Journal of Manufacturing and Materials Processing

20 pages, 6548 KB

Open AccessArticle

Blast Protection Performance of Pre-Stressed High-Strength Steel Vehicle Underbody Structures

by Tiaoqi Fu, Mingxing Li, Bing Peng, Jincheng Zhang, Gaowei Li, Xiaowang Sun, Tao Wang and Xianhui Wang

J. Manuf. Mater. Process. 2026, 10(9), 353; https://doi.org/10.3390/jmmp10090353 - 11 Sep 2026

Abstract

Conventional design paradigms for vehicle underbody armor face an inherent trade-off: enhancing blast protection invariably incurs a prohibitive weight penalty. Here, we investigate a mechanical pre-stressing strategy for high-strength steel V-shaped vehicle underbody structures. A conventional V-shaped baseline structure was first subjected to [...] Read more.

Conventional design paradigms for vehicle underbody armor face an inherent trade-off: enhancing blast protection invariably incurs a prohibitive weight penalty. Here, we investigate a mechanical pre-stressing strategy for high-strength steel V-shaped vehicle underbody structures. A conventional V-shaped baseline structure was first subjected to a 6 kg TNT blast test, and the measured response was used to validate the numerical model. Based on the validated numerical model, four mass-equivalent (100 kg) configurations were subsequently compared numerically under escalating threats (2~8 kg TNT): pre-stressed steel, homogeneous steel, and all-metallic honeycomb sandwich panels (comprising high-strength steel face sheets and an aluminum alloy core) with both positive and negative Poisson’s ratios. The numerical results predict that the pre-stressed steel configuration exhibits the smallest maximum permanent floor deformations among the four configurations, with values of 22 mm, 46 mm, 131 mm, and 208 mm under 2, 4, 6, and 8 kg loads, respectively. Mechanistically, we reveal that for V-shaped geometries, residual-stress-induced stiffening and geometric arching are profoundly more effective than core crushing in controlling global bending, while the auxetic steel-faced aluminum honeycomb offers only marginal improvements over its conventional counterpart. This study offers a potential pathway for overcoming the weight–protection trade-off in underbody armor design. While the numerical predictions are encouraging, direct experimental validation of the pre-stressed configuration remains necessary prior to practical application. Full article

(This article belongs to the Special Issue Advances in Metal Additive Manufacturing: Processes, Materials, and Applications)

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24 pages, 2838 KB

Open AccessArticle

Product Cost Estimation for Manufacturing Platforms

by Massimiliano Ceppi, Mumtaz Alam Hafiz, Federico Scalzo, Barbara Motyl and Marco Sortino

J. Manuf. Mater. Process. 2026, 10(9), 352; https://doi.org/10.3390/jmmp10090352 - 9 Sep 2026

Abstract

Manufacturing-as-a-service (MaaS) platforms require fast and accurate manufacturing cost estimation to support quotation and resource allocation across distributed networks. However, existing machine learning approaches are often constrained by limited data availability, proprietary information, and insufficient interpretability. This work presents an engineering-based framework for [...] Read more.

Manufacturing-as-a-service (MaaS) platforms require fast and accurate manufacturing cost estimation to support quotation and resource allocation across distributed networks. However, existing machine learning approaches are often constrained by limited data availability, proprietary information, and insufficient interpretability. This work presents an engineering-based framework for generating high-fidelity synthetic data to develop scalable and interpretable cost estimation models, culminating in a SHAP-interpreted XGBoost model. A parameterized prismatic workpiece was sampled using a Hammersley sequence design of experiments, producing 1355 geometrically feasible parts with representative drilling and pocket milling features. For each configuration, cutting tools, machining parameters, and CNC toolpaths were automatically generated and optimized through an integrated SolidWorks, MATLAB, and VERICUT workflow. Over 70,000 physics-based simulations were performed to obtain reference values for machining time, tool usage, and manufacturing cost. The resulting dataset integrates geometric descriptors and optimized process parameters, enabling the training and evaluation of machine learning models. The proposed methodology demonstrates that engineering-driven synthetic data provides a physically consistent foundation for fast and interpretable AI-enabled cost estimation. While applied to a specific family of three-axis milled parts, this approach serves as a proof-of-concept for predictive micro-services required in next-generation platform-based manufacturing systems. Full article

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31 pages, 1713 KB

Open AccessArticle

A Unified Continuous-Time Markov Chain Framework for Modeling and Comparative Performance Evaluation of Finite-Buffer Production Systems

by Angelos Kourepis, Nikolaos Kladovasilakis, Elias D. Georgakoudis and Michael A. Madas

J. Manuf. Mater. Process. 2026, 10(9), 351; https://doi.org/10.3390/jmmp10090351 - 9 Sep 2026

Abstract

Finite-buffer production systems are widely used in manufacturing, where performance depends on the interaction among machine reliability, buffer capacity, and maintenance policies. This study proposes a unified Continuous-Time Markov Chain (CTMC) framework for modeling and comparatively evaluating alternative finite-buffer production systems. Three configurations [...] Read more.

