA5754 aluminum alloy through blind holes employing the friction stir processing (FSP) technique to produce an aluminum matrix nanocomposite is explored in this paper. Motivated by the necessity to enhance the strength and ductility of welded joints, the impacts of varying the tool rotational speed (rpm) and blind hole diameter on the microstructure and mechanical properties of the joints are investigated. Experimental characterization techniques including SEM, optical microscopy, microhardness, and tensile tests were employed to analyze the welded joints produced under different processing parameters (tool rotational speeds of 910, 1280, and 1700 rpm, and blind hole diameters of 0, 1, 1.5, and 2 mm). Comparative analyses were conducted against base metal properties and joints without reinforcement powder. It was found that the addition of nanopowder resulted in a decrease in the maximum generated heat during FSP, while also reducing the stir zone size compared to samples without nanopowder. Moreover, enhancements in both the strength and ductility of the joints were observed with the incorporation of Al2O3 nanoparticles. The optimal combination of welding conditions, observed at 1280 rpm rotational speed and 1.5 mm hole diameter, yielded a remarkable ultimate tensile strength of 567 MPa, accompanied by a hardness of 45 HV. These results underscore the potential of nano-Al2O3 reinforcement in significantly improving the mechanical properties of the produced nanocomposite, with implications for advancing the performance of welded structures in various engineering applications.
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(This article belongs to the Special Issue Recent Developments in Friction Stir Welding Technology and Applications)
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Advances in Additive Friction Extrusion Deposition (AFED): Process and Tool Design
by
Max Hossfeld and Arnold Wright
J. Manuf. Mater. Process. 2024, 8(2), 57; https://doi.org/10.3390/jmmp8020057 - 05 Mar 2024
Abstract
Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular, the processing strategy
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Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular, the processing strategy and tool design are still in their infancy. This work contributes to the state-of-the-art of AFED through a comprehensive analysis of its working principles and an experimental program, including a representative sample component. The working principle and process mechanics of AFED are broken down into their individual components. The forces and their origins and effects on the process are described, and measures of process efficiency and theoretical minimum energy consumption are derived. Three geometrical features of the extrusion die were identified as most relevant to the active material flow, process forces, and deposition quality: the topography of the inner and outer circular surfaces and the geometry of its extrusion channels. Based on this, the experimental program investigated seven different tool designs in terms of efficiency, force reduction, and throughput. The experiments using AA 6061-T6 as feedstock show that AFED is capable of both high material throughput (close to 550 mm3/s) and reduced substrate forces, for example, the forces for a run at 100 mm3/s remained continuously below 500 N and for a run at 400 mm3/s below 3500 N. The material flow and microstructure of AFED were assessed from macro-sections. Significant differences were found between the advancing and retracting sides for both process effects and material flow. Banded structures in the microstructure show strong similarities to other solid-state processes. The manufacturing of the sample components demonstrates that AFED is already capable of producing industrial-grade components. In mechanical tests, interlayer bonding defects resulted in more brittle failure behavior in the build direction of the structure, whereas in the horizontal direction, mechanical properties corresponding to a T4 temper were achieved.
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(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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Open AccessArticle
Characterization of the Dimensional Precision, Physical Bonding, and Tensile Performance of 3D-Printed PLA Parts with Different Printing Temperature
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Rayson Pang, Mun Kou Lai, Khairul Izwan Ismail and Tze Chuen Yap
J. Manuf. Mater. Process. 2024, 8(2), 56; https://doi.org/10.3390/jmmp8020056 - 05 Mar 2024
Abstract
In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test specimens were fabricated using PLA
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In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test specimens were fabricated using PLA material, with printing temperatures ranging from 180 °C to 260 °C. Experimental investigations were conducted to investigate the dimensional accuracy and physical appearance of the parts across printing temperatures. Uniaxial tensile tests were conducted at a strain rate of 1 mm/min and repeated five times for each variable in accordance with the ASTM D638-14 standard. Results showed that increasing the printing temperatures yielded parts with better tensile properties. An approximate difference of 40% in tensile strength was observed between specimens fabricated under the two most extreme conditions (180 °C and 260 °C). The changes in tensile properties were attributed to bonding mechanisms related to interlayer bonding strength and a reduction in voids within the internal geometry. Analysis of the fracture surface using scanning electron microscopy (SEM) revealed fewer and smaller voids within the internal geometry for parts printed at higher temperature. The percentage area of voids reduced significantly when the printing temperature was increased from 180 °C to 220 °C. The tensile properties continuously improved with the printing temperature, with parts printed at 220 °C exhibiting the highest dimensional accuracy. The findings offer insight into the impact of the printing temperature on both the external physical bonds between printed roads, affecting the physical appearance and dimensional accuracy, and the internal bonds, affecting the tensile properties of the fabricated parts.
