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Advanced Materials Processing for Engineering Applications

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 December 2023) | Viewed by 14839

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Dr. Yong Chen

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Guest Editor

College of Mechanical Engineering, University of South China, Hengyang 421001, China
Interests: additive manufacturing; coating technology; plastic deformation
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Changjun Qiu

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Guest Editor

College of Mechanical Engineering, University of South China, Hengyang 421001, China
Interests: additive manufacturing; coating technology; surface engineering

Special Issue Information

Dear Colleagues,

The primary goal of this Special Issue is to present recent trends in advanced-manufacturing-related fields.

We would like to invite academics and researchers to contribute to this Special Issue, entitled “Advanced Materials Processing for Engineering Applications”, which is intended to serve as a unique multidisciplinary forum covering advanced manufacturing technology, advanced forming equipment, forming process monitoring, forming product inspection and material forming numerical simulation.

All contributions closely related to materials processing are also welcome. We welcome the submission of research papers as well as review articles.

The research topics that we would like contributors to address include but are not limited to the following:

Advanced connection technology;
Advanced machining technology;
Additive manufacturing;
Coating technology;
Metal plastic processing;
Numerical simulation of material forming processes;
Material forming process monitoring;
Rapid prototyping;
Intelligent forming technology.

Dr. Yong Chen
Prof. Dr. Changjun Qiu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

manufacturing technology
process monitoring
processing equipment
numerical simulation of material forming
molding quality inspection
product quality inspection

Published Papers (12 papers)

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Research

25 pages, 24932 KiB

Open AccessArticle

Possibilities of Increasing the Durability of Punches Used in the Forging Process in Closed Dies of Valve Forgings by Using Alternative Materials from Tool Steels and Sintered Carbides

by Marek Hawryluk, Marta Janik, Zbigniew Gronostajski, Artur Barełkowki, Maciej Zwierzchowski, Marzena Lachowicz, Jacek Ziemba and Jan Marzec

Materials 2024, 17(2), 370; https://doi.org/10.3390/ma17020370 - 11 Jan 2024

Viewed by 584

Abstract

This study refers to an analysis of the durability of forging tools applied in the second operation of producing a valve forging from the chromium–nickel steel, NC3015. Due to the extreme working conditions of the tools, caused by cyclic thermo-mechanical loads, the average durability of tools made from tool steel WLV (1.2365) equals about 1500 forgings. An in-depth, complex analysis was performed on the technology, using macroscopic tests combined with a measurement of the wear/allowance on the tool working surface through 3D scanning; microstructural tests by means of light microscopy; observations of the changes taking place on the working surface with a scanning electron microscope; microhardness measurements; and multi-variant numerical simulations. It was established that the key issue is the proper selection of the process technological parameters, such as the input material and tool temperature, friction, lubrication, tribological parameters, type of tool material, or punch design, because even small changes made to them significantly affect the service life of forging punches. Therefore, to increase the durability of the forging dies, alternative materials made of W360, as well as two high speed steels, S600 and S705, were applied. However, the implemented punch materials did not bring the assumed effect of increased durability, as the highest average durability of steel W60 equaled only 1500 forgings, whereas in the case of the tool steels, this was below 900 forgings. For this reason, at the further stage, punches with sintered carbide inserts were introduced, which made it possible to significantly improve the durability up to the level of as many as 20,000 forgings, which, at the same time, points to a promising direction of further studies on the use of materials and solutions of this type. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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16 pages, 14058 KiB

Open AccessArticle

Effects of the Laser Micromelting Process Parameters on the Preparation of Micron-Sized FeCrAl Coatings on Zr Alloy Surfaces

by Guoqing Song, Wentian Wei, Botao Liu, Bincai Shuai, Gengming Liu, Kanghui Xue and Yong Chen