Finite-buffer production systems are widely used in manufacturing, where performance depends on the interaction among machine reliability, buffer capacity, and maintenance policies. This study proposes a unified Continuous-Time Markov Chain (CTMC) framework for modeling and comparatively evaluating alternative finite-buffer production systems. Three configurations are considered: a serial production line with unreliable machines, a workstation-based system with parallel machines, and a condition-based maintenance system incorporating multi-state machine degradation and preventive maintenance. For each configuration, the state space, transition structure, infinitesimal generator matrix, and steady-state probability distribution are derived to estimate throughput, work-in-process inventory, cycle time, and total operating cost. Numerical experiments investigate the effects of buffer capacity, workstation parallelization, maintenance policies, degradation severity, reliability parameters, and financial factors. Under the baseline setting, the conventional serial configuration achieves a throughput of 0.8300 products/min, while workstation parallelization increases throughput to 1.6840 products/min, corresponding to a 102.9% improvement. The condition-based maintenance configuration achieves 0.8173 products/min while accounting for equipment deterioration and preventive-maintenance interventions. Overall, the framework enables the consistent evaluation of operational and economic trade-offs and supports production planning, maintenance optimization, and manufacturing system design. Full article

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18 pages, 7034 KB

Open AccessArticle

Multi-Objective Optimization of Shot Peening Parameters and Surface Integrity for GH4202 Superalloy

by Yanju Wang, Xufeng Song, Shehui Tang, Qun Li, Hongyi Du, Quanyi Zuo, Erbo Liu, Qingqing Lü and Liquan Yang

J. Manuf. Mater. Process. 2026, 10(9), 350; https://doi.org/10.3390/jmmp10090350 - 8 Sep 2026

Abstract

The GH4202 nickel-based superalloy is widely used in aero-engine hot-section components, where surface integrity is critical to fatigue performance. This study combined Abaqus/Explicit 2023 single-shot simulations, single-factor experiments, and an L₁₆(4⁴) orthogonal array to evaluate the effects of shot [...] Read more.

The GH4202 nickel-based superalloy is widely used in aero-engine hot-section components, where surface integrity is critical to fatigue performance. This study combined Abaqus/Explicit 2023 single-shot simulations, single-factor experiments, and an L₁₆(4⁴) orthogonal array to evaluate the effects of shot diameter, peening duration, pressure, and impact angle. Qualitative single-shot simulation results show that an increase in the prescribed impact velocity leads to higher simulated compressive residual stress and plastic deformation, whereas the growth rate slows down significantly when the velocity exceeds 30 m/s. Orthogonal main-effect analysis indicated that pressure had the greatest effect on Ra, whereas duration had the greatest effect on HV0.1. The Pareto evaluation identified Runs 1, 6, 11, and 16 as non-dominated combinations. A₃B₃C₁D₂ (0.8 mm, 45 s, 0.2 MPa, and 45°) was selected as a representative intermediate compromise for characterization and independent confirmation. The confirmation batch yielded Ra = 0.243 μm and HV0.1 = 345.3 HV. Within the tested domain, the candidate ranges for subsequent validation were 0.6–0.8 mm, 30–45 s, 0.2–0.3 MPa, and 45–60°. Full article

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21 pages, 15090 KB

Open AccessArticle

Thermomechanical Behavior of Phosphogypsum Composites Reinforced with Olive and Eucalyptus Wood Chips

by Rafaa Saaidia, Houcem Ltaeif, Imed Miraoui, Abdallah Bouabidi, Arman Ameen and Lazhar Ayed

J. Manuf. Mater. Process. 2026, 10(9), 349; https://doi.org/10.3390/jmmp10090349 - 8 Sep 2026

Abstract

This study explores the development of sustainable composite materials based on phosphogypsum (PG), an abundant industrial by-product, reinforced with olive and eucalyptus wood chips. The objective is to valorize waste streams while enhancing the mechanical, thermal, and acoustic performance of the base material [...] Read more.