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(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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Open AccessArticle
Dissimilar Probeless Friction Stir Spot Welding of Aluminum Alloy and USIBOR®1500-AS Steel Thin Plates
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Mariia Rashkovets, Maria Emanuela Palmieri, Nicola Contuzzi, Luigi Tricarico and Giuseppe Casalino
J. Manuf. Mater. Process. 2024, 8(2), 55; https://doi.org/10.3390/jmmp8020055 - 04 Mar 2024
Abstract
Lap joining of an aluminum AA6082-T6 plate and a UHSS steel plate coated with an Al-Si layer was performed using Probeless Friction Stir Spot Welding (P-FSSW). The dwell time and rotational speed were controlled in the range of 10–15 s and 1000–1500 rpm,
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Lap joining of an aluminum AA6082-T6 plate and a UHSS steel plate coated with an Al-Si layer was performed using Probeless Friction Stir Spot Welding (P-FSSW). The dwell time and rotational speed were controlled in the range of 10–15 s and 1000–1500 rpm, respectively. For all the samples, thermo-mechanical deformation occurred solely within the upper AA6082 plate. A refined grain structure was formed in the aluminum plate close to the surface. The dwell time was responsible for the intensity of the material flow, resulting in stirring between the Al-Si layer and the aluminum plate at 15 s. The microhardness distribution corresponded to the microstructure features.
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(This article belongs to the Special Issue Advanced Joining Processes and Techniques 2023)
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Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review
by
Alireza Vahedi Nemani, Mahya Ghaffari, Kazem Sabet Bokati, Nima Valizade, Elham Afshari and Ali Nasiri
J. Manuf. Mater. Process. 2024, 8(2), 54; https://doi.org/10.3390/jmmp8020054 - 02 Mar 2024
Abstract
Copper-based materials have long been used for their outstanding thermal and electrical conductivities in various applications, such as heat exchangers, induction heat coils, cooling channels, radiators, and electronic connectors. The development of advanced copper alloys has broadened their utilization to include structural applications
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Copper-based materials have long been used for their outstanding thermal and electrical conductivities in various applications, such as heat exchangers, induction heat coils, cooling channels, radiators, and electronic connectors. The development of advanced copper alloys has broadened their utilization to include structural applications in harsh service conditions found in industries like oil and gas, marine, power plants, and water treatment, where good corrosion resistance and a combination of high strength, wear, and fatigue tolerance are critical. These advanced multi-component structures often have complex designs and intricate geometries, requiring extensive metallurgical processing routes and the joining of the individual components into a final structure. Additive manufacturing (AM) has revolutionized the way complex structures are designed and manufactured. It has reduced the processing steps, assemblies, and tooling while also eliminating the need for joining processes. However, the high thermal conductivity of copper and its high reflectivity to near-infrared radiation present challenges in the production of copper alloys using fusion-based AM processes, especially with Yb-fiber laser-based techniques. To overcome these difficulties, various solutions have been proposed, such as the use of high-power, low-wavelength laser sources, preheating the build chamber, employing low thermal conductivity building platforms, and adding alloying elements or composite particles to the feedstock material. This article systematically reviews different aspects of AM processing of common industrial copper alloys and composites, including copper-chrome, copper-nickel, tin-bronze, nickel-aluminum bronze, copper-carbon composites, copper-ceramic composites, and copper-metal composites. It focuses on the state-of-the-art AM techniques employed for processing different copper-based materials and the associated technological and metallurgical challenges, optimized processing variables, the impact of post-printing heat treatments, the resulting microstructural features, physical properties, mechanical performance, and corrosion response of the AM-fabricated parts. Where applicable, a comprehensive comparison of the results with those of their conventionally fabricated counterparts is provided.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessArticle
