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
A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths
J. Manuf. Mater. Process. 2024, 8(2), 84; https://doi.org/10.3390/jmmp8020084 - 20 Apr 2024
Abstract
Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique has gained attention across diverse industries due to its ability to expedite
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Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique has gained attention across diverse industries due to its ability to expedite production and facilitate the repair or replication of valuable components. This work reviews the state-of-the-art in wire-laser directed energy deposition to gain a clear understanding of key process variables and identify challenges affecting process stability. Furthermore, this paper explores modeling and monitoring methods utilized in the literature to enhance the final quality of fabricated parts, thereby minimizing the need for repeated experiments, and reducing material waste. By reviewing existing literature, this paper contributes to advancing the current understanding of wire-laser directed energy deposition technology. It highlights the gaps in the literature while underscoring research needs in wire-laser directed energy deposition.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessArticle
Role of Li and Sc Additions and Machining Conditions on Cutting Forces on Milling Behavior of A7075-Based Alloys
by
Ali Tahmasbi, Jean Brice Mandatsy Moungomo, Agnes M. Samuel, Yasser Zedan, Victor Songmene and Fawzy H. Samuel
J. Manuf. Mater. Process. 2024, 8(2), 83; https://doi.org/10.3390/jmmp8020083 - 19 Apr 2024
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The present study focuses on the dry and wet end milling of three distinct Aluminum 7075 alloys: A7075, A7075–Sc (with a 0.18% Sc addition), and A7075–Li–Sc (containing 2.2% Li and 0.18% Sc additions). The main objective is to explore how cutting parameters (cutting
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The present study focuses on the dry and wet end milling of three distinct Aluminum 7075 alloys: A7075, A7075–Sc (with a 0.18% Sc addition), and A7075–Li–Sc (containing 2.2% Li and 0.18% Sc additions). The main objective is to explore how cutting parameters (cutting speed and feed rate), heat treatment, alloy composition, and cooling methods influence A lcutting force. In the initial phase of the investigation, all three alloys underwent heat treatment. Subsequently, the machining process centered on the softest and hardest conditions, aiming at analyzing the impact of hardness on machinability behavior of the three studied alloys, using the same milling tool and a consistent depth of cut under both dry and wet conditions. The investigations also highlight the role of Li and Sc additions on the quality of surface finish, as well as burr and chip formation. In total, a sum of 108 operations have been performed on the present alloys.
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Open AccessArticle
Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding
by
Keita Marumoto, Akira Fujinaga, Takeshi Takahashi, Hikaru Yamamoto and Motomichi Yamamoto
J. Manuf. Mater. Process. 2024, 8(2), 82; https://doi.org/10.3390/jmmp8020082 - 18 Apr 2024
Abstract
This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire
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This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire feeding speed of 10 m/min on a butt joint with a V-shaped groove using 19 mm thick steel plates. Molten pool stability and defect formation were observed using high-speed imaging and cross-sectional observations. The power consumption and heat input were predicted prior to welding and measured in the experiments. The results indicate that a combination of a welding current of 350–500 A and welding speed of 0.3–0.7 m/min is optimal to avoid defect formation and molten metal precedence using three or four passes. The higher efficiency and lower heat input achieved by hot-wire GMAW results in a weld metal of adequate hardness, narrower heat-affected zone, smaller grain size at the fusion boundary, and lower power consumption than those obtained using tandem GMAW and high-current GMAW. Based on the experimental results, a single bevel groove, which is widely used in construction machinery welding joints, was welded using hot-wire GMAW, and we confirmed that the welding part could be welded in six passes, whereas eight passes were required with GMAW only.