This study explores the development of sustainable composite materials based on phosphogypsum (PG), an abundant industrial by-product, reinforced with olive and eucalyptus wood chips. The objective is to valorize waste streams while enhancing the mechanical, thermal, and acoustic performance of the base material for eco-efficient construction applications. Composites were prepared with fiber contents of 5%, 10%, 15%, and 20% and evaluated through standardized experimental tests. Mechanical behavior was assessed via three-point bending tests, revealing a 26% improvement in flexural strength at 15% eucalyptus content. Water absorption increased with fiber content but remained lower in eucalyptus-reinforced composites due to better fiber–matrix cohesion. Thermal conductivity decreased significantly from 5% to 20% fiber content, reaching 0.60 W/m·K at 20% eucalyptus content, indicating enhanced insulation potential. Acoustic tests, performed using an impedance tube in accordance with ISO 10534-2, showed strong frequency-dependent absorption. The 20% olive composite achieved a peak absorption coefficient of 0.78 and an NRC of 0.68, demonstrating excellent sound-damping characteristics. This work introduces a novel integration of two underutilized Mediterranean biomasses into PG matrices and highlights their multifunctional benefits. The resulting composites offer a low-cost, low-carbon solution for thermally and acoustically optimized building components, advancing circular economy principles in the construction sector. Full article

(This article belongs to the Special Issue Green Heat Transfer: Towards Sustainable Manufacturing of Advanced Thermal Technologies)

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16 pages, 2344 KB

Open AccessArticle

Patterning Behavior of RAFT-Derived 3-Arm Star Terpolymers

by Yura Choi, Jinyoung Kim and Namchul Cho

J. Manuf. Mater. Process. 2026, 10(9), 348; https://doi.org/10.3390/jmmp10090348 - 8 Sep 2026

Abstract

The uniformity of polymer matrices can strongly influence pattern retention during negative-tone development. In this study, two 3-arm star terpolymers, designated HTM Random and HTM Block, were synthesized via reversible addition–fragmentation chain transfer polymerization using simultaneous and sequential monomer-addition strategies, respectively. Both polymers [...] Read more.

The uniformity of polymer matrices can strongly influence pattern retention during negative-tone development. In this study, two 3-arm star terpolymers, designated HTM Random and HTM Block, were synthesized via reversible addition–fragmentation chain transfer polymerization using simultaneous and sequential monomer-addition strategies, respectively. Both polymers were prepared using the same nominal feed ratio of 2-hydroxyethyl methacrylate, dicyclopentanyl methacrylate, and 2-methyl-2-adamantyl methacrylate. Although the two materials exhibited controlled molecular weight distributions and similar FT-IR spectral changes after ultraviolet exposure and post-exposure baking, differences were observed in their chain-packing characteristics, thermal behavior, and developed pattern morphology. The two materials exhibited comparable initial thermal stability but distinct multistep degradation profiles and glass-transition behavior. In contrast, the simultaneous-feed material showed more clearly retained and spatially uniform patterns under the tested development conditions. These results indicate that the materials produced by the two monomer-addition strategies exhibited differences in thermal response and development behavior under the investigated conditions. Full article

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30 pages, 9309 KB

Open AccessArticle

Crack Intensity Reduction in Fe–6.5Si Alloy by Adding Cr and Controlling the Thermal Gradient

by Masoud Ahmadnia, Eskandar Fereiduni and Mohamed Elbestawi

J. Manuf. Mater. Process. 2026, 10(9), 347; https://doi.org/10.3390/jmmp10090347 - 8 Sep 2026

Abstract

The Fe–6.5 wt.% Si alloy is a promising soft magnetic material for electric motor applications owing to its high electrical resistivity and low core loss. However, the intrinsic brittleness of this alloy precludes fabrication of thin laminates using conventional rolling processes. Laser Powder [...] Read more.

The Fe–6.5 wt.% Si alloy is a promising soft magnetic material for electric motor applications owing to its high electrical resistivity and low core loss. However, the intrinsic brittleness of this alloy precludes fabrication of thin laminates using conventional rolling processes. Laser Powder Bed Fusion (LPBF) has therefore been considered as an alternative manufacturing route, offering both geometric flexibility and the inherent advantages of additive manufacturing. Nevertheless, successful LPBF processing of Fe–6.5 wt.% Si has remained challenging due to its high-silicon content. In this study, the Fe–6.5 wt.% Si alloy was modified by introducing 1 wt.% Cr, and LPBF process variables were optimized to yield defect-free parts. The effect of Cr addition on suppressing the disorder–order phase transformation during solidification was investigated through Thermo-Calc^® thermodynamic simulations and quantified via X-ray diffraction phase analysis. Crack morphology analysis from optical micrographs revealed a marked reduction in both solidification and liquation cracks, attributed to the role of Cr in mitigating silicon segregation and consequently lowering the fraction of ordered phases. Preheating the build plate to 200 °C was found to effectively eliminate vertical cracks by reducing thermal stresses within the parts; however, a limited number of horizontal cracks initiated at the sample edges and propagated inward, likely due to elevated thermal gradients at the perimeter. To address this issue, sacrificial walls were introduced at distances of 1.0 mm and 0.2 mm from the cube edges, locally reducing the cooling rates and effectively increasing the primary dendrite arm spacing (PDAS). The reduced cooling rate also led to lower lattice misorientation, confirmed by electron backscatter diffraction (EBSD), and a significant decrease in the crack length from ~2 mm to ~0.7 mm. Full article

