Journal of Manufacturing and Materials Processing

23 pages, 13166 KB

Open AccessArticle

Development of ANN and ANFIS Models for Prediction of Tool Wear in High-Speed Milling

by Wei Tai Huang and Yi Cheng Pan

J. Manuf. Mater. Process. 2026, 10(7), 258; https://doi.org/10.3390/jmmp10070258 - 22 Jul 2026

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In precision machining, tool wear is one of the primary factors affecting machining quality and production efficiency. This study developed intelligent prediction models for tool wear in the high-speed milling (HSM) of AISI 1045 medium-carbon steel by integrating robust process design with backpropagation [...] Read more.

In precision machining, tool wear is one of the primary factors affecting machining quality and production efficiency. This study developed intelligent prediction models for tool wear in the high-speed milling (HSM) of AISI 1045 medium-carbon steel by integrating robust process design with backpropagation neural networks (BPNN) and adaptive neuro-fuzzy inference systems (ANFIS). Robust process design was employed to optimize the machining parameters, while the hyperparameters of both BPNN and ANFIS models were systematically optimized to improve prediction performance. Tool wear was measured after a fixed cutting length and used to establish the prediction models. The optimized machining parameters reduced tool wear by 53% compared with the worst experimental condition. The optimized BPNN model achieved a prediction accuracy of 96.68%, whereas the ANFIS model with Gaussian membership functions achieved 100%, demonstrating superior predictive performance. The proposed approach effectively combines robust process design and intelligent prediction models to accurately predict tool wear using a limited experimental dataset, providing an efficient methodology for tool wear prediction and machining parameter optimization in intelligent manufacturing applications. Full article

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17 pages, 488 KB

Open AccessArticle

Preparing for the Digital Transformation of a Production Shop Floor

by Terrance Speicher, Joanna DeFranco, Michael Bartolacci and Erin Connelly

J. Manuf. Mater. Process. 2026, 10(7), 257; https://doi.org/10.3390/jmmp10070257 - 22 Jul 2026

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Abstract

Small and Midsized Manufacturers (SMM) face challenges as they adopt digital technologies to transform their production environment. A Manufacturing Execution System (MES) requires timely accurate data from shop floor processes to efficiently control production operations. An Industrial Internet of Things (IIoT) platform of [...] Read more.

Small and Midsized Manufacturers (SMM) face challenges as they adopt digital technologies to transform their production environment. A Manufacturing Execution System (MES) requires timely accurate data from shop floor processes to efficiently control production operations. An Industrial Internet of Things (IIoT) platform of sensors provides MES software with operational information through a communications network to enable data-driven decision-making. A midsized manufacturer in southeastern Pennsylvania provides comprehensive thermoformed and injected molded products for diverse markets. Their production equipment includes light and heavy gauge thermoforming, polymer calendaring, and Computer Numerical Control (CNC) part trimming equipment supported by air compressors, vacuum pumps, and water chillers. This project partnered a manufacturer with researchers to deploy engineering and information science students to access, catalog, and characterize shop floor Programmable Logic Controllers (PLC) inputs and outputs. Utilizing this critical PLC data, the expert lead team determined quality-critical parameters, machine counters, and fault codes essential for process optimization. Full article

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15 pages, 41992 KB

Open AccessArticle

Impact of Environmental Hydrogen Pressure on Fracture Toughness and Fracture Behavior of X65 Pipeline Steel Welded Joints

by Xue Yin, Xue Wang, Yuezhang Ju, Zhaoqing Yang and Xinjie Di

J. Manuf. Mater. Process. 2026, 10(7), 256; https://doi.org/10.3390/jmmp10070256 - 22 Jul 2026

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Abstract

Hydrogen embrittlement (HE) damages the fracture toughness, often promoting brittle fracture even at low stress levels. Since welded joints are sensitive to this kind of damage, there is a very high risk of failure. For this reason, this study systematically evaluates the fracture [...] Read more.

Hydrogen embrittlement (HE) damages the fracture toughness, often promoting brittle fracture even at low stress levels. Since welded joints are sensitive to this kind of damage, there is a very high risk of failure. For this reason, this study systematically evaluates the fracture toughness and fracture behavior of X65 pipeline steel welded joints under a gaseous hydrogen environment. The crack tip opening displacement (CTOD) test and electron microscopy technology were adopted to carry out fracture toughness evaluation and microstructure analysis on the weld metal (WM) and heat-affected zone (HAZ) under hydrogen pressure conditions of 1.0 MPa, as well as 7.2 MPa. The results underscore that at the higher hydrogen pressure (7.2 MPa), the CTOD value decreased compared with that at 1.0 MPa; the reduction amplitudes of the CTOD values of the WM and HAZ were 79% and 84%, respectively. When the hydrogen pressure was 1.0 MPa, the WM and HAZ presented microvoid coalescence (MVC) fracture characteristics, the crack propagation path was tortuous, the plastic deformation at the crack tip was significant, and dislocations proliferated massively, leading to high fracture toughness. At 7.2 MPa, the fracture mechanism was into brittle fracture, the crack propagated along an almost straight path, plastic deformation and dislocation proliferation at the crack tip were significantly inhibited, and the fracture toughness decreased sharply. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)

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11 pages, 1956 KB

Open AccessArticle

Laser Remelting-Induced Microstructure Refinement and Strengthening of (TaWZrHf)₉₅Y₅ Refractory High-Entropy Alloy

by Chuanbing Huang, Junnan Jin, Yonghui Sun, Hao Lan and Weigang Zhang

J. Manuf. Mater. Process. 2026, 10(7), 255; https://doi.org/10.3390/jmmp10070255 - 21 Jul 2026

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Abstract

A novel (TaWZrHf)₉₅Y₅ refractory high-entropy alloy (RHEA) matrix was fabricated via vacuum hot pressing (VHP) sintering and subsequently modified through laser remelting (LR) surface treatment. Thermodynamic phase diagram calculations predicted the alloy’s dual-phase BCC structure, and the effects of LR [...] Read more.

A novel (TaWZrHf)₉₅Y₅ refractory high-entropy alloy (RHEA) matrix was fabricated via vacuum hot pressing (VHP) sintering and subsequently modified through laser remelting (LR) surface treatment. Thermodynamic phase diagram calculations predicted the alloy’s dual-phase BCC structure, and the effects of LR on phase composition, microstructure, and mechanical properties were systematically investigated. LR induced a significant phase transition, promoting rapid solidification and substantial grain refinement. The surface hardness increased to 848 HV₀.₂, approximately 1.5 times higher than that of the matrix, while the compressive strength reached 1635 MPa, surpassing the matrix by 200 MPa without compromising ductility. Importantly, the LR process effectively mitigated rare-earth (yttrium) segregation and loss, a common challenge in conventional arc melting of refractory HEAs, thereby enhancing solid solution strengthening and phase stability. This work pioneers the application of laser surface engineering to VHP-sintered refractory HEAs, bridging critical gaps in fabrication, microstructural optimization, and performance enhancement, and offering valuable insights for the future design of high-performance multi-principal element alloy development. Full article

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16 pages, 2625 KB

Open AccessArticle

Machine Learning-Guided Optimization of Defects in In-Situ Alloyed Additively Manufactured Parts

by Shaaf Shelesh Nezhad and Sravya Tekumalla

J. Manuf. Mater. Process. 2026, 10(7), 254; https://doi.org/10.3390/jmmp10070254 - 21 Jul 2026

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Abstract

In-situ alloying during laser powder bed fusion (LPBF) offers great compositional flexibility but is prone to process-induced defects. To address this problem, we developed a machine learning framework to predict and minimize major defects such as porosity (inclusive of lack of fusion, gas [...] Read more.