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(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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Open AccessArticle
Production of Permanent Magnets from Recycled NdFeB Powder with Powder Extrusion Moulding
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Stefan Rathfelder, Stephan Schuschnigg, Christian Kukla, Clemens Holzer and Carlo Burkhardt
J. Manuf. Mater. Process. 2024, 8(2), 81; https://doi.org/10.3390/jmmp8020081 - 18 Apr 2024
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In the last fifteen years, several groups have investigated metal injection moulding (MIM) of NdFeB powder to produce isotropic or anisotropic rare earth magnets of greater geometric complexity than that achieved by the conventional pressing and sintering approach. However, due to the powder’s
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In the last fifteen years, several groups have investigated metal injection moulding (MIM) of NdFeB powder to produce isotropic or anisotropic rare earth magnets of greater geometric complexity than that achieved by the conventional pressing and sintering approach. However, due to the powder’s high affinity for oxygen and carbon uptake, sufficient remanence and coercivity remains difficult. This article presents a novel approach to producing NdFeB magnets from recycled material using Powder Extrusion Moulding (PEM) in a continuous process. The process route uses powder obtained from recycling rare earth magnets through Hydrogen Processing of Magnetic Scrap (HPMS). This article presents the results of tailored powder processing, the production of mouldable feedstock based on a special binder system, and moulding with PEM to produce green and sintered parts. The magnetic properties and microstructures of debinded and sintered samples are presented and discussed, focusing on the influence of filling ratio and challenging processing conditions on interstitial content as well as density and magnetic properties.
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Open AccessArticle
Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power
by
Jonas Kimme, Jonas Gruner, André Hälsig and Jonas Hensel
J. Manuf. Mater. Process. 2024, 8(2), 80; https://doi.org/10.3390/jmmp8020080 - 18 Apr 2024
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Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive
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Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.
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Open AccessReview
Soft Robot Design, Manufacturing, and Operation Challenges: A Review
by
Getachew Ambaye, Enkhsaikhan Boldsaikhan and Krishna Krishnan
J. Manuf. Mater. Process. 2024, 8(2), 79; https://doi.org/10.3390/jmmp8020079 - 16 Apr 2024
Abstract
Advancements in smart manufacturing have embraced the adoption of soft robots for improved productivity, flexibility, and automation as well as safety in smart factories. Hence, soft robotics is seeing a significant surge in popularity by garnering considerable attention from researchers and practitioners. Bionic
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Advancements in smart manufacturing have embraced the adoption of soft robots for improved productivity, flexibility, and automation as well as safety in smart factories. Hence, soft robotics is seeing a significant surge in popularity by garnering considerable attention from researchers and practitioners. Bionic soft robots, which are composed of compliant materials like silicones, offer compelling solutions to manipulating delicate objects, operating in unstructured environments, and facilitating safe human–robot interactions. However, despite their numerous advantages, there are some fundamental challenges to overcome, which particularly concern motion precision and stiffness compliance in performing physical tasks that involve external forces. In this regard, enhancing the operation performance of soft robots necessitates intricate, complex structural designs, compliant multifunctional materials, and proper manufacturing methods. The objective of this literature review is to chronicle a comprehensive overview of soft robot design, manufacturing, and operation challenges in conjunction with recent advancements and future research directions for addressing these technical challenges.
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(This article belongs to the Special Issue Smart Manufacturing in the Era of Industry 4.0)
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Open AccessFeature PaperArticle
Comprehensive Distortion Analysis of a Laser Direct Metal Deposition (DMD)-Manufactured Large Prototype Made of Soft Martensitic Steel 1.4313
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Indira Dey, Raphael Floeder, Rick Solcà, Timo Schudeleit and Konrad Wegener
J. Manuf. Mater. Process. 2024, 8(2), 78; https://doi.org/10.3390/jmmp8020078 - 16 Apr 2024
Abstract
Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–thermal and structural simulations, experimental approaches using tomography, X-ray diffraction (XRD), and an
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Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–thermal and structural simulations, experimental approaches using tomography, X-ray diffraction (XRD), and an analytical approach calculating the buckling distortion of a piston. The most essential geometrical features are thin walls situated between massive rings. An eigenvalue buckling analysis, a DMD process, and heat treatment simulation are presented. The eigenvalue buckling simulation shows that it is highly dependent on the mesh size. The computational effort of the DMD and heat treatment simulation was reduced through simplifications. Moreover, artificial imperfections were imposed in the heat treatment simulation, which moved the part into the buckling state inspired by the experiment. Although the numerical results of both simulations are successful, the eigenvalue and DMD simulation cannot be validated through tomography and XRD. This is because tomography is unable to measure small elastic strain fields, the simulated residual stresses were overestimated, and the part removal disturbed the residual stress equilibrium. Nevertheless, the heat treatment simulation can predict the distortion pattern caused by an inhomogeneous temperature field during ambient cooling in an oven. The massive piston skirt cools down and shrinks faster than the massive core. The reduced yield strength at elevated temperatures and critical buckling load leads to plastic deformation of the thin walls.