Materials 2023, 16(23), 7421; https://doi.org/10.3390/ma16237421 - 29 Nov 2023

Viewed by 526

Abstract

Laser micromelting (LMM) technology allows for the remelting of pre-positioned coatings on the surface of a specimen to form a metallurgical bond with the substrate material, significantly improving the coating’s film–base bond. However, the high energy input from the laser modification process can cause severe element diffusion, rendering the coating susceptible to deformation and cracking. This can be mitigated by controlling the laser power, scanning speed, and offset of the LMM process. The temperature and stress fields of the samples in the LMM process were analyzed via finite element simulation. The effects of the LMM process parameters on the coating morphology were analyzed in conjunction with experiments. The results indicated that the laser power significantly affected the morphology of the coating after remelting, and a higher scanning speed was more likely to cause the coating to accumulate stress. Additionally, a smaller offset inhibited crack generation. At a laser power of 30 W, a scanning speed of 1200 mm/min, and a scanning spacing of 0.035 mm, the surface of the coating had no obvious defects and was relatively flat, and the adhesion and corrosion resistance were significantly improved. This study provides valuable guidance for improving the preparation of micron-sized protective coatings on Zr alloy surfaces. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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17 pages, 13330 KiB

Open AccessArticle

Investigation of the Dislocation Density of NiCr Coatings Prepared Using PVD–LMM Technology

by Guoqing Song, Wentian Wei, Bincai Shuai, Botao Liu and Yong Chen

Materials 2023, 16(22), 7234; https://doi.org/10.3390/ma16227234 - 20 Nov 2023

Viewed by 851

Abstract

Micron-sized coatings prepared using physical vapor deposition (PVD) technology can peel off in extreme environments because of their low adhesion. Laser micro-melting (LMM) technology can improve the properties of the fabricated integrated material due to its metallurgical combinations. However, the microstructural changes induced by the high-energy laser beam during the LMM process have not been investigated. In this study, we used the PVD–LMM technique to prepare NiCr coatings with a controlled thickness. The microstructural changes in the NiCr alloy coatings during melting and cooling crystallization were analyzed using molecular dynamics simulations. The simulation results demonstrated that the transition range of the atoms in the LMM process fluctuated synchronously with the temperature, and the hexagonal close-packed (HCP) structure increased. After the cooling crystallization, the perfect dislocations of the face-centered cubic (FCC) structure decreased significantly. The dislocation lines were mainly 1/6 <112> imperfect dislocations, and the dislocation density increased by 107.7%. The dislocations in the twinning region were affected by the twin boundaries and slip surfaces. They were plugged in their vicinity, resulting in a considerably higher dislocation density than in the other regions, and the material hardness increased significantly. This new technique may be important for the technological improvement of protective coatings on Zr alloy surfaces. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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17 pages, 13932 KiB

Open AccessArticle

Thermo-Mechanical Treatment for Reducing the Wear Rate of CuCrZr Tool Electrodes during Electro-Discharge Machining

by Jacek Skiba, Mariusz Kulczyk, Sylwia Przybysz-Gloc, Monika Skorupska, Julita Smalc-Koziorowska, Mariusz Kobus and Kamil Nowak

Materials 2023, 16(20), 6787; https://doi.org/10.3390/ma16206787 - 20 Oct 2023

Cited by 1 | Viewed by 684

Abstract

The research presented in this paper focused on optimising the process of unconventional plastic forming by hydrostatic extrusion (HE) with post-processing heat treatment of a copper alloy (CuCrZr) for electro-discharge machining (EDM) applications. The treatment was carried out in such a way as to obtain a material with an improved microstructure, characterised by a significant increase in hardness and strength while maintaining a high electrical conductivity, thus achieving the main goal of reducing electrode wear in the EDM process. As part of the research, a material with an ultrafine-grained structure was obtained with an average grain size of d₂ = 320 nm and a much higher strength of UTS = 645 MPa compared to the material in the initial state (UTS = 413 MPa). The post-processing treatment (ageing) allowed us to obtain a material with a high electrical conductivity after the HE process, at 78% IACS. The electrodes made of CuCrZr subjected to HE had a reduced electrical discharge wear in relation to electrodes made of the initial material. The best results were obtained for electrodes made of the material subjected to a five-stage HE process combined with ageing at 480 °C for 1 h. The electrical discharge wear in these electrodes was reduced by more than 50% compared to electrodes made of non-deformed copper. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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13 pages, 7175 KiB

Open AccessArticle

Study on Porosity Defect Detection in Narrow Gap Laser Welding Based on Spectral Diagnosis

by Jinping Liu, Baoping Xu, Yingchao Feng, Peng Chen, Cancan Yan, Zhuyuan Li, Kaisong Yang, Kun She and Yiming Huang