In-situ alloying during laser powder bed fusion (LPBF) offers great compositional flexibility but is prone to process-induced defects. To address this problem, we developed a machine learning framework to predict and minimize major defects such as porosity (inclusive of lack of fusion, gas pores, and keyhole-induced porosity) and unmelted Nb particles (partially and completely unmelted particles) in LPBF-fabricated in-situ alloyed Ti–45Nb alloy. For this purpose, two independent least-squares boosting (LSBoost) ensemble regressors were trained using five process parameters (part shape, laser power, scan speed, hatch spacing, and scan rotation), along with their polynomial and interaction terms, to capture nonlinear relationships. Under a restricted 4-fold cross-validation, these models achieved pooled out-of-fold R² values of 0.672 for porosity and 0.702 for unmelted Nb, despite being trained on a small dataset. The grouped permutation importance analysis revealed that porosity is primarily governed by hatch spacing and laser power, whereas unmelted Nb particles are primarily governed by laser power and scan speed. The models were implemented in two graphical interfaces: a forward predictor for real-time defect estimation and an inverse optimizer for identifying low-defect parameter sets. Together, they establish a unified, data-driven approach for defect-aware process detection, prediction, and optimization in in-situ alloyed systems, offering a pathway towards reproducible, low-defect additive manufacturing. Full article

(This article belongs to the Special Issue Advanced Additive Manufacturing of Functional and Structural Alloys)

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23 pages, 3983 KB

Open AccessArticle

Particle Size Refinement and Kinetic Modeling of Hercynite Powders Under Wet Mechanical Milling

by Leonel Díaz-Tato, Luis Angel Iturralde Carrera, Edgar Omar García-Sánchez, Yoisdel Castillo Alvarez, Ismael Flores-Vivian, Juan Jacobo Ruiz-Valdés, Juvenal Rodríguez-Reséndiz and Edén Amaral Rodríguez-Castellanos

J. Manuf. Mater. Process. 2026, 10(7), 253; https://doi.org/10.3390/jmmp10070253 - 21 Jul 2026

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Abstract

The particle size refinement of hercynite (FeAl₂O₄) powders during wet high-energy mechanical milling was investigated through an integrated experimental and kinetic modeling approach. Hercynite powders were milled for different durations, and their microstructural, chemical, and particle size evolution was [...] Read more.

The particle size refinement of hercynite (FeAl₂O₄) powders during wet high-energy mechanical milling was investigated through an integrated experimental and kinetic modeling approach. Hercynite powders were milled for different durations, and their microstructural, chemical, and particle size evolution was characterized using scanning electron microscopy, X-ray diffraction, semi-quantitative X-ray fluorescence analysis, and SEM–ImageJ-based particle size reconstruction. Particle size distributions were reconstructed from large particle populations, and the characteristic descriptors

D_{10}

,

D_{50}

, and

D_{90}

were determined from empirical cumulative distributions. The results revealed a pronounced reduction in median particle size from approximately 83.1

μ

m in the as-received powder to 0.422

μ

m after 8 h of milling. X-ray diffraction analysis showed progressive peak broadening and intensity reduction with increasing milling time, suggesting milling-induced structural disorder and possible crystallite refinement and/or lattice strain accumulation, while no additional crystalline phases associated with milling-induced decomposition were detected within the detection limit of XRD. Semi-quantitative chemical analysis indicated limited metallic transfer from the stainless-steel milling media under the applied wet milling conditions. The evolution of

D_{50}

with milling time exhibited a non-linear behavior characterized by rapid particle fragmentation at early stages, followed by a gradual transition toward a refinement-limited regime. This behavior was described using a first-order kinetic model with saturation behavior, yielding an asymptotic particle size of 0.443

μ

m and an effective milling rate constant of 1.539 h⁻¹. Overall, the proposed kinetic framework provides a descriptive and condition-specific quantitative basis for interpreting the competing fracture and agglomeration mechanisms governing particle size evolution during wet mechanical milling of refractory spinel powders. Full article

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25 pages, 5266 KB

Open AccessArticle

Effect of Active Air-Cooling Configuration During Interlayer Friction Stir Processing on Grain Morphology and Within-Wall Homogeneity in UAMFSP-Fabricated Aluminum 4043 Walls: A Single-Replicate Exploratory Study

by Ahmed Nabil Elalem, Husam Alrehaili and Xin Wu

J. Manuf. Mater. Process. 2026, 10(7), 252; https://doi.org/10.3390/jmmp10070252 - 20 Jul 2026

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Abstract

The Unified Additive-Deformation Manufacturing Process (UAMFSP) integrates MIG-based Wire Arc Additive Manufacturing (WAAM) with interlayer Friction Stir Processing (FSP) on a single CNC platform, applying severe plastic deformation to each deposited layer. The novelty of this work is the first controlled comparison, to [...] Read more.

The Unified Additive-Deformation Manufacturing Process (UAMFSP) integrates MIG-based Wire Arc Additive Manufacturing (WAAM) with interlayer Friction Stir Processing (FSP) on a single CNC platform, applying severe plastic deformation to each deposited layer. The novelty of this work is the first controlled comparison, to the authors’ knowledge, of the spatial position of forced-air cooling applied concurrently with the FSP traverse in such an integrated platform: cooling was directed at the top bead surface (TC), at the bottom substrate (BC), or at both surfaces simultaneously (DC), with a MIG-only wall serving as the baseline. Single-layer, four-bead ER4043 aluminum walls were deposited on AA6061 substrates, and optical micrographs from three within-bead locations per condition were quantified with ImageJ, yielding 2038 to 2723 grains per condition. A lumped-parameter thermal model calibrated to infrared thermography ranked the comparative cooling rates as NC < TC < BC < DC. The principal finding is grain homogenization: every FSP condition reduced the grain area scatter by 55 to 71 percent relative to MIG-only, eliminating the coarse-grain tail of the as-deposited distribution regardless of cooling position. Mean equivalent diameters of all four conditions lie within 0.5 µm of one another, at the resolution limit of the optical measurement, so the mean-size ordering (DC finest, 2.76 µm) is reported as a ranking rather than as net refinement. Vickers microhardness on the MIG-only and uncooled FSP walls revealed a 27 HV within-wall gradient (86 ± 7 HV at the stir-zone center versus 59 ± 2 HV at the bead edge), which motivates bilateral cooling for thermal-field homogenization. Because the design is single-replicate, between-condition differences are presented as hypotheses for replicate study with EBSD and spatially resolved hardness mapping. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technologies)

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18 pages, 19099 KB

Open AccessArticle

Synthesis of Mo–Ti–Ta–Cr Alloy Powders by Calciothermic Reduction

by Mariia Teslia, Serhii Teslia and Ievgen Solodkyi

J. Manuf. Mater. Process. 2026, 10(7), 251; https://doi.org/10.3390/jmmp10070251 - 19 Jul 2026

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Abstract

In this work, the synthesis of Mo–Ti–Ta–Cr alloy powders via the calciothermic reduction (CTR) of MoO₃, TiO₂, Ta₂O₅, and Cr₂O₃ was investigated. The synthesis process was supported by thermodynamic calculations and TG–DSC [...] Read more.

In this work, the synthesis of Mo–Ti–Ta–Cr alloy powders via the calciothermic reduction (CTR) of MoO₃, TiO₂, Ta₂O₅, and Cr₂O₃ was investigated. The synthesis process was supported by thermodynamic calculations and TG–DSC thermal analysis. XRD analysis of the synthesized powder confirmed the formation of Mo-based BCC solid solutions. Microstructural studies have documented the formation of submicron-sized powder particles. A mechanism for Mo-based alloy formation has been proposed. Full article

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24 pages, 9870 KB

Open AccessArticle

Prioritization of Process Improvement Measures in a Forging Process Using an IPF-AHP-Based SREM Framework

by Nikola Kastratović, Dušan Arsić, Nikola Komatina, Marko Delić and Dragan Marinković

J. Manuf. Mater. Process. 2026, 10(7), 250; https://doi.org/10.3390/jmmp10070250 - 19 Jul 2026

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Abstract

Forging represents a very important process in the metal processing industry, for which risk analysis and continuous improvement activities are required in order to satisfy customer requirements regarding product quality and mechanical properties. In practice, Process Failure Mode and Effects Analysis (PFMEA) is [...] Read more.