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(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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Open AccessArticle
Interrelations between Printing Patterns and Residual Stress in Fused Deposition Modelling for the 4D Printing of Acrylonitrile Butadiene Styrene and Wood–Plastic Composites
by
Yerong Huang, Sandra Löschke, Yixiang Gan and Gwénaëlle Proust
J. Manuf. Mater. Process. 2024, 8(2), 77; https://doi.org/10.3390/jmmp8020077 - 15 Apr 2024
Abstract
Four dimensional printing enables the advanced manufacturing of smart objects that can morph and adapt shape over time in response to stimuli such as heat. This study presents a single-material 4D printing workflow which explores the residual stress and anisotropy arising from the
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Four dimensional printing enables the advanced manufacturing of smart objects that can morph and adapt shape over time in response to stimuli such as heat. This study presents a single-material 4D printing workflow which explores the residual stress and anisotropy arising from the fused deposition modelling (FDM) printing process to create heat-triggered self-morphing objects. In particular, the study first investigates the effect of printing patterns on the residual stress of FDM-printed acrylonitrile butadiene styrene (ABS) products. Through finite element analysis, the raster angle of printing patterns was identified as the key parameter influencing the distribution of residual stresses. Experimental investigations further reveal that the non-uniform distribution of residual stress results in the anisotropic thermal deformation of printed materials. Thus, through the design of printing patterns, FDM-printed materials can be programmed with desired built-in residual stresses and anisotropic behaviours for initiating and controlling the transformation of 4D-printed objects. Using the proposed approach, any desktop FDM printers can be turned into 4D printers to create smart objects that can self-morph into target geometries. A series of 4D printing prototypes manufactured from conventional ABS 3D printing feedstock are tested to illustrate the use and reliability of this new workflow. Additionally, the custom-made wood–plastic composite (WPC) feedstocks are explored in this study to demonstrate the transposability of the 4D printing approach.
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(This article belongs to the Special Issue Manufacturing Process Development of Advanced Composite Materials)
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Open AccessReview
Computer-Aided Optimisation in Additive Manufacturing Processes: A State of the Art Survey
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Tanja Emilie Henriksen, Tanita Fossli Brustad, Rune Dalmo and Aleksander Pedersen
J. Manuf. Mater. Process. 2024, 8(2), 76; https://doi.org/10.3390/jmmp8020076 - 15 Apr 2024
Abstract
Additive manufacturing (AM) is a field with both industrial and academic significance. Computer-aided optimisation has brought advances to this field over the years, but challenges and areas of improvement still remain. Design to execution inaccuracies, void formation, material anisotropy, and surface quality are
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Additive manufacturing (AM) is a field with both industrial and academic significance. Computer-aided optimisation has brought advances to this field over the years, but challenges and areas of improvement still remain. Design to execution inaccuracies, void formation, material anisotropy, and surface quality are examples of remaining challenges. These challenges can be improved via some of the trending optimisation topics, such as artificial intelligence (AI) and machine learning (ML); STL correction, replacement, or removal; slicing algorithms; and simulations. This paper reviews AM and its history with a special focus on the printing process and how it can be optimised using computer software. The most important new contribution is a survey of the present challenges connected with the prevailing optimisation topics. This can be seen as a foundation for future research. In addition, we suggest how certain challenges can be improved and show how such changes affect the printing process.