The Impact of PP-g-MAH on Mechanical Properties of Injection Molding of Long Glass Fiber/Polypropylene Pellets from Thermoplastic Pultrusion Process
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Ponlapath Tipboonsri and Anin Memon
J. Manuf. Mater. Process. 2024, 8(2), 53; https://doi.org/10.3390/jmmp8020053 - 02 Mar 2024
Abstract
Long fiber thermoplastic pellets are pellets containing discontinuous reinforced fibers and a matrix, offering excellent mechanical properties, good processability, recyclability, and low cost. Typically, commercial LFTP is manufactured through the hot melt impregnation process, combining extrusion and pultrusion. Although there is a thermoplastic
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Long fiber thermoplastic pellets are pellets containing discontinuous reinforced fibers and a matrix, offering excellent mechanical properties, good processability, recyclability, and low cost. Typically, commercial LFTP is manufactured through the hot melt impregnation process, combining extrusion and pultrusion. Although there is a thermoplastic pultrusion process for LFTP production, characterized by a simple machine and an easy method, its mechanical properties have not yet approached those of commercial LFTP. In improving the mechanical characteristics of LFTP manufactured via thermoplastic pultrusion, this research employed polypropylene-graft-maleic anhydride as a coupling agent during the injection molding procedure. The LFTP is composed of polypropylene material reinforced with glass fiber. Mechanical and physical properties of the LFTP were investigated by introducing PP-g-MAH at concentrations of 4, 8, and 12 wt% through injection molding. The results revealed that, at a 4 wt% concentration of PP-g-MAH, the LFTP composites exhibited heightened tensile, flexural and impact strengths. However, these properties began to decrease upon exceeding 4 wt% PP-g-MAH. The enhanced interfacial adhesion among glass fibers, induced by PP-g-MAH, contributed to this improvement. Nonetheless, excessive amounts of PP-g-MAH led to a reduction in molecular weight, subsequently diminishing the impact strength, tensile modulus, and flexural modulus. In LFTP composites, both tensile and flexural strengths exhibited a positive correlation with the PP-g-MAH concentration, attributed to improved interfacial adhesion between glass fibers and polypropylene, coupled with a reduction in fiber pull-out. Based on morphological analysis by SEM, the incorporation of PP-g-MAH improved interfacial bonding and decreased fiber pull-out. The presence of maleic anhydride in the LFTPc was confirmed through the utilization of FTIR spectroscopy. Mechanical properties of LFTP containing 4 wt% PP-g-MAH were found to be equivalent to or superior to those of commercial LFTP, according to the results of a comparative analysis.
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(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)
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Parametric Optimization of Selective Laser Melted 13Ni400 Maraging Steel by Taguchi Method
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Viraj Vishwas Patil, Chinmaya P. Mohanty and K. G. Prashanth
J. Manuf. Mater. Process. 2024, 8(2), 52; https://doi.org/10.3390/jmmp8020052 - 02 Mar 2024
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This study’s novel 13Ni400 maraging steel parts are additively manufactured through a selective laser melting process. The Taguchi approach is adopted to evaluate the combined influence of process variables (energy density), viz., laser power, layer thickness, hatch spacing, and scan speed, on responses
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This study’s novel 13Ni400 maraging steel parts are additively manufactured through a selective laser melting process. The Taguchi approach is adopted to evaluate the combined influence of process variables (energy density), viz., laser power, layer thickness, hatch spacing, and scan speed, on responses like relative density, microhardness, surface roughness, and tensile strength. The powder and material characterization studies are conducted in terms of an optical microscope, scanning electron microscope (SEM), electron backscatter diffraction (EBSD), X-ray diffraction (XRD), and fractography analysis to explore the pre- and post-fabrication scenarios of the build parts. The consequences of energy density and process variables are studied through meticulous parametric studies. Finally, the optimum level of built parameters is identified and validated by a confirmative test predicting an average error of ~1.80%. This work is proficient in producing defect-free parts with maximum densification and improved mechanical properties for newly developed 13Ni-400 maraging steel by the selective laser melting (SLM) technique.