Materials 2023, 16(14), 4989; https://doi.org/10.3390/ma16144989 - 13 Jul 2023

Cited by 1 | Viewed by 1377

Abstract

As an advanced connection technology for large thick-walled components, narrow gap laser welding has the advantages of small heat input and high efficiency and quality. However, porosity defects are prone to occur inside the weld due to the complex welding environment. In this study, the influence of the process parameters and pollutants such as water and oil on the porosity defect were explored. The action mechanism of water on the electron temperature and spectral intensity of the laser-induced plasma was analyzed. The results showed that the spectral intensity during narrow gap laser welding was weaker than that of flat plate butt welding. Under the optimal welding process conditions, the electron temperature during narrow gap laser self-fusion welding was calculated as 7413.3 K by the Boltzmann plot method. The electron density was 5.6714 × 10¹⁵ cm⁻³, conforming to the thermodynamic equilibrium state. With six groups of self-fusion welding parameters, only sporadic porosity defects were observed according to the X-ray detection. When there was water on the base metal surface, a large number of dense pores were observed on the weld surface and in the weld through X-ray inspection. Compared with the spectral data obtained under the normal process, the relative light intensity of the spectrometer in the whole band was reduced. The electron temperature decreased to the range of 6900 to 7200 K, while the electron density increased. The spectrum variation during narrow gap laser wire filling welding was basically the same as that of laser self-fusion welding. The porosity defects caused by water and oil pollutants in the laser welding could be effectively identified based on the intensity of the Fe I spectral lines. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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21 pages, 3018 KiB

Open AccessArticle

A Simulation Model for the Inductor of Electromagnetic Levitation Melting and Its Validation

by Błażej Nycz, Roman Przyłucki, Łukasz Maliński and Sławomir Golak

Materials 2023, 16(13), 4634; https://doi.org/10.3390/ma16134634 - 27 Jun 2023

Cited by 2 | Viewed by 1113

Abstract

This article presents a numerical model of electromagnetic levitation melting and its experimental validation. Levitation melting uses the phenomenon of magnetic induction to float a melted, usually metallic, conductor in an electromagnetic field. With the appropriate configuration of the coil (the source of the alternating magnetic field), the eddy currents induced in the molten batch interact with the coil magnetic field, which causes the melted metal to float without direct contact with any element of the heating system. Such a contactless process is very beneficial for melting very reactive metals (e.g., titanium) or metals with a high melting point (e.g., tungsten). The main disadvantage of levitation melting is the low efficiency of the process. The goal of the authors is to develop, by means of a numerical simulation and optimization tools, a system for levitation melting with acceptable efficiency. To achieve this, it is necessary to develop a reliable and representative computational model. The proposed model includes an analysis of the electromagnetic field, with innovative modeling of the convective heat transport. Experimental validation of the model was performed using aluminum alloy, due to the lack of the need to use a protective atmosphere and the ease of measurements. The measurements included electrical values, the melted batch positions during levitation, the melting time, and the temperature distribution in its area. The verification showed that the compliance between the computational model and the simulation for the position of the batch was accurate to 2 mm (

6.25

%), and the consistency of the batch melting time was accurate to 5 s (

5.49

%). The studies confirmed the good representativeness of the developed numerical model, which makes it a useful tool for the future optimization of the levitation melting system. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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14 pages, 4229 KiB

Open AccessArticle

Numerical Modeling of a Sustainable Solid-State Recycling of Aluminum Scraps by Means of Friction Stir Extrusion Process

by Sara Bocchi, Gianluca D’Urso and Claudio Giardini

Materials 2023, 16(12), 4375; https://doi.org/10.3390/ma16124375 - 14 Jun 2023

Viewed by 773

Abstract

One of the most important purposes of the modern industry is a sustainable production, considering the minimization of the energy and of the raw materials used, together with the reduction of polluting emissions. In this context, Friction Stir Extrusion stands out, since it allows to obtain extrusions starting from metal scraps deriving from traditional mechanical machining processes (e.g., chips deriving from cutting operations), heated only by the friction generated between the scraps and the tool, so avoiding the material melting phase. Given the complexity of this new kind of process, the objective of this research is the study of the bonding conditions considering both the heat and the stresses generated during the process under different working parameters, namely tool rotational and descent speeds. As a result, the combined approach involving the Finite Element Analysis and the Piwnik and Plata criterion proves to be a valid tool for forecasting if bonding phenomenon occurs and how it is influenced by the process parameters. The results have also demonstrated that it is possible to achieve completely massive pieces between 500 rpm and 1200 rpm, but at different tool descent speeds. Specifically, up to 1.2 mm/s for 500 rpm and just over 2 mm/s for 1200 rpm. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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11 pages, 3213 KiB