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(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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Open AccessArticle
Rolling Eccentric Steel Rings on an Industrial Radial–Axial Ring Rolling Mill
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Mirko Gröper, Marten Quadfasel, David Bailly and Gerhard Hirt
J. Manuf. Mater. Process. 2024, 8(2), 75; https://doi.org/10.3390/jmmp8020075 - 12 Apr 2024
Abstract
Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, significant material wastage or uneven microstructures. The radial–axial ring rolling process serves to create seamless
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Various industries, including mechanical engineering, utilize steel rings featuring variable cross-sectional profiles, such as eccentric rings. Presently employed methods for producing eccentric rings possess drawbacks like restricted geometries, significant material wastage or uneven microstructures. The radial–axial ring rolling process serves to create seamless rolled steel rings with near-net-shaped cross-sections. A novel technique involves achieving eccentricity by dynamically adjusting the mandrel’s position during the ring rolling process. This method’s fundamental feasibility has previously been showcased using a blend of oil clay and a labor test bench. Transferring the possibility of manufacturing eccentric rings on industrial radial–axial ring rolling mills would expand the product range of ring manufacturers without encountering drawbacks associated with existing manufacturing processes. The objective of this paper is to demonstrate the basic feasibility of the concept of an industrial radial–axial ring rolling mill. In the first step, FEA simulation studies were carried out to develop the rolling strategy and estimate the achievable eccentricity on the institute’s radial–axial ring mill. Subsequently, the rolling strategy was implemented on an industrial ring rolling mill with the help of a unique technology module programmed in C++. Finally, an eccentric ring was ring rolled and compared with the FEA simulation, and the reproducibility was demonstrated to be successful.
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(This article belongs to the Topic Modern Technologies and Manufacturing Systems, 2nd Volume)
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Open AccessArticle
Influence of the Hot-Top Thermal Regime on the Severity and Extent of Macrosegregation in Large-Size Steel Ingots
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Neda Ghodrati, Henri Champliaud, Jean-Benoit Morin and Mohammad Jahazi
J. Manuf. Mater. Process. 2024, 8(2), 74; https://doi.org/10.3390/jmmp8020074 - 11 Apr 2024
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The influence of hot-top designs with different heat capacities on the distribution of positive and negative macrosegregation was investigated on a 12 metric tonne (MT) cast ingot made using Cr-Mo low-alloy steel. The three-dimensional finite element modeling code THERCAST® was used to
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The influence of hot-top designs with different heat capacities on the distribution of positive and negative macrosegregation was investigated on a 12 metric tonne (MT) cast ingot made using Cr-Mo low-alloy steel. The three-dimensional finite element modeling code THERCAST® was used to simulate the thermo-mechanical phenomena associated with the solidification process, running from filling the mold until complete solidification. The model was validated on an industrial-scale ingot and then utilized to evaluate the influence of the thermal history of the hot-top, a crucial component in the cast ingot setup. This assessment aimed to comprehend changes in solidification time, temperature, and heat flux—all of which contribute to the determination of macrosegregation severity. The results showed that preheating the hot-top had a minor effect on solidification time, while modifications of thermal conductivity in the hot-top region increased the solidification time by 31%, thereby significantly affecting the macrosegregation patterns. The results are discussed and interpreted in terms of the fundamental mechanisms governing the kinetics of solidification and macrosegregation phenomena.
