Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimisation Using Directed Energy Deposition Hybrid Manufacturing

Round 1

Reviewer 1 Report

The authors investigate the efficacy of Directed Energy Deposition (DED) in repairing and optimizing forging tools and moulds. The study compares the mechanical properties of specimens fabricated from conventional sheet metal with those manufactured via DED techniques. The research reveals significant differences in mechanical characteristics, emphasizing the nuanced balance between tensile strength and ductility in DED-produced components. The article highlights the advantages of DED-based repair processes, such as precision, material efficiency, reduced lead times, and cost-effectiveness. It also discusses critical considerations like material compatibility and quality assurance in the context of extending product lifecycles and fabricating complex geometries. While the topic is suitable for Applied Sciences, I have some questions for the authors to further refine the work.

·      How does the layering process in DED influence the mechanical properties, specifically tensile strength and ductility, of the manufactured components?

·      What are the specific benefits and limitations of DED in comparison to conventional manufacturing methods in terms of material efficiency and cost?

·      How does the use of DED for repairs impact the lifespan of metal forging tools and moulds?

·      What are the potential challenges in material compatibility when using DED for repairing and optimizing forging tools and moulds?

·      Can the findings be generalized to other manufacturing sectors or are they specific to metal forging tools and moulds?

·      How do environmental factors, like temperature and humidity, affect the DED process and the properties of the final product?

Author Response

Dear reviewer,

We would like to express our gratitude for your feedback and constructive comments on our article titled "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing." Your evaluation has immensely contributed to refining and improving the scientific quality of our research.

We addressed each of your concerns which identified areas for improving our manuscript in the attached file.

Thank you once again for your time, attention, and valuable insights.

Sincerely the authors.

Author Response File: Author Response.docx

Reviewer 2 Report

The article "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing" investigates the use of Directed Energy Deposition (DED) in repairing and optimizing metal forging tools and molds. The study compares mechanical properties of specimens fabricated from conventional methods and those made using DED techniques. It explores the balance between tensile strength and ductility in DED-manufactured components, emphasizing the influence of layering. There are certain improvements that the authors can make. Below are my comments.

1.       The article could benefit from a more diverse range of materials to test the DED process's effectiveness across different metal types.

2.       A comparative analysis with more conventional repair methods would provide a clearer perspective on the advantages and limitations of the DED process.

3.       The discussion on the balance between tensile strength and ductility in DED-produced components could be expanded with more in-depth analysis or case studies.

4.       Including a broader range of mechanical tests (e.g., hardness, wear resistance) would provide a more comprehensive understanding of the material properties.

5.       A section discussing potential industrial applications beyond the scope of metal forging tools and molds could broaden the article's relevance.

Author Response

Dear reviewer,

We would like to express our gratitude for your feedback and constructive comments on our article titled "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing." Your evaluation has immensely contributed to refining and improving the scientific quality of our research.

We addressed each of your concerns which identified areas for improving our manuscript in the attached file.

Thank you once again for your time, attention, and valuable insights.

Sincerely the authors.

Author Response File: Author Response.docx

Reviewer 3 Report

 The manuscript explores the efficacy of Directed Energy Deposition (DED) processes in repairing forging tools and moulds, comparing mechanical properties of specimens from conventional sheet metal to those manufactured with DED techniques. The presentation quality is high, with smooth transitions between sections and commendable work. Encountered issues sections are interesting. However, some revisions are suggested before recommendation:

1. Consider replacing Figure 9 with a higher-quality version, and maintaining consistent stress scales (same minimum and maximum bounds) on the Y-axis for all four diagrams. This adjustment will enhance reader understanding.

2. It is recommended to omit the title of the diagram in Figure 10 for a clearer presentation."

3. In Figure 10, using consistent phrases such as 'Mean stress' and 'Mean elongation' throughout would contribute to improved clarity.

4. Provide an explanation or mention the method and software utilized for the regression analysis.

5. In Equation (1), change the format of '0' to subscript.

6. It is suggested to declare the names of the CAD/CAM software used.

7. Consider the addition of quantities and graphical reports to results, such as CMM outputs, to further ensure the effectiveness of the method and improve the overall quality of the manuscript.

Author Response

Dear reviewer,

We would like to express our gratitude for your feedback and constructive comments on our article titled "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing." Your evaluation has immensely contributed to refining and improving the scientific quality of our research.

We addressed each of your concerns which identified areas for improving our manuscript in the attached file.

Thank you once again for your time, attention, and valuable insights.

Sincerely the authors.

Author Response File: Author Response.docx

Round 2

Reviewer 1 Report

I recommend publishing it as all the comments have been addressed

Author Response

Dear reviewer,

We would like to express our gratitude for your feedback and constructive comments on our article titled "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing." Your evaluation has immensely contributed to refining and improving the scientific quality of our research.

Author Response File: Author Response.docx

Reviewer 3 Report

The manuscript is currently in good form. One point might have been overlooked: "In Figure 10, ensuring consistent phrases such as 'Mean stress' and 'Mean elongation' throughout would contribute to improved clarity."

 Please double-check.

Author Response

Dear reviewer,

We would like to express our gratitude for your feedback and constructive comments on our article titled "Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimization Using Directed Energy Deposition Hybrid Manufacturing." Your evaluation has immensely contributed to refining and improving the scientific quality of our research.

Author Response File: Author Response.docx