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Ensuring Part Quality for Material Extrusion by Developing a Methodology for Use-Case-Specific Parameter Set Determination Using Machine Learning Models
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Carsten Schmidt, Rainer Griesbaum, Jan T. Sehrt and Florian Finsterwalder
J. Manuf. Mater. Process. 2024, 8(2), 51; https://doi.org/10.3390/jmmp8020051 - 02 Mar 2024
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The material extrusion of plastics has matured into a lucrative and flexible alternative to conventional manufacturing. A major downside of this process is the missing quality assurance caused by the influence of process parameters on part quality. Such parameters—e.g., infill density and print
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The material extrusion of plastics has matured into a lucrative and flexible alternative to conventional manufacturing. A major downside of this process is the missing quality assurance caused by the influence of process parameters on part quality. Such parameters—e.g., infill density and print speed—are selected prior to manufacturing. As a result, the achieved part quality is mostly unknown, limiting the use of material extrusion and leading to increased material costs and print times. A promising approach to overcome this drawback are prediction models, especially methods of machine learning. Yet, a methodology that enables their integration in the manufacturing process is lacking. This paper provides a methodology based on a lookup approach and calculated safety factors. The methodology is tested and subsequently applied to two exemplary use cases. The result empowers users and researchers with a methodology to use prediction models for quality assurance in their company environment. On the other hand, future improvements and new research results can be integrated into the methodology to verify its applicability in practice.
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Modelling the Evolution of Phases during Laser Beam Welding of Stainless Steel with Low Transformation Temperature Combining Dilatometry Study and FEM
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Karthik Ravi Krishna Murthy, Fatma Akyel, Uwe Reisgen, Simon Olschok and Dhamini Mahendran
J. Manuf. Mater. Process. 2024, 8(2), 50; https://doi.org/10.3390/jmmp8020050 - 01 Mar 2024
Abstract
In this study, the evolution of volume fractions during laser beam welding (LBW) of stainless steel, with a specific focus on incorporating the low transformation temperature (LTT) effect using the dilatometer, has been proposed. The LTT effect refers to the phase transformations that
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In this study, the evolution of volume fractions during laser beam welding (LBW) of stainless steel, with a specific focus on incorporating the low transformation temperature (LTT) effect using the dilatometer, has been proposed. The LTT effect refers to the phase transformations that occur at lower temperatures and lead to the formation of a martensitic microstructure, which will significantly influence the residual stresses and distortion of the welded joints. In this research, the LTT conditions are achieved by varying the Cr and Ni content in the weld seam by varying the weld parameter, including laser power, welding speed and filler wire speed. The dilatometer analysis technique is employed to simulate the thermal conditions encountered during LBW. By subjecting the stainless steel samples to controlled heating and cooling cycles, the kinetics of the volume fractions can be measured using the lever rule and empirical method (KOP and Lee). The phase transformation simulation model is computed by integrating the thermal and metallurgical effects to predict the volume fractions in LBW joints and has been validated using dilatometer results. This provides valuable insight into the relationship between welding parameters and phase transformations in stainless steel with the LTT effect during laser beam welding. Using this relationship, the weld quality can be improved by reducing the residual stresses and distortion.