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Open AccessArticle
Theoretical-Numerical Investigation of a New Approach to Reconstruct the Temperature Field in PBF-LB/M Using Multispectral Process Monitoring
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Lisa May and Martin Werz
J. Manuf. Mater. Process. 2024, 8(2), 73; https://doi.org/10.3390/jmmp8020073 - 10 Apr 2024
Abstract
The monitoring of additive manufacturing processes such as powder bed fusion enables the detection of several process quantities important to the quality of the built part. In this context, radiation-based monitoring techniques have been used to obtain information about the melt pool and
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The monitoring of additive manufacturing processes such as powder bed fusion enables the detection of several process quantities important to the quality of the built part. In this context, radiation-based monitoring techniques have been used to obtain information about the melt pool and the general temperature distribution on the surface of the powder bed. High temporal and spatial resolution have been achieved at the cost of large storage requirements. This contribution aims to offer an alternative strategy of gaining information about the powder bed’s temperature field with sufficient resolution but with an economical amount of data. The investigated measurement setup uses a spectrometer to detect the spectral radiation intensities emitted by an area enclosing the melt pool and part of its surroundings. An analytical description of this process is presented, which shows that the measured spectral entities can be reconstructed by the Ritz method. It is also shown that the corresponding weighting factors can be physically interpreted as subdomains of constant temperature within the measurement area. Two different test cases are numerically analyzed, showing that the methodology allows for an approximation of the melt pool size while further assumptions remain necessary to reconstruct the actual temperature distribution.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessArticle
Investigation of Deposition Parameters for Near-Beta Alloy Ti-55511 Fabricated by Directed Energy Deposition
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Addison J. Rayner, Greg A. W. Sweet, Owen Craig, Mahdi Habibnejad-Korayem and Paul Bishop
J. Manuf. Mater. Process. 2024, 8(2), 72; https://doi.org/10.3390/jmmp8020072 - 10 Apr 2024
Abstract
The directed energy deposition (DED) parameters were determined for near-β alloy Ti-55511 by employing statistical design of experiments (DOEs) methods. Parameters resulting in fully dense freeform deposits were identified using two sequential DOEs. Single laser tracks were printed with several laser power, traverse
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The directed energy deposition (DED) parameters were determined for near-β alloy Ti-55511 by employing statistical design of experiments (DOEs) methods. Parameters resulting in fully dense freeform deposits were identified using two sequential DOEs. Single laser tracks were printed with several laser power, traverse rate, and powder feed rate settings in an initial DOE to identify promising build parameters. The capture efficiency and effective deposition rate were used to characterize and rank the single track deposits. The best parameters were then used to print a solid cube with various X–Y and Z overlaps (different hatch spacing, HS, and layer thickness, ZS) in a second DOE. Suitable deposition parameters were selected based on the cube density and microstructure and were used to fabricate larger tensile samples for mechanical testing. Multiple parameter sets were found to provide dense Ti-55511 deposits with acceptable mechanical properties and the parametric models showed statistical significance.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessArticle
Particle Size Effect on Powder Packing Properties and Molten Pool Dimensions in Laser Powder Bed Fusion Simulation
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Jun Katagiri, Sukeharu Nomoto, Masahiro Kusano and Makoto Watanabe
J. Manuf. Mater. Process. 2024, 8(2), 71; https://doi.org/10.3390/jmmp8020071 - 01 Apr 2024
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Various defects are produced during the laser powder bed fusion (L-PBF) process, which can affect the quality of the fabricated part. Previous studies have revealed that the defects formed are correlated with molten pool dimensions. Powder particles are thinly spread on a substrate
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Various defects are produced during the laser powder bed fusion (L-PBF) process, which can affect the quality of the fabricated part. Previous studies have revealed that the defects formed are correlated with molten pool dimensions. Powder particles are thinly spread on a substrate during the L-PBF process; hence, powder packing properties should influence the molten pool dimensions. This study evaluated the influence of particle size on powder packing properties and molten pool dimensions obtained through numerical simulations. Using particles with different average diameters ( ) of 24, 28, 32, 36, and 40 m, a series of discrete-element method (DEM) simulations were performed. The packing fraction obtained from DEM simulations became high as became small. Several particles piled up for small , whereas particles spread with almost one-particle diameter thickness for large . Moreover, the packing structure was inhomogeneous and sparse for large . As a result of multiphysics computational fluid dynamics (CFD) simulations incorporating particles’ positions as initial solid metal volume, the molten pool width obtained was hardly dependent on the and was roughly equivalent to the laser spot size used in the simulations. In contrast, the molten pool depth decreased as decreased. Even if the powder bed thickness is the same, small particles can form a complex packing structure by piling up, resulting in a large specific surface area. This can lead to a complex laser reflection compared to the large particles coated with almost one-particle thickness. The complex reflection absorbs the heat generated by laser irradiation inside the powder bed formed on the substrate. As a result, the depth of the molten pool formed below the substrate is reduced for small particles.