Forging represents a very important process in the metal processing industry, for which risk analysis and continuous improvement activities are required in order to satisfy customer requirements regarding product quality and mechanical properties. In practice, Process Failure Mode and Effects Analysis (PFMEA) is used for risk identification and assessment. However, since this analysis provides only recommended process improvement measures as an output, without prioritizing them according to technical, economic, and operational aspects, this study develops a Multi-Criteria Decision-Making (MCDM) approach based on the integration of the Analytic Hierarchy Process (AHP) and the Square-Root-Based Evaluation Method (SREM), extended through the application of Interval-Valued Pythagorean Fuzzy Numbers (IVPFNs) to model uncertainty in the assessments of the expert team. In this way, a decision-making framework was developed that enables the prioritization of process improvement measures identified through PFMEA in an exact and mathematically based manner. The proposed approach was tested through a case study conducted in a company primarily engaged in the production of forgings as a supplier to various industrial sectors. A total of six process improvement measures were considered and evaluated with respect to seven technical, economic, and operational criteria. The results of the study clearly demonstrated that the additional die-leading measure ranked first and represented the most stable solution, maintaining its leading position regardless of the changes introduced through the sensitivity analysis. Full article

(This article belongs to the Special Issue Data Science in Manufacturing Processes)

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24 pages, 17688 KB

Open AccessArticle

3D-Printed PLA Gyroid Filter Supports: Manufacturing, Mechanical Response and Hydrochar Deposition Screening

by Mohamed Chairi, Viviana Bressi, Mariasofia Parisi, Tiziana Cappello, Claudia Espro and Guido Di Bella

J. Manuf. Mater. Process. 2026, 10(7), 249; https://doi.org/10.3390/jmmp10070249 - 18 Jul 2026

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Abstract

This study investigates the design, fabrication, and manufacturing/mechanical characterization of 3D-printed polylactic acid (PLA) cylindrical filter supports developed as substrates for subsequent hydrochar functionalization. Filters with an outer diameter of 30 mm, a height of 20 mm, and a wall thickness of 3 [...] Read more.

This study investigates the design, fabrication, and manufacturing/mechanical characterization of 3D-printed polylactic acid (PLA) cylindrical filter supports developed as substrates for subsequent hydrochar functionalization. Filters with an outer diameter of 30 mm, a height of 20 mm, and a wall thickness of 3 mm were manufactured by material extrusion additive manufacturing and internally filled with gyroid architectures generated in Bambu Studio at three density levels, namely 10%, 15%, and 20%. The printed filters were first evaluated in terms of weight and compressive response. The main focus of the work was the manufacturing consistency and mechanical response of the gyroid supports, while hydrochar deposition was considered as an initial functionalization screening step. The results showed that increasing gyroid density led to higher maximum compressive stress, while mass-normalized analysis revealed a trade-off between absolute mechanical resistance and material efficiency. Surface-treatment screening trials were then carried out on flat PLA specimens to evaluate whether algae-derived hydrochar could be retained on PLA after alkaline activation. Visual and SEM observations showed partial and heterogeneous hydrochar-related surface coverage, with localized agglomerates and partial masking of the original printing lines, but without the formation of a homogeneous coating. EDX analysis of selected agglomerates revealed C and O together with Na, Cl, K, and Ca, supporting the presence of hydrochar-related/mineral-containing deposits on the treated PLA surface, although K may also be associated with residual species from the KOH activation step. FTIR analysis did not reveal clear hydrochar-related spectral features, indicating that FTIR alone was not sufficient to demonstrate effective homogeneous surface functionalization and supporting the interpretation of heterogeneous surface retention. Overall, the study provides a first manufacturing-oriented basis for PLA gyroid filter supports intended for hydrochar deposition and highlights the need for improved surface activation strategies before subsequent functional validation. Full article

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17 pages, 33036 KB

Open AccessArticle

Analysis of the Fracture Toughness of ERCuAl A2 Cladding on API X70 Using the Instrumented Charpy Impact Test

by Martín Aguirre-Pulido, Francisco Fernando Curiel-López, José Jaime Taha-Tijerina, Jorge Alejandro Verduzco-Martínez, Víctor Hugo López-Morelos, Heriberto Granados-Becerra and Ariosto Medina-Flores

J. Manuf. Mater. Process. 2026, 10(7), 248; https://doi.org/10.3390/jmmp10070248 - 15 Jul 2026

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Abstract

The degradation of steel used in the oil industry has become a serious problem due to the high costs associated with material loss from corrosion. Applying thin layers of corrosion-resistant material promises to be a viable alternative for extending the service life of [...] Read more.

The degradation of steel used in the oil industry has become a serious problem due to the high costs associated with material loss from corrosion. Applying thin layers of corrosion-resistant material promises to be a viable alternative for extending the service life of pipelines. ERCuAl-A2 electrode claddings were applied to API X70 carbon steel using the MIG brazing process with direct current (DC) and pulsed current (P). The cladding was applied under three conditions: base material (BM) at room temperature, BM preheated to 120 °C, and Ni-buttered BM. Microhardness profiles and Charpy impact tests were performed on the MB and all cladding conditions. The API X70 carbon steel showed a microhardness value of 186.95 ± 11.17 Vickers, while the microhardness profiles of the ERCuAl A2 cladding showed values that differed in the intermetallic zone generated by the welding process. Likewise, the impact behavior of the base material and the applied claddings was ductile, except for conditions C2PF and C3PF, which showed a brittle–ductile behavior. The highest values of absorbed energy obtained from the tests were found in the conditions applied with DC, with values of approximately 50 MJm-3, due to the transfer mode of application of the cladding and/or the position in which the notch was made. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)

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20 pages, 4594 KB

Open AccessArticle

An Experimental Study on SiC Nanofluid-Assisted MQL in Hard Milling of AISI D2 Tool Steel

by Ngo Minh Tuan, Tran Minh Duc, Nguyen The Doan, Tran Ngoc Diep, Vu Nhu Nguyet and Tran The Long

J. Manuf. Mater. Process. 2026, 10(7), 247; https://doi.org/10.3390/jmmp10070247 - 14 Jul 2026

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Abstract

The new technological solutions supporting hard machining processes are becoming an up-to-date research area. The enhancement of cooling lubrication efficiency in the cutting zone plays a crucial role in improving cutting performance. This paper investigates the effectiveness of Minimum Quantity Lubrication (MQL) using [...] Read more.

