Journal of Manufacturing and Materials Processing, Volume 7, Issue 3

The innovative Green Ceramic Hybrid Machining (GCHM) process sequentially combines milling with a cutting tool (GCM, Green Ceramic Machining) and laser beam machining (GCLBM) of a ceramic material (black Y-TZP in this study) at the green stage mainly...

In this paper, a void closure model applicable to the general hot forming process has been proposed. Through the representative volume element (RVE) method, the influences of void shape, orientation, and stress state on void closure tendency were ana...

The design of most electric vehicles provides for the positioning of the heavy energy storage units in the underbody of the cars. In addition to crash safety, the battery housing has to meet high requirements for gas tightness. In order to test the u...

The poor surface roughness associated with additively manufactured parts can influence the surface integrity and geometric tolerances of produced components. In response to this issue, laser polishing (LP) has emerged as a potential technique for imp...

Filament-based material extrusion additive manufacturing (FMEAM) is an additive manufacturing technique that uses 3D printing. Additive manufacturing could build parts with infill variations. Solid or triangular infill pattern could be selected as ne...

Arc-directed energy deposition using wire as feedstock is establishing itself as a 3D printing method capable of obtaining additively manufactured large structures. Contrasting results are reported in the literature about the effect of the deposition...

Centrifugal atomization is a rapid solidification technique involving fast cooling rates to produce high-quality powders. The final microstructure of the atomized particles is closely linked with the thermal history and cooling rates experienced duri...

Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (T_off), and pulse-on-duration (T_off) were identified as vital input factors for th...

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) an...

Refill friction stir spot welding (RFSSW) is an emerging solid-state welding technology that demonstrates an outstanding ability to join aerospace aluminum alloys. The thermomechanical processing of RFSSW may cause variations in the workpiece in the...

Part design is the principal source of communicating design intent to manufacturing and inspection. Design data are often communicated through computer-aided design (CAD) systems. Modern analytics tools and artificial intelligence integration into ma...

This paper introduces a new formability test based on double-action radial extrusion to characterize material formability in the three-dimensional to plane-stress material flow transitions that are found in bulk metal-formed parts. The presentation d...

An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was co...

In order to capitalize on the cost-effectiveness of additive manufacturing (AM), it is critical to understand how to build components with consistency and high quality. Directed energy deposition (DED) is an AM method for creating parts layer by laye...

A precise prediction of the rolling force is critical to ensure the quality of the final product, especially in the cold rolling of thin strips. Based on this, a new mathematical model is developed to work out the rolling force when considering the r...

Component porosity is a quality attribute in additive manufacturing (AM). One possibility for the non-destructive three-dimensional determination of porosity or pore shape is X-ray computed tomography (CT), which enables an investigation of the influ...

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization...

Thermo-deformation treatment refers to methods of strengthening during which strengthened layers with a nanocrystalline structure are formed in the surface layers by modifying the metal surface layer, which changes its phase and structural and chemic...

The residual stress state of the machined sub-surface influences the service quality indicators of a component, such as fatigue life, tribological properties, and distortion. During machining, the radius of the cutting edge changes due to tool wear....

The time taken to exchange a cutting tool and the actual machining time are the components in a total production cycle time for a part, that affects productivity. Automated plate exchange systems strive for the simplest possible principles to achieve...

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a fi...

Wire arc additive manufacturing (WAAM) is an emerging and promising technology for producing medium-to-large-scale metallic components/structures for different industries, i.e., aerospace, automotive, shipbuilding, etc. It is now a feasible alternati...

To develop new areas of application for laser-based powder bed fusion of polymers (PBF-LB/P), a deeper process understanding of the resulting mechanical properties, particularly for thin-walled and complex structures, is needed. This work addresses t...

X-ray-computed tomography (CT) is today’s gold standard for the non-destructive evaluation of internal component defects such as cracks and porosity. Using automated standardized evaluation algorithms, an analysis can be performed without knowl...

The development of thin-film photovoltaics has emerged as a promising solution to the global energy crisis within the field of solar cell technology. However, transitioning from laboratory scale to large-area solar cells requires precise and high-qua...

The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major fact...

The research on methods for monitoring sheet metal stamping is benefiting from the increased availability of enabling technologies such as sensors, data mining software, cloud computing, and artificial intelligence. The predictive maintenance policie...

At present, there are no experimental methods that allow for the complete direction-dependent mechanical characterization of tubes. This considerably limits the parameterization of complex, anisotropic material models. The present study introduces a...

In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive ma...

Ultrafast lasers are proven and continually evolving manufacturing tools. Concurrently, additive manufacturing (AM) has emerged as a key area of interest for 3D fabrication of objects with arbitrary geometries. Use of ultrafast lasers for AM presents...

The mechanical properties in laser-based powder bed fusion (PBF-LB/M) manufactured parts are anisotropic in nature due to the layer-wise build-up but also change due to different solidification conditions in dependence on the process strategy and the...

The recent success of the process monitoring method Electron Optical Imaging, applied in the additive manufacturing process Electron Beam Powder Bed Fusion, necessitates a clear understanding of the underlying image formation process. Newly developed...

VDM Alloy 780 is a novel Ni-based superalloy that allows for approximately 50 °C higher operating temperatures, compared to Inconel 718, without a significant decrease in mechanical properties. The age hardenable NiCoCr Alloy combines increased t...

In the original publication [...]

Standing on the brink of the fourth industrial revolution, Cyber Physical Systems (CPS) are considered the basic components of the Smart Factory. One important challenge in cyber physical production systems is dynamic scheduling that can handle rando...

In this paper, we report the use of additive manufacturing methods to fabricate a high aspect ratio, low noise amplifier (LNA) for a handheld active sensor device operating at up to 1 GHz. The new form factor LNA incorporates a modification of a squa...

One major advantage of additive manufacturing is the high freedom of design, which supports the fabrication of complex structures. However, geometrical features such as combined massive volumes and cellular structures in such parts can lead to an une...

The interfacial adhesion, friction, and resulting tool-part interaction during composites manufacturing contribute to the formation of residual stresses and process-induced deformations (PIDs). Tool-part interaction and PIDs are highly sensitive to p...

Additive Manufacturing (AM) has been a growing industry, specifically when trying to mass produce products more cheaply and efficiently. However, there are too many current setbacks for AM to replace traditional production methods. One of the major p...