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(This article belongs to the Special Issue Advanced Joining Processes and Techniques 2023)
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In Situ Stereo Digital Image Correlation with Thermal Imaging as a Process Monitoring Method in Vacuum-Assisted Thermoforming
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Rasoul Varedi, Bart Buffel and Frederik Desplentere
J. Manuf. Mater. Process. 2024, 8(2), 49; https://doi.org/10.3390/jmmp8020049 - 01 Mar 2024
Abstract
This experimental study probes the dynamic behaviour of a 3 mm ABS sheet during positive mould vacuum-assisted thermoforming. In this process, the sheet undergoes large and fast deformations caused by the applied vacuum and mechanical stretching by the mould. The objective is to
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This experimental study probes the dynamic behaviour of a 3 mm ABS sheet during positive mould vacuum-assisted thermoforming. In this process, the sheet undergoes large and fast deformations caused by the applied vacuum and mechanical stretching by the mould. The objective is to elucidate the complexities of these large, rapid, and non-isothermal deformations. The non-isothermal conditions are caused by the radiative heating of the sheet, convective heat loss to the surrounding air, and conductive heat transfer from the sheet to the mould. By utilizing stereo digital image correlation (DIC) in tandem with thermal imaging, the present study accurately maps the occurring displacement, strain, and strain rate field in relation to real-time temperature variation in the material. The study progresses to observe the ABS material from the moment it contacts the mould until it conforms to a positive 250 mm diameter semi-sphere cast aluminum mould. The DIC methods are validated by comparing thickness values derived from DIC’s principal strain directions to ultrasonic thickness gauge readings. This knowledge not only broadens the understanding of the thermo-mechanical behaviour of the material but also aids in optimizing process parameters for improved thickness uniformity in thermoformed products.
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(This article belongs to the Special Issue Advances in Material Forming)
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Characterization of Microstructural and Mechanical Properties of 17-4 PH Stainless Steel by Cold Rolled and Machining vs. DMLS Additive Manufacturing
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Pablo Moreno-Garibaldi, Melvyn Alvarez-Vera, Juan Alfonso Beltrán-Fernández, Rafael Carrera-Espinoza, Héctor Manuel Hdz-García, J. C. Díaz-Guillen, Rita Muñoz-Arroyo, Javier A. Ortega and Paul Molenda
J. Manuf. Mater. Process. 2024, 8(2), 48; https://doi.org/10.3390/jmmp8020048 - 01 Mar 2024
Abstract
The 17-4 PH stainless steel is widely used in the aerospace, petrochemical, chemical, food, and general metallurgical industries. The present study was conducted to analyze the mechanical properties of two types of 17-4 PH stainless steel—commercial cold-rolled and direct metal laser sintering (DMLS)
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The 17-4 PH stainless steel is widely used in the aerospace, petrochemical, chemical, food, and general metallurgical industries. The present study was conducted to analyze the mechanical properties of two types of 17-4 PH stainless steel—commercial cold-rolled and direct metal laser sintering (DMLS) manufactured. This study employed linear and nonlinear tensile FEM simulations, combined with various materials characterization techniques such as tensile testing and nanoindentation. Moreover, microstructural analysis was performed using metallographic techniques, optical microscopy, scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The results on the microstructure for 17-4 PH DMLS stainless steel reveal the layers of melting due to the laser process characterized by complex directional columnar structures parallel to the DMLS build direction. The mechanical properties obtained from the simple tension test decreased by 17% for the elastic modulus, 7.8% for the yield strength, and 7% for the ultimate strength for 17-4 PH DMLS compared with rolled 17-4 PH stainless steel. The FEM simulation using the experimental tension test data revealed that the 17-4 PH DMLS stainless steel experienced a decrease in the yield strength of ~8% and in the ultimate strength of ~11%. A reduction of the yield strength of the material was obtained as the grain size increased.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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In Situ Synchrotron Investigations of Beam Diameter Influence on Vapor Capillary Formation during Laser Beam Welding of Copper Alloy with a Blue Laser Beam Source