The new technological solutions supporting hard machining processes are becoming an up-to-date research area. The enhancement of cooling lubrication efficiency in the cutting zone plays a crucial role in improving cutting performance. This paper investigates the effectiveness of Minimum Quantity Lubrication (MQL) using SiC nanoparticle-enhanced oil in the hard milling process of AISI D2 tool steel. The results are compared with dry and pure MQL modes based on criteria including cutting force components, surface roughness, tool wear, and tool life. The research results show that compared to dry and pure MQL, the SiC nanofluid MQL environment provides the best performance with reductions in feed force F_x (22.3–23.8%), thrust force F_y (20.5–55.3%), tangential force F_z (26.5–34%), surface roughness (37–62.3%), tool wear (46.1–73.3%), and increased tool life (80–200%). These findings demonstrate that the lubrication and cooling efficiency of the base oil is improved with the addition of SiC nanoparticles. The deep penetration of oil droplets into the cutting zone and the formation of the oil film significantly contributed to reducing friction and cutting heat. SiC nanoparticles not only improved the lubricating and cooling capabilities of the base cutting oil but also created secondary mechanisms within the cutting zone. Furthermore, monitoring cutting forces and surface roughness can be suggested as supplementary criteria for evaluating tool wear and tool life. This research will provide important technological guidance and a theoretical basis for the improvement of hard milling and application of the SiC nanofluid MQL technique. Full article

(This article belongs to the Special Issue Prediction and Estimation of Tool Wear and Failure in the Milling Process of Difficult-to-Cut Materials)

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24 pages, 33648 KB

Open AccessArticle

The Influence of Mixing Modes on Structure Formation and Mechanical Properties of Ti-Al-Fe-O-C Powder Materials During Vacuum Sintering

by Elena N. Korosteleva, Kirill O. Akimov and Andrey I. Dmitriev

J. Manuf. Mater. Process. 2026, 10(7), 246; https://doi.org/10.3390/jmmp10070246 - 13 Jul 2026

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Abstract

One of the possible ways to increase the functional properties of titanium-based composites is the use of additional components in the form of solid inclusions of oxides, carbides, etc. The key task in this case is to achieve a uniform distribution of such [...] Read more.

One of the possible ways to increase the functional properties of titanium-based composites is the use of additional components in the form of solid inclusions of oxides, carbides, etc. The key task in this case is to achieve a uniform distribution of such inclusions in the structure of the material. This study demonstrates that this problem can be more effectively solved at the stage of preparing the powder mixture from which a titanium matrix composite is subsequently obtained. The paper presents the results of a study of the structure and mechanical properties of sintered powder materials of the Ti-Al-Fe-O-C system using two procedures for mixing the initial components. In the first case, traditional mixing of titanium, aluminum, soot and iron oxide Fe₂O₃ powders was used, and in the second case, a two-stage procedure was used with preliminary mechanical activation of the powder composition Al + Fe₂O₃ and the subsequent addition of titanium and soot powders to the product of this treatment. Analysis of the structure formation and mechanical properties of sintered compacts from the studied powder mixtures showed the advantage of the two-stage option in terms of the formation of a denser structure in the samples with minimal residual porosity and higher values of compressive strength. Full article

(This article belongs to the Special Issue Mechanics and Manufacturing of Advanced Composite Materials and Structures)

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18 pages, 3780 KB

Open AccessArticle

Research on the Formation Mechanism and Distribution Characteristics of Surface Roughness in End Milling

by Can Liu, Zhiyi Mo, Runhua Lu, Jiajia He, Ningxia Yin and Huanlao Liu

J. Manuf. Mater. Process. 2026, 10(7), 245; https://doi.org/10.3390/jmmp10070245 - 9 Jul 2026

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Abstract

The cutting variables of end milling are positively correlated with the machined surface roughness, but their mechanism of action remains unclear. Since the cutting tool used in end milling is a three-dimensional solid, under the action of horizontal cutting force, there exist both [...] Read more.

The cutting variables of end milling are positively correlated with the machined surface roughness, but their mechanism of action remains unclear. Since the cutting tool used in end milling is a three-dimensional solid, under the action of horizontal cutting force, there exist both axial tensile strain and axial compressive strain in the cutting tool at the same time, thus putting forward an assumption about the formation mechanism of machined surface roughness: cutting variables affect the axial tensile strain of the cutting edge through the horizontal cutting force, and cause the cutting-edge tip to vertically wedge into the machined surface, thereby influencing the unevenness of the processed surface. Based on the cutting-tool deflection model of a two-segment cantilever beam and the horizontal cutting force formula, the mathematical expression for the axial strain at the sharp tip of the cutting edge was derived. Groove milling and half-groove milling experiments were done, and the experimental results show that the roughness Ra value in the central area is significantly higher than that in the cut-in area, with its maximum average value being 1.32 times that of the cut-in area. The surface roughness rises following the rise in depth of machining and feed per cutting tooth, but this relationship is significant. The laboratory findings are consistent with the theoretical analysis results, indicating that the assumption about the formation mechanism of surface roughness should be reasonable, and the surface roughness in the central area is greater than that in the cutting tool cut-in area. The research results provide a kind of new insight into the formation mechanism of machined surface roughness, which can serve as a reference for relevant research and cutting practices. Full article

(This article belongs to the Special Issue Advances in Metal Cutting and Cutting Tools, 2nd Edition)

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19 pages, 1260 KB

Open AccessArticle

Adapting Laser Ablation Models from Simulation to Experiment: A Transfer Learning Approach for Stainless Steel, Silicon and Aluminum

by Javier F. Troncoso, Beatriz Blanco-Filgueira, Vanessa Alvear-Puertas, Marta Gallego-Vázquez, Sara Vidal, Tamara Delgado, Céline Petit, David Bruneel, Pablo Romero and Santiago Muiños-Landin

J. Manuf. Mater. Process. 2026, 10(7), 244; https://doi.org/10.3390/jmmp10070244 - 9 Jul 2026

Viewed by 563

Abstract

Ultrashort Pulse Laser (USPL) ablation is a versatile manufacturing process, but predicting its outcomes across different materials often requires extensive and costly experimentation. This work provides a machine learning framework that leverages transfer learning to bridge the gap between simulation and experimental data, [...] Read more.

Ultrashort Pulse Laser (USPL) ablation is a versatile manufacturing process, but predicting its outcomes across different materials often requires extensive and costly experimentation. This work provides a machine learning framework that leverages transfer learning to bridge the gap between simulation and experimental data, enabling accurate prediction of material behavior during USPL ablation under data-scarce conditions. We generated a high-fidelity computational dataset using the LS-PLUME^® simulator for Stainless Steel 316 (SS 316), and then complemented with targeted experimental studies on SS 316, Silicon (Si) and Aluminum (Al) to capture real-world deviations. A model pre-trained on the simulation data was successfully adapted to the experimental domain, effectively absorbing systematic deviations and extending its predictive capability to new materials with minimal experimental data. Our transfer learning framework bridged the simulation-to-experiment gap using minimal data, successfully fine-tuning a base model trained on 3075 samples with just 49 experimental points for Si and 46 for Al with mean percentage errors under 5%, thus demonstrating high data efficiency for industrial laser surface texturing. Furthermore, the application of explainable artificial intelligence revealed that the model predictions are more sensitive to peak fluence and the number of passes, with SS 316 exhibiting higher overall sensitivity to input parameter variations than Si and Al, thus providing actionable physical and process-level insight relevant for industrial optimization. Full article

(This article belongs to the Special Issue Advanced Microstructural Characterization and Data-Driven Modeling of Engineering Materials for Manufacturing Processes)

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24 pages, 37456 KB

Open AccessArticle

Effect of GMAW Process Parameters and Filler Alloys on Solidification Cracking and Mechanical Behavior of AA6061 and AA7075 Aluminum Alloys

by Mohammed Alkhabbat and Xuan-Tan Pham

J. Manuf. Mater. Process. 2026, 10(7), 243; https://doi.org/10.3390/jmmp10070243 - 9 Jul 2026

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Abstract

This study investigates the effect of Gas Metal Arc Welding (GMAW) parameters on solidification cracking and mechanical behavior of AA6061 and AA7075 aluminum alloys, which are widely used in automotive, aerospace, and battery-related applications due to their low density, corrosion resistance, and high [...] Read more.