Open AccessArticle

Experimental Investigation of Cobalt Deposition on 304 Stainless Steel in Borated and Lithiated High-Temperature Water

by Jian Deng, Jieheng Lei, Guolong Wang, Lin Zhong, Mu Zhao and Zeyong Lei

Materials 2023, 16(10), 3834; https://doi.org/10.3390/ma16103834 - 19 May 2023

Viewed by 1184

Abstract

The radioactive corrosion products ⁵⁸Co and ⁶⁰Co in the primary loops of pressurized water reactors (PWRs) are the main sources of radiation doses to which workers in nuclear power plants are exposed. To understand cobalt deposition on 304 stainless steel (304SS), which is the main structural material used in the primary loop, the microstructural characteristics and chemical composition of a 304SS surface layer immersed for 240 h in borated and lithiated high-temperature water containing cobalt were investigated with scanning electron microscopy (SEM), X-ray diffraction (XRD), laser Raman spectroscopy (LRS), X-ray photoelectron spectroscopy (XPS), glow discharge optical emission spectrometry (GD-OES), and inductively coupled plasma emission mass spectrometry (ICP-MS). The results showed that two distinct cobalt deposition layers (an outer layer of CoFe₂O₄ and an inner layer of CoCr₂O₄) were formed on the 304SS after 240 h of immersion. Further research showed that CoFe₂O₄ was formed on the metal surface by coprecipitation of the iron preferentially dissolved from the 304SS surface with cobalt ions from the solution. The CoCr₂O₄ was formed by ion exchange between the cobalt ions entering the metal inner oxide layer and (Fe, Ni) Cr₂O₄. These results are useful in understanding cobalt deposition on 304SS and have a certain reference value for exploring the deposition behavior and mechanism of radionuclide cobalt on 304SS in the PWR primary loop water environment. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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18 pages, 18790 KiB

Open AccessArticle

Control System for Automated Technological Process of Hot Stamping—A Case Study

by Ireneusz Wróbel and Piotr Danielczyk

Materials 2023, 16(10), 3658; https://doi.org/10.3390/ma16103658 - 11 May 2023

Cited by 1 | Viewed by 1768

Abstract

Hot forming process has been used more and more frequently in the production of body structures of modern ultralight passenger cars for several years. This, unlike the commonly used cold stamping, is a complicated process, combining heat treatment and plastic-forming methods. For this reason, permanent control at each stage is required. This includes, among others, measurement of the blank thickness, monitoring its heating process in the suitable atmosphere in the furnace, control of the forming process itself, measurement of shape-dimensional accuracy as well as mechanical parameters of the finished drawpiece. This paper discusses the method of controlling the values of production parameters during the hot stamping process of a selected drawpiece. For this purpose, digital twins of the production line and the stamping process, made in accordance with the assumptions of Industry 4.0, have been used. Individual components of the production line with sensors for monitoring process parameters have been shown. The system’s response to emerging threats has also been described. The correctness of the adopted values is confirmed via tests of mechanical properties and the assessment of the shape-dimensional accuracy of a drawpiece test series. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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20 pages, 4094 KiB

Open AccessArticle

Provision of Rational Parameters for the Turning Mode of Small-Sized Parts Made of the 29 NK Alloy and Beryllium Bronze for Subsequent Thermal Pulse Deburring

by Nikita V. Martyushev, Dmitriy A. Bublik, Vladislav V. Kukartsev, Vadim S. Tynchenko, Roman V. Klyuev, Yadviga A. Tynchenko and Yuliya I. Karlina