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29 pages, 30122 KB

Open AccessArticle

Assessment of Residual Stresses in MAG-Welded Steel Joints by X-Ray Diffraction and Incremental Hole-Drilling

by João Paulo Nobre, Thorsten Manns and Altino Loureiro

J. Manuf. Mater. Process. 2026, 10(9), 346; https://doi.org/10.3390/jmmp10090346 - 8 Sep 2026

Abstract

This study provides a detailed comparison between X-ray diffraction (XRD, sin²ψ method) and incremental hole-drilling (IHD, regularised integral method) for assessing residual stresses in steel plates MAG-welded with three commonly used joint configurations (II-, X- and V-grooves), with and without mechanical [...] Read more.

This study provides a detailed comparison between X-ray diffraction (XRD, sin²ψ method) and incremental hole-drilling (IHD, regularised integral method) for assessing residual stresses in steel plates MAG-welded with three commonly used joint configurations (II-, X- and V-grooves), with and without mechanical constraints. Surface and in-depth residual stresses were evaluated on both faces of each sample, supported by hardness and metallographic analysis. After removal of the mechanical constraints and sectioning, XRD revealed similar tensile stresses at the weld toe for all joints, with longitudinal values of approximately +200 MPa, but marked differences at the weld centre, where compressive stresses of approximately −390 MPa were measured in the II-joint, associated with the combined effects of groove geometry, welding sequence and pass-specific heat input during welding under common restraint conditions. IHD provided smooth depth profiles but consistently overestimated stress magnitudes relative to XRD, with differences reaching approximately 150–200 MPa at depths ≥ 0.2 mm in the X-joint. Plasticity effects were identified as an important contributor to these discrepancies. The plasticity factor was used as a complementary indicator of when local yielding may influence IHD results, exceeding the adopted reference value of

f = 0.2

near the surface in all joint configurations and supporting the interpretation that yielding occurred during the first drilling increments in all joints. The integral method, used for non-uniform in-depth stress evaluation by IHD, propagates near-surface inaccuracies into deeper layers. A preliminary application of a plasticity-correction procedure, developed for uniform stress fields, reduced IHD stresses but was not fully effective. Overall, the results highlight the strengths and limitations of XRD and IHD for residual-stress evaluation in MAG-welded joints and emphasise the need for caution—and ideally correction—when applying IHD to determine welding residual stresses. Full article

(This article belongs to the Special Issue Recent Advances in Welding and Joining Metallic Materials)

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24 pages, 8110 KB

Open AccessArticle

Influence of Laser Parameters on the Activation of Cr₂O₃-Doped ZTA Ceramics for Selective Electroless Copper Plating in the Manufacture of 3D Ceramic Circuit Carriers

by Alexander Schilling, Andrea Knöller, Philipp Ninz, Wolfgang Eberhardt, Frank Kern and André Zimmermann

J. Manuf. Mater. Process. 2026, 10(9), 345; https://doi.org/10.3390/jmmp10090345 - 7 Sep 2026

Abstract

Due to the superior thermal, mechanical and chemical properties of ceramics, metallized ceramics are widely used as circuit carriers and interconnect devices, wherever standard polymer-based circuit boards come to their limits. 2D metallization represents the current state of the art. The metallization of [...] Read more.

Due to the superior thermal, mechanical and chemical properties of ceramics, metallized ceramics are widely used as circuit carriers and interconnect devices, wherever standard polymer-based circuit boards come to their limits. 2D metallization represents the current state of the art. The metallization of 3D-shaped ceramics cannot be achieved with standard metallization techniques, such as screen printing, but, for example, with the so-called laser-induced direct metallization (LDM). For LDM, a pulsed laser is used to locally activate the ceramic surface, followed by a selective electroless copper plating on the laser-irradiated areas. Although it has already been shown that LDM on Al₂O₃-based ceramics is possible with different laser systems, a comprehensive study on the effect of different laser parameters on ablation and activation, which includes the influences of structuring on inclined surfaces, has not been done yet. In this study, laser power, pulse repetition frequency, pulse overlap and the number of passes were varied systematically to determine the parametric sensitivity of the ablation and metallization behavior for pulsed infrared laser activation of Cr₂O₃-doped ZTA. It was found that ablation is necessary for the metallization and that the peak fluence is the governing factor for the ablation and metallization process. It was further shown that ablation can be well predicted with an accumulated fluence, which includes pulse overlap. Structuring under an inclination angle up to 60° does not result in a reduced activation or adhesion strength of the deposited copper. Injection-molded 3D ceramic substrates were successfully metallized and functionalized by applying an optimized set of laser parameters, showing that LDM enables the functionalization of complex 3D ceramic substrates and therefore opens up new possibilities for integrated ceramic circuit carriers. Full article