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Open AccessArticle
Analytical Model of Quantitative Texture Prediction Considering Heat Transfer Based on Single-Phase Material in Laser Powder Bed Fusion
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Wei Huang, Wenjia Wang, Jinqiang Ning, Hamid Garmestani and Steven Y. Liang
J. Manuf. Mater. Process. 2024, 8(2), 70; https://doi.org/10.3390/jmmp8020070 - 30 Mar 2024
Abstract
Laser powder bed fusion (LPBF) is widely used in metal additive manufacturing to create geometrically complex parts, where heat transfer and its affected temperature distribution significantly influence the parts’ materials’ microstructure and the resulting materials’ properties. Among all the microstructure representations, crystallographic orientations
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Laser powder bed fusion (LPBF) is widely used in metal additive manufacturing to create geometrically complex parts, where heat transfer and its affected temperature distribution significantly influence the parts’ materials’ microstructure and the resulting materials’ properties. Among all the microstructure representations, crystallographic orientations play a paramount role in determining the mechanical properties of materials. This paper first developed a physics-based analytical model to predict the 3D temperature distribution in PBF considering heat transfer boundary conditions; heat input using point-moving heat source solutions; and heat loss due to heat conduction, convection, and radiation. The superposition principle obtained temperature distributions based on linear heat sources and linear heat loss solutions. Then, the temperature distribution was used to analytically obtain the texture grown on a substrate with random grain orientations considering columnar-to-equiaxed transition (CET). Thus, the link between process parameters and texture was established through CET models and physical rules. Ti-6Al-4V was selected to demonstrate the capability of the analytical model in a single-phase situation. By applying advanced thermal models, the accuracy of the texture prediction was evaluated based on a comparison of experimental data from the literature and past analytical model results. Hence, this work not only provides a method of the fast analytical simulation of texture prediction in the single-phase mode for metallic materials but also paves the road for subsequent studies on microstructure-affected or texture-affected materials’ properties for both academic research and industrial applications. The prediction of single-phase material texture has never been achieved before, and the scalability has been expanded.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessArticle
Minimum Quantity Lubrication (MQL) Supply through Internal Cooling Channels in Drilling Processes
by
Lukas Schumski, Teresa Tonn, Jens Sölter, Kerstin Avila, Lizoel Buss, Bernhard Karpuschewski and Udo Fritsching
J. Manuf. Mater. Process. 2024, 8(2), 69; https://doi.org/10.3390/jmmp8020069 - 29 Mar 2024
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Minimum quantity lubrication (MQL) technologies possess great potential for improving the sustainability of manufacturing processes, which can reduce the absolute quantity of metalworking fluid (MWF) and also enable near-dry chips that are easier to recycle. During drilling in particular, the MWF is transported
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Minimum quantity lubrication (MQL) technologies possess great potential for improving the sustainability of manufacturing processes, which can reduce the absolute quantity of metalworking fluid (MWF) and also enable near-dry chips that are easier to recycle. During drilling in particular, the MWF is transported to the contact zone through internal cooling channels of the drilling tool. The MWF supply and its associated flow behaviour in the transfer from the outlet of the cooling channels to the contact zone have not been sufficiently investigated yet. Great potential is seen in the proper delivery of the MQL into the contact zone. This work aims to visualize and quantify the cooling lubricant supply into the cutting zone using the MQL technique. The visualization of the MQL application is made possible by high-speed shadowgraphic imaging. Detailed image processing is used to evaluate the resulting images. The developed evaluation routine allows for the assessment of the impact of the main process parameters such as the varying pressure of the aerosol generator and the cooling channel diameter. It is found that the oil leaves the cooling channels at the tip of the drill bit in the form of ligaments. An increase in pressure and cooling channel diameter leads to an increase in the frequency of oil ligament separation. Three main flow regimes are identified with different separation frequencies. Low inlet pressures result in intermittently dispersed droplets. The most upper pressure levels lead to an almost continuous dispersion of the oil. At the same time, the air and oil mass flow rates also increase.