This study investigates the effect of Gas Metal Arc Welding (GMAW) parameters on solidification cracking and mechanical behavior of AA6061 and AA7075 aluminum alloys, which are widely used in automotive, aerospace, and battery-related applications due to their low density, corrosion resistance, and high specific strength. The influence of filler metals, ER4043 and ER5356, welding speed, wire feed speed, and calculated heat input was evaluated using the Circular Patch Test (CPT). Surface and internal cracking were examined by X-ray inspection, while microstructural evolution, phase formation, hardness, tensile behavior, and local strain distribution were analyzed using optical microscopy, SEM/EDS, XRD, microhardness testing, micro-tensile testing, and Digital Image Correlation (DIC). The results show that cracking susceptibility depends on the combined effects of welding speed, heat input, filler-metal chemistry, and dilution. The observed cracking behavior is associated with local compositional variations, weld defects, and the formation of low-melting/eutectic or secondary constituents within the fusion zone, rather than being attributed to a single factor. ER5356 showed favorable cracking resistance for AA7075 under the selected conditions, while ER4043 generally improved cracking resistance for AA6061. The mechanical response and fracture behavior were also influenced by filler composition and local weld microstructure. These findings provide useful guidance for selecting welding parameters and filler metals to improve weld quality and reduce solidification cracking in AA6061 and AA7075 aluminum alloys. Full article

(This article belongs to the Special Issue Advances in Welding Technology: 2nd Edition)

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23 pages, 3668 KB

Open AccessArticle

Development and Performance Analysis of an Automated Flat Blade Grinding Machine for Wood Processing and Plastic Recycling Industries

by John Vera, Santiago López, Carmen Tisalema and Marco Zurita

J. Manuf. Mater. Process. 2026, 10(7), 242; https://doi.org/10.3390/jmmp10070242 - 8 Jul 2026

Viewed by 515

Abstract

This study presents the design, development, and experimental validation of an automated flat blade grinding machine for the wood processing and plastic recycling industries in Ecuador. The machine was engineered following the VDI 2221/2222/2225 design methodology, integrating SolidWorks-based 3D modeling and ANSYS finite [...] Read more.

This study presents the design, development, and experimental validation of an automated flat blade grinding machine for the wood processing and plastic recycling industries in Ecuador. The machine was engineered following the VDI 2221/2222/2225 design methodology, integrating SolidWorks-based 3D modeling and ANSYS finite element analysis (FEA) to validate critical structural components. The selected configuration includes a Type 6 alumina grinding wheel (38A-60-K-VS), a mechanical clamping system, cutting fluid cooling, and a hardwired electromechanical control system that does not require a programmable logic controller (PLC). FEA results confirmed adequate safety factors (ηs > 16; ηf > 14) for the ACME 3/4–8 power screw under operational loads. Experimental testing on blade specimens (thickness: 3 mm; length: 70 mm; steel up to 60 HRC) demonstrated that four grinding passes at a 45° inclination angle reduced mean surface roughness (Ra) from 5.39 ± 1.83 µm (used blades) to 0.162 ± 0.092 µm, achieving values comparable to new blades (Ra = 0.601 ± 0.153 µm): a point-estimate reduction of 97% in mean Ra relative to the used-blade condition. The automated process reduced average grinding time by approximately 30% compared to manual methods, while maintaining noise levels within the 85 dB occupational exposure limit. Operator satisfaction surveys rated the system above 4.5/5.0 across all ergonomic and usability criteria. These results validate the proposed machine as a cost-effective, locally manufacturable solution to standardize blade maintenance in small and medium enterprises (SMEs) across Latin America. Full article

(This article belongs to the Special Issue Advanced Design, Manufacturing, and Applications of Precision Machine Tools)

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28 pages, 13085 KB

Open AccessArticle

Design and Performance Evaluation of a FSW Tool for Welding of AW 7075-T651 Aluminum Alloy

by Roman Kukuča, Jozef Bárta, Katarína Bártová, Ivan Buranský, Milan Marônek, František Jurina and Peter Gogola

J. Manuf. Mater. Process. 2026, 10(7), 241; https://doi.org/10.3390/jmmp10070241 - 7 Jul 2026

Viewed by 500

Abstract

Friction stir welding (FSW) is a solid-state joining process capable of producing high-quality joints in materials that are difficult to weld, particularly lightweight alloys. It is especially suitable for high-strength aluminum alloys like AW7075-T651, which are prone to hot cracking and mechanical degradation [...] Read more.

Friction stir welding (FSW) is a solid-state joining process capable of producing high-quality joints in materials that are difficult to weld, particularly lightweight alloys. It is especially suitable for high-strength aluminum alloys like AW7075-T651, which are prone to hot cracking and mechanical degradation during conventional fusion welding. The AW7075-T651 alloy is one of the strongest commercially available aluminum alloys, whose high strength is primarily provided by MgZn₂ precipitates. The influence of welding parameters, especially welding speed, on heat input was studied using thermocouples positioned beneath the tool shoulder and in the weld root region. Tool lifetime was evaluated using WC-Co probes with different Co content, while tool wear was analyzed by 3D scanning. Microstructural characterization was performed using EBSD and TEM analyses. The maximum tool lifetime reached 2.7 km. Welding speed significantly affected the temperature in the weld root region, and a minimum temperature of 0.58T_M was required to produce a sound weld. Weld efficiency of 90% was reached; microhardness profiles showed a typical W-shape. TEM and SAED analyses confirmed the presence of an α-Al matrix and strengthening MgZn₂ precipitates and showed a more uniform distribution and refinement of precipitates in the stir zone. Full article

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16 pages, 4089 KB

Open AccessArticle

Spatter, Melt Pool Stability, and Their Correlations Using Deep Learning for Laser Directed Energy Deposition

by Md Sakibul Hasan Nahid, Deepak Gadde, Jakob D. Hamilton, Shan Jiang and Yang Du

J. Manuf. Mater. Process. 2026, 10(7), 240; https://doi.org/10.3390/jmmp10070240 - 7 Jul 2026

Viewed by 653

Abstract

Laser directed energy deposition (LDED) is a promising metal additive manufacturing process, but printed parts’ quality highly depends on spatter formation and melt pool stability. In this work, a high-speed camera is employed to capture and record the complex interaction between the laser, [...] Read more.

Laser directed energy deposition (LDED) is a promising metal additive manufacturing process, but printed parts’ quality highly depends on spatter formation and melt pool stability. In this work, a high-speed camera is employed to capture and record the complex interaction between the laser, fed powders, and fusion region under various LDED process conditions. A deep learning algorithm, the YOLOv7 model, is trained to automatically detect and track the location and motion of the melt pool and spatter particles. The well-trained YOLOv7 model achieves a precision of 0.94 and is then applied to extract information on spatter count, spatter size, and melt pool geometry. We find that an elevated laser power intensifies spatter formation due to augmented vapor recoil pressure, while a high scanning speed promotes spatter ejection through Plateau–Rayleigh capillary instability. A low powder feed rate further exacerbates spatter formation owing to high metal evaporation and hydrodynamic instability within the small melt pool. In addition, this work introduces a novel melt pool stability index for real-time process assessment based on the melt pool length change rate. A stable melt pool with a high stability index generates less spatter. Otherwise, more spatters are detected. These findings advance the mechanistic understanding of spatter dynamics in LDED, introduce a novel quantitative metric for real-time melt pool stability assessment, and establish a direct correlation between the detected spatter amount and the melt pool stability. This work provides a practical framework for spatter mitigation, melt pool stability enhancement, and in-process control in advanced manufacturing. Full article

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

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19 pages, 14352 KB

Open AccessArticle

Development of Microwave Attenuator Based on Magnetic Composites and Frequency Selective Surface (FSS) in the X-Band Using FEKO

by Braulio Haruo Kondo Lopes, Felipe de Moraes Yamamoto, Giovana Silva Cembranelli, Isaias De Oliveira, Carlos Eduardo Santos Leal, Fabio Roberto Passador and Mauricio Ribeiro Baldan

J. Manuf. Mater. Process. 2026, 10(7), 239; https://doi.org/10.3390/jmmp10070239 - 7 Jul 2026

Viewed by 493

Abstract

The development of a magnetic composite based on a silicone matrix containing carbonyl iron (CI), combined with the Frequency Selective Surface (FSS) for radiation-attenuating material (RAM) applications in the X-band (8.2–12.4 GHz), is presented in this work. Four FSS geometries were investigated: square, [...] Read more.