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20 pages, 3330 KB

Open AccessArticle

Natural Rubber-Based Encapsulation for Wireless Intraruminal Monitoring: Effects of Latex Processing Parameters on Mechanical, Chemical, and RF Transmission Performance

by Prachid Saramolee, Siraporn Sakphrom, Choosak Rittiphet, Supawat Kotchparadit, Koki Ogura and Sarawuth Chaimool

J. Manuf. Mater. Process. 2026, 10(9), 344; https://doi.org/10.3390/jmmp10090344 - 7 Sep 2026

Abstract

Encapsulation for wireless dairy-cattle implants must resist acidic, moisture-rich gastrointestinal conditions while remaining transparent to radio-frequency (RF) signals. This study evaluated vulcanized natural rubber (NR) latex as an intraruminal encapsulant, examining how total solid content (TSC; 30, 40, 50 wt%), stirring duration (24–72 [...] Read more.

Encapsulation for wireless dairy-cattle implants must resist acidic, moisture-rich gastrointestinal conditions while remaining transparent to radio-frequency (RF) signals. This study evaluated vulcanized natural rubber (NR) latex as an intraruminal encapsulant, examining how total solid content (TSC; 30, 40, 50 wt%), stirring duration (24–72 h), and TiO₂ loading affect tensile and tear strength, acidic swelling, dip-coating thickness, and received signal strength indicator (RSSI) at 433 MHz. Multilayer dip-coating produced films 0.25–0.38 mm thick. Tensile strength rose with TSC and stirring (26.6 → 32.2 MPa), whereas tear strength peaked at 40 wt% (31.97 N mm⁻¹). Adding 5 phr (parts per hundred rubber) TiO₂ cut pH-4 swelling ~four-fold (21.1 → 5.25%) with a negligible RSSI penalty, and 3–5 coating layers kept the link well above the −120 dBm sensitivity floor over 5–55 m. The optimum—40 wt% TSC, 72 h stirring, 5 phr TiO₂—best balanced mechanical integrity, swelling resistance, thickness, and wireless performance. Vulcanized NR is therefore a promising bio-based encapsulant under simulated conditions; dielectric characterization, long-term aging, and in vivo validation remain future work. Full article

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27 pages, 16070 KB

Open AccessArticle

Comparative SPH–Finite Element Assessment of Aerospace Material Systems Under Bird-Strike Loading

by Mohsen Lalehparvar, Alex Nuttall, Dhruva Bavaria, Felix Massó Etxeberria, Kaustubh Dwivedi, Hessam Ghasemnejad, Pablo Coladas Mato and Wydo van de Waerdt

J. Manuf. Mater. Process. 2026, 10(9), 343; https://doi.org/10.3390/jmmp10090343 - 7 Sep 2026

Abstract

Bird strikes cause aircraft damage, create serious risks to human safety and can contribute to catastrophic incidents, while continuing to impose substantial economic costs on airlines. The impact combines high kinetic energy with discontinuous, strongly nonlinear contact over a short duration, producing large [...] Read more.

Bird strikes cause aircraft damage, create serious risks to human safety and can contribute to catastrophic incidents, while continuing to impose substantial economic costs on airlines. The impact combines high kinetic energy with discontinuous, strongly nonlinear contact over a short duration, producing large structural deformations; appropriate nonlinear simulation techniques are therefore required to capture this complex interaction. For this purpose, the present study applies established Smoothed Particle Hydrodynamics (SPH)–finite element modelling ingredients to a controlled matrix of aerospace material systems and target geometries. The approach is first benchmarked against a published aluminium flat-plate bird-impact test using a raster-digitised force-history comparison, after which monolithic metallic and composite structures and source-described honeycomb-sandwich alternatives are assessed in flat-panel and curved leading-edge configurations. The results show that contact-force and local-displacement rankings depend strongly on target geometry and response metric, with the curved leading edge changing the ordering observed for the flat panel. More compliant systems generally permit greater local displacement, whereas stiffer systems restrict displacement but can sustain higher short-duration force peaks; consequently, no universal material ranking follows from a single response measure, and the results are most suitable for preliminary design screening. Full article

(This article belongs to the Special Issue External Field-Assisted Welding and Advanced Processing of Lightweight Metallurgical Structures)