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Open AccessArticle
Enhancing Tool Performance in High-Speed End Milling of Ti-6Al-4V Alloy: The Role of AlCrN PVD Coatings and Resistance to Chipping Wear
by
Qianxi He, Victor Saciotto, Jose M. DePaiva, Monica C. Guimaraes, Joern Kohlscheen, Marcelo M. Martins and Stephen C. Veldhuis
J. Manuf. Mater. Process. 2024, 8(2), 68; https://doi.org/10.3390/jmmp8020068 - 29 Mar 2024
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The conventional cutting tools used for machining titanium alloys normally experience rapid tool wear, and it is generally difficult to achieve a cutting speed over 60 m/min. In this paper, a comprehensive study on improving the machining of Ti-6Al-4V alloy is presented, focusing
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The conventional cutting tools used for machining titanium alloys normally experience rapid tool wear, and it is generally difficult to achieve a cutting speed over 60 m/min. In this paper, a comprehensive study on improving the machining of Ti-6Al-4V alloy is presented, focusing on high-speed end milling at 100 m/min. Three different AlCrN PVD-coated cemented carbide tools were employed over cemented solid carbide endmills. The study aimed to understand the factors influencing tool performance and, particularly, the uncommon tool wear behavior characterized by chipping on the rake face. The research methodology involves a detailed investigation of coating properties, mechanical characteristics, surface defects, and tool edge geometries. Mechanical properties were measured to assess the resistance to plastic deformation and impact fatigue fracture resistance. Surface defects were meticulously observed, and tool edge geometries were evaluated through optical microscopies. These analyses uncover the key factors contributing to the best tool performance, notably the resistance to plastic deformation (H3/E2 ratio), impact fatigue fracture resistance, and maintaining uniform tool edge geometries. The results of this study reveal that the moderate stress C3 coating outperformed the other two coatings, exhibiting a 1.5-times-longer tool life, a relatively stable cutting force curve, and favorable friction conditions in the cutting zone.
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Open AccessArticle
A Comprehensive Study on the Optimization of Drilling Performance in Hybrid Nano-Composites and Neat CFRP Composites Using Statistical and Machine Learning Approaches
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Tanzila Nargis, S. M. Shahabaz, Subash Acharya, Nagaraja Shetty, Rashmi Laxmikant Malghan and S. Divakara Shetty
J. Manuf. Mater. Process. 2024, 8(2), 67; https://doi.org/10.3390/jmmp8020067 - 29 Mar 2024
Abstract
Carbon fiber-reinforced polymer (CFRP) composites have gradually replaced metals due to their exceptional strength-to-weight ratio compared to metallic materials. However, the drilling process often reveals various defects, such as surface roughness, influenced by different drilling parameters. This study explores the drilling quality of
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Carbon fiber-reinforced polymer (CFRP) composites have gradually replaced metals due to their exceptional strength-to-weight ratio compared to metallic materials. However, the drilling process often reveals various defects, such as surface roughness, influenced by different drilling parameters. This study explores the drilling quality of uni-directional CFRP composites, as well as hybrid Al2O3 alumina and hybrid SiC silicon carbide nano-composites, through experimental exploration using step, core, and twist drills. Response surface methodology (RSM) and statistical tools, including main effect plots, ANOVA, contour plots, and optimization techniques, were used to analyze the surface roughness of the hole. Optimization plots were drawn for optimal conditions, suggesting a spindle speed of 1500 rpm, feed of 0.01 mm/rev, and a 4 mm drill diameter for achieving minimum surface roughness. Furthermore, two machine learning models, artificial neural network (ANN) and random forest (RF), were used for predictive analysis. The findings revealed the robust predictive capabilities of both models, with RF demonstrating superior performance over ANN and RSM. Through visual comparisons and error analyses, more insights were gained into model accuracy and potential avenues for improvement.