The development of a magnetic composite based on a silicone matrix containing carbonyl iron (CI), combined with the Frequency Selective Surface (FSS) for radiation-attenuating material (RAM) applications in the X-band (8.2–12.4 GHz), is presented in this work. Four FSS geometries were investigated: square, circular, triangular, and hexagonal. The electromagnetic properties, namely relative electrical permittivity and magnetic permeability, were characterized using a vector network analyzer employing both waveguide and free-space measurement techniques. The attenuation performance was evaluated through reflection loss (RL) measurements and numerically simulated using FEKO software. The stability of the attenuation performance was also assessed for different wave incidence angles (0° to 45°), demonstrating a robust average peak attenuation of −32.1 dB at 11.18 GHz, with optimal resonance values reaching as low as −60.34 dB at an incidence angle of 30°, in good agreement with the simulation results. The results indicate that the capacitive and inductive behavior associated with FSS geometries plays a key role in tailoring the electromagnetic response, demonstrating the effectiveness of FSS-based magnetic composites for controlled attenuation performance. Full article

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38 pages, 40871 KB

Open AccessReview

Recent Advances in Ultrasonic Vibration-Assisted Machining of Ti-Al Intermetallic Compounds

by Zongxia Fu, Xuansheng Zhao, Haichao Sun and Xiaofeng Jia

J. Manuf. Mater. Process. 2026, 10(7), 238; https://doi.org/10.3390/jmmp10070238 - 6 Jul 2026

Viewed by 655

Abstract

Ti-Al intermetallic compounds (Ti-Al IMCs) are emerging as lightweight, high-temperature structural materials with considerable application potential. Owing to their low density and high-temperature capability, these materials can improve the thrust-to-weight ratio of aeroengines, enhance the high-temperature service performance of aircraft, increase fuel efficiency, [...] Read more.

Ti-Al intermetallic compounds (Ti-Al IMCs) are emerging as lightweight, high-temperature structural materials with considerable application potential. Owing to their low density and high-temperature capability, these materials can improve the thrust-to-weight ratio of aeroengines, enhance the high-temperature service performance of aircraft, increase fuel efficiency, and improve adaptability to harsh environments. However, their intrinsic room-temperature brittleness leads to high cutting forces, elevated cutting temperatures, and severe tool wear during machining, making it difficult to ensure machining quality and limiting their large-scale applications in the aerospace industry. Ultrasonic vibration-assisted machining (UVAM) introduces a high-frequency, low-amplitude intermittent cutting mechanism that actively regulates material removal and offers a feasible route for overcoming the machining bottleneck of Ti-Al IMCs. This review summarizes the recent progress in UVAM for machining Ti-Al IMCs. First, the typical applications and machining characteristics of Ti-Al IMCs are discussed. Existing studies are then reviewed in terms of cutting performance, including cutting force, cutting temperature, chip morphology, tool wear, and post-machining surface integrity, including surface roughness, surface defects, residual stress, and work hardening. The reviewed evidence indicates that UVAM can reduce cutting forces and temperatures, improve chip morphology, and extend the tool life. It can also improve machined surface integrity by decreasing surface roughness, suppressing surface defects, inducing beneficial residual compressive stress layers, and regulating work-hardening behavior. This review provides systematic theoretical guidance and technical references for improving the machinability of Ti-Al IMCs via UVAM, thereby enabling the controllable, high-performance, and high-reliability fabrication of these difficult-to-machine materials in aerospace precision manufacturing. Full article

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24 pages, 18353 KB

Open AccessArticle

Optimization of Technological Processes on CNC Lathes with Robotic Loading

by Irina Aleksandrova, Hristo Metev, Nikolai Kolev and Hristian Mitev

J. Manuf. Mater. Process. 2026, 10(7), 237; https://doi.org/10.3390/jmmp10070237 - 6 Jul 2026

Viewed by 363

Abstract

The article presents a methodology for multi-objective compromise optimization of the process of turning on CNC machines with robotic loading by the methods of determining the optimum compromise area and carrying out optimization, using the generalized arithmetic mean utility function with weight coefficients. [...] Read more.

The article presents a methodology for multi-objective compromise optimization of the process of turning on CNC machines with robotic loading by the methods of determining the optimum compromise area and carrying out optimization, using the generalized arithmetic mean utility function with weight coefficients. The methodology has been applied to determine the optimal cutting conditions, ensuring the best combination of technological parameters for the CNC turning process when machining parts made of 42CrMoS4 steel with cutting tools from different manufacturers. A complex study and modeling of the main technological parameters (production rate, cutting tool lifetime, and roughness of machined surfaces) in the CNC turning process have been performed depending on the conditions of cutting. By applying a genetic algorithm, the optimal conditions for implementing the process using both optimization methods have been determined, and a comparative analysis of the technological parameters has been made. Models have been created for predicting the number of machined parts, which exclude unplanned stops for tool changes, under the specified optimal conditions of cutting, taking into account the capacity of the tool magazine, the loading mechanism, and the volume of the production batch. Full article

(This article belongs to the Topic Manufacturing and Mechanics of Materials)

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18 pages, 6395 KB

Open AccessArticle

Development of Conductive Nanocomposite Filaments from Reused Selective Laser Sintering Powder for Fused Filament Fabrication

by Cátia S. Silva, Ana C. Lopes, Álvaro M. Sampaio and António J. Pontes

J. Manuf. Mater. Process. 2026, 10(7), 236; https://doi.org/10.3390/jmmp10070236 - 4 Jul 2026

Viewed by 371

Abstract

In polymer selective laser sintering (SLS), powder acts as a support material during additive manufacturing, generating significant amounts of un-sintered powder exposed to prolonged thermal cycles. Although partial reuse with virgin powder is common practice, material degradation eventually renders the powder unsuitable for [...] Read more.

In polymer selective laser sintering (SLS), powder acts as a support material during additive manufacturing, generating significant amounts of un-sintered powder exposed to prolonged thermal cycles. Although partial reuse with virgin powder is common practice, material degradation eventually renders the powder unsuitable for further SLS processing. This study investigates a sustainable approach for valorising SLS waste powder through its conversion into filament feedstock for fused filament fabrication (FFF). Polyamide 12 filaments containing 0, 2, 3, and 4 wt.% multi-walled carbon nanotubes (MWCNTs) were produced by twin-screw extrusion to tailor the electrical conductivity of the polymer matrix. The filaments were processed by FFF to manufacture specimens for thermal, mechanical, and electrical characterization. Differential scanning calorimetry revealed the influence of reprocessing on the thermal behaviour of the reused material and resulting filaments, while thermogravimetric analysis demonstrated improved thermal stability with increasing MWCNT content. Tensile testing showed increased Young’s modulus (up to 9.4%), despite an initial drop, and tensile stress at break (up to 56.3%) with increasing nanofiller concentration. In addition, distinct electrostatic-discharge (ESD) protection ranges were achieved depending on the MWCNT loading. The results demonstrate the potential of reused SLS powder as a sustainable feedstock for functional AM materials suitable for ESD-sensitive applications. Full article

(This article belongs to the Special Issue Next-Generation Material Designs and Processes for Additive Manufacturing)

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20 pages, 14664 KB

Open AccessArticle

Multi-Objective Optimization of the Geometry of a Modular Friction Disk Cutter for Thermo-Friction Processing of Spur Gear Teeth

by Ansagan Suleimenov, Karibek Sherov, Assylbek Kassenov, Assylkhan Mazdubay, Jamshid Ravshanov, Doniyor Isaev, Musurmon Juraev, Gulerke Tattimbek, Sayagul Tussupova, Davran Radjibaev and Zhanara Mussina

J. Manuf. Mater. Process. 2026, 10(7), 235; https://doi.org/10.3390/jmmp10070235 - 3 Jul 2026

Viewed by 521

Abstract

This study presents multi-objective geometric optimization of a modular friction disk cutter for spur gear thermo-friction processing within the ANSYS Workbench 2024 R1. The integrated workflow—Geometry → Steady-State Thermal → Static Structural → Design of Experiments → Response Surface → Response Surface Optimization—enables [...] Read more.