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Christoph Spurk, Frederik Dietrich, Marc Hummel, Arnold Gillner, Felix Beckmann, Julian Moosmann and Constantin Häfner
J. Manuf. Mater. Process. 2024, 8(2), 47; https://doi.org/10.3390/jmmp8020047 - 01 Mar 2024
Abstract
Laser beam welding as a reliable tool for high-precision joining of batteries or microelectronics is more and more the choice for achieving reproducible results in production processes. In addition to a high automation capability, the precise control of the energy deposition into the
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Laser beam welding as a reliable tool for high-precision joining of batteries or microelectronics is more and more the choice for achieving reproducible results in production processes. In addition to a high automation capability, the precise control of the energy deposition into the material plays an important role, especially when highly reflective materials, such as copper or aluminum, must be welded together. Alongside the use of highly brilliant fiber lasers in the near-infrared range with a focal diameter of a few tens of micrometers, diode lasers in the wavelength range of 445 nm are increasingly being used. Here, beam diameters of a few hundred micrometers can be achieved. With a wavelength of 445 nm, the absorptivity in copper can be increased by more than a factor of 10 compared to a near-infrared laser beam sources in solid state at room temperature. This paper presents the in situ X-ray observation of laser welding processes on CuSn6 with a laser beam source with a wavelength of 445 nm using synchrotron radiation at DESY Petra III Beamline P07 EH4 in Hamburg, Germany. For the experiments, the laser radiation was focused via two separate optics to focal diameters of 362 µm and 609 µm. To characterize the dynamics of the vapor capillaries depending on the different focal diameters dF, the parameters were varied with respect to laser power PL and feed rate v. For the investigations, a synchrotron beam of 2 × 2 mm2 in size with a photon energy of 89 keV was used, and the material samples were analyzed by means of phase-contrast videography to show the boundaries between solid, liquid, and gaseous material phases. The results of this paper show the welding depths achieved and how the geometry of the vapor capillary behaves by changing the focal diameter, laser power and feed rate.
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(This article belongs to the Special Issue Advanced Joining Processes and Techniques 2023)
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Open AccessArticle
Simulation-Assisted Tool Design for Pulsed Electrochemical Machining of Magnetic Shape-Memory Alloys
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Falko Böttcher, Ingo Schaarschmidt, Jan Edelmann and Andreas Schubert
J. Manuf. Mater. Process. 2024, 8(2), 46; https://doi.org/10.3390/jmmp8020046 - 01 Mar 2024
Abstract
Shape-memory alloys set high demands on the production technologies being used. During cutting, continuous heat input and mechanical stress have an undesirable influence on the shape-memory effect. Pulsed electrochemical machining (PECM), which is based on anodic dissolution, enables force-free machining without thermomechanical influence
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Shape-memory alloys set high demands on the production technologies being used. During cutting, continuous heat input and mechanical stress have an undesirable influence on the shape-memory effect. Pulsed electrochemical machining (PECM), which is based on anodic dissolution, enables force-free machining without thermomechanical influence on the edge-zone properties of the workpiece. Depending on the desired geometry, the development of a customized PECM fixture is necessary. The design of the fixtures is often based on the experiences of the designers and manufacturers, which often results in an estimation of the functionally critical dimensions. For this reason, the study focuses on a methodical approach for evaluating crucial fixture dimensions using knowledge of the specific material dissolution behavior linked with a numerical simulation model. It has been shown that the shape-memory alloy NiMnGa has a non-linear dissolution behavior in sodium nitrate. A reduction of stray currents up to 20% resulting from a lateral gap between the cathode and electrical insulation was demonstrated using numerical simulation. The study shows that a low cathode shaping height has the strongest influence on precise processing. Varying the process parameters allowed for the lateral gap to be adjusted between 0.15 and 0.25 mm.