Materials 2023, 16(9), 3490; https://doi.org/10.3390/ma16093490 - 30 Apr 2023

Cited by 17 | Viewed by 1189

Abstract

The increase in the share of physical and technical processing methods in the arsenal of deburring technologies used in modern production is associated both with the use of difficult-to-machine materials, such as beryllium bronze and the 29 NK alloy, and with the need to solve technological problems for the production of small-sized products with hard-to-reach surfaces. The aim of the study is to improve the processes of blade processing of small-sized parts made of beryllium bronze and the 29 NK alloy to provide rational conditions for thermal pulse deburring. Surface samples were experimentally obtained after turning in different modes on a CITIZEN CINCOM K16E-VII automatic lathe equipped with an Applitec micromechanics tool. The surface quality and burr characteristics were examined using a JEOL JIB-Z4500 electron microscope and a ContourGT-K optical profilometer. The program Statistica 6 allowed processing of the results. The relationship between the parameters of the turning mode and the thickness of the root of the burrs formed on the machined surface, the limitation of which is one of the conditions for the application of the thermal pulse method, was established. The obtained empirical regression dependencies establish a rational range of cutting mode parameters, and the implementation of the formulated recommendations for setting blade modes ensures deburring by the thermal pulse method in compliance with the requirements of drawing under maximum processing performance. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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18 pages, 9862 KiB

Open AccessArticle

Investigation of MAF for Finishing the Inner Wall of Super-Slim Cardiovascular Stents Tube

by Guangxin Liu, Yugang Zhao, Zhihao Li, Chen Cao, Jianbing Meng, Hanlin Yu and Haiyun Zhang

Materials 2023, 16(8), 3022; https://doi.org/10.3390/ma16083022 - 11 Apr 2023

Viewed by 1651

Abstract

The internal wall of cardiovascular stent tubing produced by a drawing process has defects such as pits and bumps, making the surface rough and unusable. In this research, the challenge of finishing the inner wall of a super-slim cardiovascular stent tube was solved by magnetic abrasive finishing. Firstly, a spherical CBN magnetic abrasive was prepared by a new method, plasma molten metal powders bonding with hard abrasives; then, a magnetic abrasive finishing device was developed to remove the defect layer from the inner wall of ultrafine long cardiovascular stent tubing; finally, response surface tests were performed and parameters were optimized. The results show that the prepared spherical CBN magnetic abrasive has a perfect spherical appearance; the sharp cutting edges cover the surface layer of the iron matrix; the developed magnetic abrasive finishing device for a ultrafine long cardiovascular stent tube meets the processing requirements; the process parameters are optimized by the established regression model; and the inner wall roughness (Ra) of the nickel–titanium alloy cardiovascular stents tube is reduced from 0.356 μm to 0.083 μm, with an error of 4.3% from the predicted value. Magnetic abrasive finishing effectively removed the inner wall defect layer and reduced the roughness, and this solution provides a reference for polishing the inner wall of ultrafine long tubes. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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15 pages, 7408 KiB

Open AccessArticle

Study on Microstructure and Mechanical Properties of TC4/AZ31 Magnesium Matrix Nanocomposites

by Yong Chen, Yuan Yao, Shengli Han, Xiaowei Feng, Tiegang Luo and Kaihong Zheng

Materials 2023, 16(3), 1139; https://doi.org/10.3390/ma16031139 - 29 Jan 2023

Cited by 6 | Viewed by 1875

Abstract

In the field of metal matrix composites, it is a great challenge to improve the strength and elongation of magnesium matrix composites simultaneously. In this work, xTC4/AZ31 (x = 0.5, 1, 1.5 wt.%) composites were fabricated by spark plasma sintering (SPS) followed by hot extrusion. Scanning electron microscopy (SEM) showed that nano-TC4 (Ti-6Al-4V) was well dispersed in the AZ31 matrix. We studied the microstructure evolution and tensile properties of the composites, and analyzed the strengthening mechanism of nano-TC4 on magnesium matrix composites. The results showed that magnesium matrix composites with 1 wt.%TC4 had good comprehensive properties; compared with the AZ31 matrix, the yield strength (YS) was increased by 20.4%, from 162 MPa to 195 MPa; the ultimate tensile strength (UTS) was increased by 11.7%, from 274 MPa to 306 MPa, and the failure strain (FS) was increased by 21.1%, from 7.6% to 9.2%. The improvement in strength was mainly due to grain refinement and good interfacial bonding between nano-TC4 and the Mg matrix. The increase in elongation was the result of grain refinement and a weakened texture. Full article

(This article belongs to the Special Issue Advanced Materials Processing for Engineering Applications)

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