This study presents multi-objective geometric optimization of a modular friction disk cutter for spur gear thermo-friction processing within the ANSYS Workbench 2024 R1. The integrated workflow—Geometry → Steady-State Thermal → Static Structural → Design of Experiments → Response Surface → Response Surface Optimization—enables selection of a rational tool geometry within a single parametric model. Variable dimensions (a, b, c) describe the load-bearing part: a characterizes the transitional thin profile zone, b is the massive supporting part, and c is the intermediate disk thickness controlling thermo-mechanical load transmission. Dimension c most significantly influences equivalent stresses and directional deformation, while maximum temperature depends on combined a and c effects. Based on Response Surface Optimization, the rational solution domain is concentrated near

a \approx 3 m m

,

b \approx 10 m m

, and

c \approx 4 m m

, yielding

P 4 \approx 33.306 M P a

,

P 5 \approx 295.93 ° C

, and

P 6 \approx - 5.7488 \cdot 10^{- 5} m

. These values demonstrate a sufficient calculated safety margin within the finite element framework, providing a technically justified direction for prototype manufacturing. Although currently evaluated as purely computational without direct full-scale physical measurements, these results establish a foundation for subsequent experimental validation using thermal imaging and optical deformation analysis. Future research will focus on transient thermo-mechanical modeling with impulse cooling and experimental verification. Full article

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29 pages, 6060 KB

Open AccessArticle

Study on the Synergistic Effects of Pre-Deformation and Post-Aging Treatments on the Mechanical and Corrosion Properties of a 2A97 Al-Cu-Li Alloy

by Danyang Liu, Bangguo Wu, Xin Liu, Li Wang, Hua Zhou, Lei Tang, Kefu Gan and Jinfeng Li

J. Manuf. Mater. Process. 2026, 10(7), 234; https://doi.org/10.3390/jmmp10070234 - 2 Jul 2026

Viewed by 469

Abstract

This work systematically investigates the effects of pre-deformation, post-aging temperature, and aging time on the mechanical properties, corrosion behavior, and microstructure of a 2A97 Al-Cu-Li alloy. Microstructural characterization indicates that the main precipitates are T₁ (Al₂CuLi), δ′ (Al₃Li), [...] Read more.

This work systematically investigates the effects of pre-deformation, post-aging temperature, and aging time on the mechanical properties, corrosion behavior, and microstructure of a 2A97 Al-Cu-Li alloy. Microstructural characterization indicates that the main precipitates are T₁ (Al₂CuLi), δ′ (Al₃Li), θ′ (Al₂Cu), and S′ (Al₂CuMg). At 160 °C with 0% pre-deformation strain, increasing aging time increases the size and number density of T₁, changing the size and number density of δ′ and θ′ accordingly, whereas raising the aging temperature to 180 °C mainly coarsens precipitates. Increasing pre-deformation from 0% to 12% increases T₁ number density and refines its size. Significantly, after aging at 180 °C, θ′ is absent in the 8% and 12% pre-deformed alloys, and T₁ re-dissolves in the over-aged 12% alloy. Grain-boundary (GB) phases evolve from fine/discontinuous (under-aged) to fine/continuous (peak-aged) to coarse/discontinuous (over-aged). At the same time, higher pre-strain reduces their size, and higher aging temperature promotes coarsening. Higher aging temperature and pre-deformation accelerate age hardening and shorten the peak-aging time. In the peak-aged state, strength increases but elongation decreases with increasing pre-deformation or aging temperature. Among all, the 4% pre-deformed alloy aged at 160 °C for 30 h shows optimal room-temperature properties, i.e., ultimate tensile strength ~613 MPa, yield strength ~564 MPa, and total elongation ~6.91%. Corrosion resistance was closely related to microstructural evolution during aging, and both prolonged aging and increased pre-deformation decreased the susceptibility to intergranular corrosion. The results provide a basis for optimizing the thermomechanical processing of 2A97 Al-Cu-Li alloys. Full article

(This article belongs to the Topic Advances in Processing, Microstructure and Mechanical Properties of Lightweight Alloys)

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15 pages, 727 KB

Open AccessArticle

High-Throughput Fused Filament Fabrication of PLA: Effects of Melting Zone Length and Filament Diameter on Extrusion Force and Volumetric Flow Rate

by Philipp Wüst, Julian Kattinger, Frederik Dahmen, Dieter Spiehl, Christian Bonten and Andreas Blaeser

J. Manuf. Mater. Process. 2026, 10(7), 233; https://doi.org/10.3390/jmmp10070233 - 1 Jul 2026

Viewed by 619

Abstract

Fused filament fabrication (FFF) is a widely used additive manufacturing method in which the process forces within the hotend play an important role in terms of print quality and speed, particularly in high-throughput applications. This work reports on the influence of filament diameter, [...] Read more.

Fused filament fabrication (FFF) is a widely used additive manufacturing method in which the process forces within the hotend play an important role in terms of print quality and speed, particularly in high-throughput applications. This work reports on the influence of filament diameter, melting zone length, and nozzle set temperature on the process forces and the maximum achievable volumetric flow rate. Experimental measurements were carried out using a test rig that integrates a load cell to capture the resulting forces, complemented by non-isothermal numerical simulations. The results show that increasing the melting zone length reduces process forces and increases the attainable volumetric flow rate at high feed rates, as the filament has more time to melt. However, the effect depends strongly on filament diameter. For a diameter of 2.85 mm, extending the melting zone leads to a monotonic increase in the maximum achievable flow rate across the entire investigated range. For a diameter of 1.75 mm, an optimum is observed at an intermediate melting zone length, beyond which additional flow resistance outweighs the benefit of improved melting and thus reduces the attainable flow rate. When normalizing for the maximum transferable extruder force, the smaller filament diameter consistently yields superior throughput performance. The simulations reproduce the experimentally observed trends well and support the interpretation that throughput is limited by the competition between heat-transfer-controlled melting and viscous pressure losses. Full article

(This article belongs to the Special Issue Recent Advances in Optimization of Additive Manufacturing Processes)

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22 pages, 43581 KB

Open AccessArticle

Optimization of Robotic Laser Brazing for Electrolytically Galvanized DC06 Steel Under Prototype Production Conditions

by Dušan Sabadka, Janette Brezinová, Ján Viňáš, Jakub Brezina and Štefan Novotný

J. Manuf. Mater. Process. 2026, 10(7), 232; https://doi.org/10.3390/jmmp10070232 - 30 Jun 2026

Viewed by 455

Abstract

Laser brazing is commonly used for joining visible automotive body panels where both mechanical integrity and surface quality are required. The present work addresses optimization of a robotic laser brazing workstation intended for prototype vehicle production. During initial commissioning, irregular braze formation was [...] Read more.