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23 pages, 9798 KB

Open AccessArticle

Water Collection Performance of Additively Manufactured TPMS Condensation Structures in Peltier-Driven Atmospheric Water Generation: Effects of Geometry and Surface Treatment

by Fatema Tuz Zohra, Hribhu Chowdhury and Bahram Asiabanpour

J. Manuf. Mater. Process. 2026, 10(9), 342; https://doi.org/10.3390/jmmp10090342 - 4 Sep 2026

Abstract

The performance of Peltier-driven atmospheric water generation (AWG) systems depends strongly on the surface geometry and wetting behavior of the condensation structure. Triply periodic minimal surfaces (TPMS) provide high surface area-to-volume ratio and geometric tunability, but their effectiveness as three-dimensional condensation structures requires [...] Read more.

The performance of Peltier-driven atmospheric water generation (AWG) systems depends strongly on the surface geometry and wetting behavior of the condensation structure. Triply periodic minimal surfaces (TPMS) provide high surface area-to-volume ratio and geometric tunability, but their effectiveness as three-dimensional condensation structures requires experimental evaluation. In this study, five additively manufactured TPMS geometries, Gyroid, Diamond, Lidinoid, SplitP, and Schwarz, were evaluated in a Peltier-driven AWG setup under controlled laboratory conditions. The measured water collection response varied among the tested TPMS geometries, which showed different condensation, retention, and collection trends. Water collection was measured with and without surface treatment, while the monitored surface temperature remained below the calculated dew point during testing. Without surface treatment, total water collection ranged from approximately 0.9 to 1.4 g, whereas surface-treated specimens collected approximately 0.6 to 1.2 g. The specimens with surface treatment exhibited predominantly discrete droplets rather than the film-wise morphology observed without surface treatment, but the total water collection did not increase consistently. Gyroid and Lidinoid showed slight increases with surface treatment, while SplitP, Diamond, and Schwarz showed reductions. Water collection also did not scale directly with calculated TPMS surface area, which suggests that effective air exposure, droplet retention, drainage, and coating uniformity contributed strongly to the observed performance. These findings provide experimental insights into additively manufactured TPMS geometry and surface treatment conditions for Peltier-driven AWG. Full article

(This article belongs to the Special Issue Application of 3D Printing Technology in Manufacturing and Material Processing)

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56 pages, 20358 KB

Open AccessReview

A Review of Meltpool Dynamics and Grain Evolution in Inconel Alloys Produced by Laser Powder Bed Fusion

by Sanjeevi Sharma R, Venkatachalaiah K N, Ramakrishna Pramod and M. E. Shashi Kumar

J. Manuf. Mater. Process. 2026, 10(9), 341; https://doi.org/10.3390/jmmp10090341 - 3 Sep 2026

Abstract

Laser powder bed fusion (LPBF) is a disruptive additive manufacturing process for producing high-performance Inconel superalloy parts with complex shapes for the aerospace, energy, and other demanding industries. However, uniform part quality remains a persistent challenge, as process parameters, melt-pool dynamics, microstructural evolution, [...] Read more.

Laser powder bed fusion (LPBF) is a disruptive additive manufacturing process for producing high-performance Inconel superalloy parts with complex shapes for the aerospace, energy, and other demanding industries. However, uniform part quality remains a persistent challenge, as process parameters, melt-pool dynamics, microstructural evolution, defect formation, and mechanical performance are closely coupled across a wide range of spatial and temporal scales. In previous reviews, these dimensions have been considered in isolation with limited insight into their interactions and implications for predictive process control. The present review aims to address this lacuna by proposing a unified Process–Structure–Property–Control (PSPC) framework for LPBF-produced Inconel 625, 718, and 738. The discussion begins with material attributes governing alloy processability, and then synthesises the melt-pool physics governing thermal behaviour, solidification, and energy transfer. Attention then turns to a critical assessment of grain evolution, defect formation, and process stability, showing how the thermal history governs microstructural development and, in turn, mechanical performance via linked process–structure–property relationships. Progress in multiscale numerical modelling, such as finite-element analysis, computational fluid dynamics, phase-field modelling, cellular automata, and phase-diagram calculation (CALPHAD), is reviewed to establish a comprehensive modelling ecosystem for predictive LPBF. The review also discusses the potential of emerging technologies, such as beam shaping, multi-laser processing, in situ monitoring, artificial intelligence, and powder recyclability, to increase the robustness and productivity of the process. Building on these advances, a digital-twin-enabled predictive-manufacturing framework that integrates physics-based models, data-driven algorithms, and real-time monitoring is introduced to enable closed-loop process optimisation. The review ends with a scientific synthesis and future research roadmap for intelligent, reliable, and autonomous LPBF of next-generation Inconel superalloys. Full article