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(This article belongs to the Special Issue Advances in Machining of Difficult-to-Cut Materials)
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Open AccessArticle
Fatigue Life and Residual Stress of Flat Stainless Steel Specimens Laser-Cladded with a Cobalt-Based Alloy and Postprocessed with Laser Shock Peening
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Santiago Flores-García, Carlos E. Martínez-Pérez, Carlos Rubio-González, J. Antonio Banderas-Hernández, Christian Félix-Martínez and Salomón M. A. Jiménez
J. Manuf. Mater. Process. 2024, 8(2), 45; https://doi.org/10.3390/jmmp8020045 - 28 Feb 2024
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Laser cladding (LC) is a versatile additive manufacturing process where strands of metallic material are deposited and melted by a laser. However, there are some limitations associated with this process that may affect the performance of the final manufactured parts. In the present
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Laser cladding (LC) is a versatile additive manufacturing process where strands of metallic material are deposited and melted by a laser. However, there are some limitations associated with this process that may affect the performance of the final manufactured parts. In the present work, the influence of laser shock peening (LSP) on the fatigue life of 304 stainless steel flat specimens with a cobalt-based alloy (Stellite 6) coating applied by LC was investigated. The analysis was carried out both experimentally and numerically. In the LSP simulation, the ABAQUS/Explicit code was used to determine the residual stress distribution of specimens with double central notches with a radius of curvature of 5, 10, 15, and 20 mm. From the numerical results, an improvement was found regarding fatigue life up to 48% in samples with LSP. Experimentally, 14% in fatigue life enhancement was observed. The residual stress, determined by the contour method, showed good agreement with the LSP simulation. The SEM images revealed that the fatigue failure started at the Stellite 6 coating and propagated towards the center of the specimen. LSP has been shown to be a suitable postprocessing alternative for laser-cladded parts that will be subjected to fatigue loading since it led to fatigue improvement through the introduction of compressive residual stresses on clad coatings.
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Open AccessArticle
Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers
by
Nickolay S. Lubimyi, Mihail Chepchurov, Andrey A. Polshin, Michael D. Gerasimov, Boris S. Chetverikov, Anastasia Chetverikova, Alexander A. Tikhonov and Ardalion Maltsev
J. Manuf. Mater. Process. 2024, 8(2), 44; https://doi.org/10.3390/jmmp8020044 - 21 Feb 2024
Abstract
This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation
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This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation and justification of the selected loads on the drill body arising from metal-cutting forces. The described methodology for designing a digital model of a metal-cutting tool for the purpose of its further production using SLM 3D metal printing methods facilitates the procurement of a digital model characterized by a reduced weight and volume of material. The described design technology involves the production of a thin-walled outer shell that forms the external technological surfaces necessary for the drill body, as well as internal structural elements formed as a result of topological optimization of the product shape. Much attention in this article is paid to the description of the technology for filling internal cavities with a viscous metal polymer, formed as a result of the topological optimization of the original model. Due to this design approach, it is possible to reduce the volume of 3D metal printing by 32%, which amounts to more than USD 135 in value terms.
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(This article belongs to the Special Issue Recent Advances in Multi-Material Metal Additive Manufacturing)
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Open AccessArticle
Predicting the Dynamic Parameters for Milling Thin-Walled Blades with a Neural Network
by
Yu Li, Feng Ding, Dazhen Wang, Weijun Tian and Jinhua Zhou
J. Manuf. Mater. Process. 2024, 8(2), 43; https://doi.org/10.3390/jmmp8020043 - 21 Feb 2024
Abstract
Accurately predicting the time-varying dynamic parameters of a workpiece during the milling of thin-walled parts is the foundation of adaptively selecting chatter-free machining parameters. Hence, a method for accurately and quickly predicting the time-varying dynamic parameters for milling thin-walled parts is proposed, which
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Accurately predicting the time-varying dynamic parameters of a workpiece during the milling of thin-walled parts is the foundation of adaptively selecting chatter-free machining parameters. Hence, a method for accurately and quickly predicting the time-varying dynamic parameters for milling thin-walled parts is proposed, which is based on the shell FEM and a three-layer neural network. The time-dependent dynamics of the workpiece can be calculated using the FEM by obtaining the geometrical parameters of the arc-faced junctions within the discrete cells of the initial and machined workpiece. It is unnecessary to re-divide the mesh cells of the thin-walled parts at each cutting position, which enhances the computational efficiency of the workpiece dynamics. Meanwhile, in comparison with the three-dimensional cube elements, the shell elements can reduce the number of degrees of freedom of the FEM model by 74%, which leads to the computation of the characteristic equation that is about nine times faster. The results of the modal test show that the maximum error of the shell FEM in predicting the natural frequency of the workpiece is about 4%. Furthermore, a three-layer neural network is constructed, and the results of the shell FEM are used as samples to train the model. The neural network model has a maximum prediction error of 0.409% when benchmarked against the results of the FEM. Furthermore, the three-layer neural network effectively enhances computational efficiency while guaranteeing accuracy.