Laser brazing is commonly used for joining visible automotive body panels where both mechanical integrity and surface quality are required. The present work addresses optimization of a robotic laser brazing workstation intended for prototype vehicle production. During initial commissioning, irregular braze formation was associated with unstable filler wire feeding. Therefore, the wire feeding system was modified and subsequently evaluated together with the influence of laser power and wire feed speed on joint quality under a constant robot travel speed. Experimental joints were produced from electrolytically galvanized DC06 steel using CuSi3Mn1 filler wire. Joint performance was assessed by tensile testing and metallographic examination. Tensile strengths between 293 and 314 MPa were obtained, while fracture occurred exclusively in the base material outside the brazed region. Metallographic observations revealed regular braze geometry for parameter sets A, B and D, whereas excessive thermal input resulted in blowhole formation, zinc coating degradation and enlargement of the heat-affected zone. Quantitative evaluation showed a nearly linear increase in the HAZ area with increasing delivered energy (R² = 0.982). The results indicate that stable brazing conditions can be achieved through an appropriate balance between laser power and wire feed speed under constant robot travel speed conditions. The proposed parameter limits may serve as a practical guideline for robotic laser brazing of thin galvanized automotive sheets under prototype production conditions. Full article

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35 pages, 9489 KB

Open AccessArticle

Effects of HFMI Treatment on the Boron-Alloyed Austenite Medium-Manganese Steel 140Mn6Cr3TiB Deposit: Enhanced Wear Resistance Induced by Heterogeneous Microstructure

by Bohdan Trembach, Bohdan Mordyuk, Michal Krbata, Pavlo Openko, Vadim Zakiev, Vladyslav Shyvaniuk, Tetyana Vladimirova, Mykola Skoryk, Oleksii Kolomiitsev, Vadym Krykun, Yuliia Musairova and Olga Gyrka

J. Manuf. Mater. Process. 2026, 10(7), 231; https://doi.org/10.3390/jmmp10070231 - 30 Jun 2026

Viewed by 921

Abstract

This paper aims to analyse the microstructure and properties of the titanium- and boron-alloyed high-carbon medium-manganese 140Mn6Cr3TiB steel deposit before and after high-frequency mechanical impact (HFMI) treatment. XRD, SED, and EDS analyses were applied to evaluate the microstructural peculiarities of the studied deposit. [...] Read more.

This paper aims to analyse the microstructure and properties of the titanium- and boron-alloyed high-carbon medium-manganese 140Mn6Cr3TiB steel deposit before and after high-frequency mechanical impact (HFMI) treatment. XRD, SED, and EDS analyses were applied to evaluate the microstructural peculiarities of the studied deposit. Nanoindentation and scratch/sliding tests respectively revealed distinct correlations between the phase composition and the deformation/wear behaviour. HFMI results in the formation of the strain-induced ε- and α’-martensites (~66% and 3–6%, respectively), a significant grains/crystallites refinement (down to 31–54 nm), and dislocation density, which support essential hardening (by ~50%). The HFMI regime (load = 100 N, amplitude = 10 µm, and time = 60 s) was found to be the best, which led to the enhanced wear resistance (decreased wear volume) by ~4 times. The heterogeneous nature of the steel deposit creates a “shield-and-buffer” effect, where the hard eutectic framework resists penetration and tough matrix prevents brittle failure, maintaining a high tolerance to abrasion damage. The HFMI-hardening changed the wear mechanism from the ‘wedge/pile-up’ formation to ploughing. Thus, the HFMI shows a good efficiency in finishing the protective medium-manganese steel deposits of enhanced wear resistance to prolong the operation life of responsible parts. Full article

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28 pages, 6557 KB

Open AccessArticle

Influence of Heat Input and Strength Matching on the Microstructure and Mechanical Properties of GMAW Butt-Welded S700MC High-Strength Low-Alloy Steel

by João Ricardo Boff Preichardt, Rafael Luciano Dalcin, Richard Thomas Lermen and Ivan Guerra Machado

J. Manuf. Mater. Process. 2026, 10(7), 230; https://doi.org/10.3390/jmmp10070230 - 30 Jun 2026

Cited by 1 | Viewed by 536

Abstract

High-strength low-alloy (HSLA) steels produced by thermomechanical controlled processing (TMCP) are widely used in structural applications because of their high strength and weldability. However, the performance of welded joints is strongly affected by welding thermal cycles. This study investigated the effects of heat [...] Read more.

High-strength low-alloy (HSLA) steels produced by thermomechanical controlled processing (TMCP) are widely used in structural applications because of their high strength and weldability. However, the performance of welded joints is strongly affected by welding thermal cycles. This study investigated the effects of heat input (0.6, 1.4, and 1.8 kJ/mm) and filler metal strength (matching and undermatching) on the microstructure and mechanical properties of S700MC steel joints produced by metal-cored arc welding (MCAW). Microstructural characterization, hardness measurements, tensile testing, Charpy impact testing, and analysis of variance (ANOVA) were performed. Heat input was identified as the dominant factor controlling heat-affected zone (HAZ) development and mechanical performance. Increasing heat input enlarged the HAZ and reduced hardness through enhanced microstructural recovery. Filler metal strength mainly influenced failure location and joint strength. The lowest heat input (0.6 kJ/mm) provided the highest strength retention, particularly with the matching consumable, but also produced localized hardness peaks approaching 400 HV_0.01 at the weld metal (WM)/HAZ interface, reducing ductility and impact toughness. An intermediate heat input (1.4 kJ/mm) produced the best balance between strength and toughness by promoting a more homogeneous microstructure and smoother hardness distribution. These results provide practical guidance for optimizing welding procedures for TMCP HSLA steels. Full article

(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding, 2nd Edition)

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38 pages, 2038 KB

Open AccessArticle

Practical Multivariate Equivalency Testing for Additively Manufactured Parts: Comparing Independent and Dependent Cases

by Colin M. Lynch, Rene Villalobos, Brenda Leticia Valadez Mesta, Cesar Gomez Guillen, Jorge Mireles and Ryan B. Wicker

J. Manuf. Mater. Process. 2026, 10(7), 229; https://doi.org/10.3390/jmmp10070229 - 30 Jun 2026

Viewed by 523

Abstract

Additive manufacturing (AM) requalification and change-control workflows often require evidence that a candidate machine, parameter set, scanner subsystem, facility, or measurement workflow remains comparable to a stable reference process after a change, but fabrication and testing costs limit exhaustive multifeature studies. The aim [...] Read more.

Additive manufacturing (AM) requalification and change-control workflows often require evidence that a candidate machine, parameter set, scanner subsystem, facility, or measurement workflow remains comparable to a stable reference process after a change, but fabrication and testing costs limit exhaustive multifeature studies. The aim of this study was to address this engineering design problem by developing a practical multifeature equivalency screening framework for AM settings in which prior engineering evidence already suggests that the candidate process should be comparable to the reference process. Building on prior work focused on the univariate problem, the proposed framework uses reference-defined percentile bins, feature-wise distributional tests, and family-wise error-rate control to screen for evidence of non-equivalency across multiple measured attributes. A direct joint-binning approach was first shown to become sample-intensive as dimensionality increases, after which an independent feature-wise method and an exploratory dependent bivariate extension were developed. Simulation-based power analyses quantified the trade-offs among power, detectable effect size, distributional resolution, feature count, and the combined costs of fabrication and measurement. In a laser-based powder bed fusion validation study with 40 observations per process and three corner-deviation features, the expected-equivalent AconityMIDI+ candidate satisfied all feature-wise equivalency criteria (

\tilde{V} = 0.207

–

0.214 < C I^{+} = 0.276

), whereas the expected non-equivalent SLM280 HL candidate failed all three feature-wise tests (

\tilde{V} = 0.357

–

1.000 > C I^{+} = 0.276

). These results support multivariate equivalency as a requalification screening tool for AM process comparability and change control, while confirming that it should not be interpreted as proof of physical-process identity or as a replacement for first-time formal qualification. Core procedures are implemented in the open-source R package MultivariateEquivalency. Full article

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

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