(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)

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19 pages, 4282 KB

Open AccessArticle

Cross-Study of Techniques for the Analysis of Deformations Generated in the Injection Molding Process

by Vladimir Zagoya-Juárez, Héctor Plascencia-Mora, Jaime Navarrete Damián, Ismael Ruiz-López, Juan Francisco Reveles Arredondo and María Cristina López-Mendez

J. Manuf. Mater. Process. 2026, 10(9), 340; https://doi.org/10.3390/jmmp10090340 - 3 Sep 2026

Abstract

Injection molding is a plastic material processing technique used in the polymer industry. Because it is a complex process that requires injection cycles to achieve the desired aesthetic quality in the molded parts, it is essential to evaluate and configure all process parameters [...] Read more.

Injection molding is a plastic material processing technique used in the polymer industry. Because it is a complex process that requires injection cycles to achieve the desired aesthetic quality in the molded parts, it is essential to evaluate and configure all process parameters to predict and reduce defects, thereby decreasing the processing time and energy consumption. This study presents the results of tests performed on molded HDPE parts, including modeling and simulation using ANSYS^® (2025 R1), a design of experiments (DOE), and 3D scanning of the molded parts. The study compares the behavior of defects (warpages and sink-marks) in molded parts using 3D scanning with the results obtained from coupled thermal-structural field finite element simulations. These simulations were performed using software to assess the residual thermal stress of the ejection phase. The results visually display information that helps designers and engineers in the polymer processing sector evaluate molding-process failures using different software. Full article

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18 pages, 3796 KB

Open AccessArticle

Influence of Process Parameters and Rake Angle on Modeling of Cutting Forces in Wood-Based Materials

by Oleksandr Burdin, Armin Schleinitz, Florian Morczinek and Martin Dix

J. Manuf. Mater. Process. 2026, 10(9), 339; https://doi.org/10.3390/jmmp10090339 - 2 Sep 2026

Abstract

The environmental impact of technical systems is becoming increasingly important. Particularly in mechanical engineering, with its high demands on process stability and product quality, environmentally beneficial materials such as wood, with its heterogeneous and anisotropic structure, present challenges. Therefore, understanding the cutting process [...] Read more.

The environmental impact of technical systems is becoming increasingly important. Particularly in mechanical engineering, with its high demands on process stability and product quality, environmentally beneficial materials such as wood, with its heterogeneous and anisotropic structure, present challenges. Therefore, understanding the cutting process and the cutting forces is of great importance. This publication builds upon an established cutting force model and presents experiments to determine the specific cutting force (k_c0.5) and normal cutting force (k_cn0.5) for birch plywood. Furthermore, the influence of the rake angle (K_γc and K_γcn) and the cutting speed (K_vc and K_vcn) on the cutting forces is investigated. These correction factors are integrated into the established cutting model and verified under the assumption of no relevant directional dependence of the cutting forces due to the fibers of the plywood under investigation at the macroscopic level. The correction factors were determined based on the experiments and show a high degree of agreement with experimentally measured values. The correction factors lead to an increase in accuracy of predicting cutting forces during the peripheral milling of birch plywood. The model enables the prediction of cutting force with an average 30% increase in accuracy compared to the reference model. The results thus allow for a more accurate description of the cutting forces, from which important insights can be derived in the future for optimizing the cutting process and the tool, as well as for addressing tool wear and process quality. Full article

(This article belongs to the Special Issue Advanced and Sustainable Machining)

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22 pages, 23427 KB

Open AccessArticle

Design Optimization of Focus Ring Geometry for Improved Wafer-Edge Ion Energy-Angle Distributions in Pulsed Capacitively Coupled Plasma Etching

by Sun Jeong Hwang and Hae June Lee

J. Manuf. Mater. Process. 2026, 10(9), 338; https://doi.org/10.3390/jmmp10090338 - 2 Sep 2026

Abstract

Wafer-edge uniformity is a critical issue in plasma etching because local variations in ion bombardment can directly affect the etch profile and process yield. Ion transport near the wafer-edge is strongly influenced by the sheath formed around the boundary between the wafer and [...] Read more.