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(This article belongs to the Topic Advanced Manufacturing and Surface Technology)
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Open AccessArticle
Effect of Liquid Miscibility Gap on Defects in Inconel 625–GRCop42 Joints through Analysis of Gradient Composition Microstructure
by
Jakub Preis, Donghua Xu, Brian K. Paul, Peter A. Eschbach and Somayeh Pasebani
J. Manuf. Mater. Process. 2024, 8(1), 42; https://doi.org/10.3390/jmmp8010042 - 14 Feb 2024
Abstract
Joining of Cu-based dispersion-strengthened alloys to Ni-based superalloys has garnered increased attention for liquid rocket engine applications due to the high thermal conductivity of Cu-based alloys and high temperature tensile strength of Ni-based superalloys. However, such joints can suffer from cracking when joined
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Joining of Cu-based dispersion-strengthened alloys to Ni-based superalloys has garnered increased attention for liquid rocket engine applications due to the high thermal conductivity of Cu-based alloys and high temperature tensile strength of Ni-based superalloys. However, such joints can suffer from cracking when joined via liquid state processes, leading to part failure. In this work, compositions of 15–95 wt.% GRCop42 are alloyed with Inconel 625 and characterized to better understand the root cause of cracking. Results indicate a lack of miscibility between Cu-deprived and Cu-rich liquids in compositions corresponding to 30–95 wt.% GRCop42. Two distinct morphologies are observed and explained by use of CALPHAD; Cu-deprived dendrites with Cu-rich interdendritic zones at 30–50 wt.% GRCop42 and Cu-deprived spheres surrounded by a Cu-rich matrix at 60–95 wt.% GRCop42. Phase analysis reveals brittle intermetallic phases precipitate in the 60–95 wt.% GRCop42 Cu-deprived region. Three cracking mechanisms are proposed herein that provide guidance on the avoidance of defects Ni-based superalloy to Cu-based dispersion strengthened alloy joints.
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(This article belongs to the Special Issue Joining of Unweldable Materials: Concepts, Techniques and Processes)
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Exploring New Parameters to Advance Surface Roughness Prediction in Grinding Processes for the Enhancement of Automated Machining
by
Mohammadjafar Hadad, Samareh Attarsharghi, Mohsen Dehghanpour Abyaneh, Parviz Narimani, Javad Makarian, Alireza Saberi and Amir Alinaghizadeh
J. Manuf. Mater. Process. 2024, 8(1), 41; https://doi.org/10.3390/jmmp8010041 - 14 Feb 2024
Abstract
Extensive research in smart manufacturing and industrial grinding has targeted the enhancement of surface roughness for diverse materials including Inconel alloy. Recent studies have concentrated on the development of neural networks, as a subcategory of machine learning techniques, to predict non-linear roughness behavior
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Extensive research in smart manufacturing and industrial grinding has targeted the enhancement of surface roughness for diverse materials including Inconel alloy. Recent studies have concentrated on the development of neural networks, as a subcategory of machine learning techniques, to predict non-linear roughness behavior in relation to various parameters. Nonetheless, this study introduces a novel set of parameters that have previously been unexplored, contributing to the advancement of surface roughness prediction for the grinding of Inconel 738 superalloy considering the effects of dressing and grinding parameters. Hence, the current study encompasses the utilization of a deep artificial neural network to forecast roughness. This implementation leverages an extensive dataset generated in a recent experimental study by the authors. The dataset comprises a multitude of process parameters across diverse conditions, including dressing techniques such as four-edge and single-edge diamond dresser, alongside cooling approaches like minimum quantity lubrication and conventional wet techniques. To evaluate a robust algorithm, a method is devised that involves different networks utilizing various activation functions and neuron sizes to distinguish and select the best architecture for this study. To gauge the accuracy of the methods, mean squared error and absolute accuracy metrics are applied, yielding predictions that fall within acceptable ranges for real-world industrial roughness standards. The model developed in this work has the potential to be integrated with the Industrial Internet of Things to further enhance automated machining.
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(This article belongs to the Special Issue Industry 4.0: Manufacturing and Materials Processing)
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