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(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing)
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Open AccessArticle
Synthetic-to-Real Composite Semantic Segmentation in Additive Manufacturing
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Aliaksei Petsiuk, Harnoor Singh, Himanshu Dadhwal and Joshua M. Pearce
J. Manuf. Mater. Process. 2024, 8(2), 66; https://doi.org/10.3390/jmmp8020066 - 28 Mar 2024
Abstract
The application of computer vision and machine learning methods for semantic segmentation of the structural elements of 3D-printed products in the field of additive manufacturing (AM) can improve real-time failure analysis systems and potentially reduce the number of defects by providing additional tools
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The application of computer vision and machine learning methods for semantic segmentation of the structural elements of 3D-printed products in the field of additive manufacturing (AM) can improve real-time failure analysis systems and potentially reduce the number of defects by providing additional tools for in situ corrections. This work demonstrates the possibilities of using physics-based rendering for labeled image dataset generation, as well as image-to-image style transfer capabilities to improve the accuracy of real image segmentation for AM systems. Multi-class semantic segmentation experiments were carried out based on the U-Net model and the cycle generative adversarial network. The test results demonstrated the capacity of this method to detect such structural elements of 3D-printed parts as a top (last printed) layer, infill, shell, and support. A basis for further segmentation system enhancement by utilizing image-to-image style transfer and domain adaptation technologies was also considered. The results indicate that using style transfer as a precursor to domain adaptation can improve real 3D printing image segmentation in situations where a model trained on synthetic data is the only tool available. The mean intersection over union (mIoU) scores for synthetic test datasets included 94.90% for the entire 3D-printed part, 73.33% for the top layer, 78.93% for the infill, 55.31% for the shell, and 69.45% for supports.
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(This article belongs to the Special Issue Smart and Advanced Manufacturing)
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Effect of the Printing Angle on the Microstructure and Tensile Performance of Iron-Reinforced Polylactic Acid Composite Manufactured Using Fused Filament Fabrication
by
Sofiane Guessasma and Sofiane Belhabib
J. Manuf. Mater. Process. 2024, 8(2), 65; https://doi.org/10.3390/jmmp8020065 - 27 Mar 2024
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This work emphasizes an innovative approach utilizing 3D imaging technology based on synchrotron radiation to assess the microstructure of second-phase iron particles and the porous structure within 3D-printed PLA/magnetic iron composites at different printing angles. The study examines how these observations relate to
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This work emphasizes an innovative approach utilizing 3D imaging technology based on synchrotron radiation to assess the microstructure of second-phase iron particles and the porous structure within 3D-printed PLA/magnetic iron composites at different printing angles. The study examines how these observations relate to the material’s ductility when processed using fused filament fabrication. In particular, this study examines the impact of one processing parameter, specifically the printing angle, on the microstructure and mechanical behaviour of a polylactic acid (PLA)–iron (PLI) composite designed for magnetic actuation. Fused filament fabrication is employed to produce PLI tensile specimens, with varied printing angles to create different layups. X-ray microtomography is utilized to analyse the microstructure, while tensile mechanical properties are evaluated for all composites, with findings discussed in relation to printing angle conditions. Scanning Electron Microscopy is used to examine the fractography of broken specimens. Results indicate that the printing angle significantly influences the tensile properties and mechanical anisotropy of 3D-printed PLI composites, with an optimal 45°/45° layup enhancing tensile performance. These findings suggest that 3D-printed PLI composites offer a cost-efficient means of producing bio-sourced, light-adaptive materials with intricate magnetic actuation capabilities. By quantifying the modulation of mechanical properties based on printing parameters that influence microstructural arrangement, the research sheds light on a novel aspect of composite material characterization.
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