Wafer-edge uniformity is a critical issue in plasma etching because local variations in ion bombardment can directly affect the etch profile and process yield. Ion transport near the wafer-edge is strongly influenced by the sheath formed around the boundary between the wafer and the focus ring. Although focus ring geometry, dielectric properties, and applied voltage conditions can all modify this local sheath, their respective roles in controlling ion incidence angle and energy have not been clearly distinguished. In this study, two-dimensional particle-in-cell Monte Carlo collision simulations were performed for an argon capacitively coupled plasma to compare the effects of focus-ring height, electrode-to-focus-ring gap width, dielectric permittivity, and applied voltage conditions. The electrical conditions included a single-frequency waveform and a pulsed dual-frequency waveform with a variation in the low-frequency (LF) voltage amplitude. Geometric changes in focus-ring height and gap width modify the local sheath contour and ion acceleration direction, leading to more pronounced changes in the ion incidence angle than those caused by dielectric permittivity. The ion energy, however, is more strongly influenced by the applied voltage condition, particularly the LF voltage amplitude. These findings provide fundamental insights into wafer-edge ion control, although their quantitative applicability to reactive and electronegative etching remains to be verified. Full article

(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)

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16 pages, 2209 KB

Open AccessArticle

Functional Architecture and Exploratory Operational Assessment of a Mobile Hydraulic Clay-Brick Molding Machine for Small-Scale Manufacturing

by Luis Alberto Flores Chaires, José Ricardo Gómez Rodríguez, Hugo Pineda Martínez, Ana Gabriela Castañeda Miranda, Remberto Sandoval Aréchiga, Víktor Ivan Rodríguez Abdala, Salvador Ibarra Delgado and Oscar Osvaldo Ordaz-García

J. Manuf. Mater. Process. 2026, 10(9), 337; https://doi.org/10.3390/jmmp10090337 - 2 Sep 2026

Abstract

Small-scale clay-brick yards require molding equipment that increases output while remaining mobile, locally serviceable, and compatible with intermittent material supply. This article documents the functional architecture and exploratory operational performance of the mobile 12-cavity hydraulic clay-brick molding machine (ML12). Its design contribution is [...] Read more.

Small-scale clay-brick yards require molding equipment that increases output while remaining mobile, locally serviceable, and compatible with intermittent material supply. This article documents the functional architecture and exploratory operational performance of the mobile 12-cavity hydraulic clay-brick molding machine (ML12). Its design contribution is the integration of a dimensioned wheeled steel chassis, seated paired-lever controls, a translating feed hopper/distributor, a 12-cavity mold, two vertical hydraulic actuators, and a water-spray cleaning subsystem in a four-stage operating cycle. A retrospective concept-appraisal matrix compares this architecture with fixed automated and mobile manual concepts; equal weighting and one-at-a-time ±25% weight variations preserve the ML12’s highest internal score, without establishing stakeholder preference or empirical superiority. The evidence base also comprises sequential daily production logs: ten days of traditional manual molding followed by ten days of ML12-assisted molding. Mean gross green-brick output was 720 ± 86 bricks/day in the traditional period and 1495 ± 16 bricks/day in the ML12 period; corresponding descriptive throughputs were 86.5 and 186.9 bricks/h. A rejection-rate sensitivity analysis shows that, if traditional production had no rejects, ML12 conforming output would equal the traditional gross mean at a 51.8% ML12 rejection rate; this quantity boundary is not an estimate of quality or economic break-even. A preliminary linear-static finite-element case for a reconstructed frame returned a maximum von Mises stress of 112.3 MPa, 1.82 mm resultant displacement, and a minimum elastic safety factor of 2.23 on the reported medium mesh; the result is limited to the specified 1.0 kN load case and is not structural certification of the complete machine. Because the operational comparison was non-randomized and did not control staffing, operators, clay batch, moisture, weather, energy use, or rejection rate, the observed difference cannot be attributed exclusively to the machine. The results establish the machine architecture, an operational signal, and a bounded preliminary frame response, but not brick quality, ergonomic benefit, full structural safety, environmental benefit, or commercial return. Full article

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5 pages, 169 KB

Open AccessEditorial

Polymer Composites for Additive Manufacturing: Processing, Microstructure, and Mechanical Properties

by Mohd Shahneel Saharudin

J. Manuf. Mater. Process. 2026, 10(9), 336; https://doi.org/10.3390/jmmp10090336 - 2 Sep 2026

Abstract

Additive manufacturing (AM) has moved beyond prototyping and now produces functional, load-bearing components [...] Full article

(This article belongs to the Special Issue Innovative and Sustainable Advances in Polymer Composites for Additive Manufacturing: Processing, Microstructure, Machining, and Mechanical Properties)

4 pages, 172 KB

Open AccessEditorial

Innovative Approaches in Metal Forming and Joining Technologies

by Mohammad Mehdi Kasaei

J. Manuf. Mater. Process. 2026, 10(9), 335; https://doi.org/10.3390/jmmp10090335 - 2 Sep 2026

Abstract

The continuing evolution of transportation, aerospace, energy, electronics, and other high-performance engineering sectors is placing increasingly demanding requirements on manufacturing technologies [...] Full article

(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)

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