Journal of Manufacturing and Materials Processing, Volume 9, Issue 12

Aluminum alloy 2024 (AA2024) is widely used in the aerospace sector, where a fine, uniform, and equiaxed grain structure is crucial for achieving enhanced mechanical properties. This study examines the effect of dynamic solidification, assisted by me...

Machining of medium-carbon steels, such as AISI 1050, poses a significant challenge in terms of achieving stable cutting conditions, controlled chip evacuation and high surface integrity, in particular when full-face milling is performed under elevat...

The advancement of polymeric materials for orthopedic applications has enabled the development of lightweight, adaptable structures that support patient-specific solutions. This study focuses on the design, fabrication, and mechanical characterizatio...

A roller straightening process of a pure magnesium strip, accompanied by alternating elastic-plastic deformation, was performed through one and three passes, where one pass corresponded to 19 bending events. It was discovered that roller straightenin...

Material Extrusion (ME) is a layer-by-layer additive manufacturing technique that has gained prominence due to its simplicity, cost-effectiveness, design freedom, and adaptability to a wide range of thermoplastic materials. However, the mechanical pe...

The progress in metal additive manufacturing (AM) technology has enabled the printing of parts with intricate geometries. Predicting and reducing geometrical deviations (i.e., the difference between the printed part and the design) in metal AM parts...

Tube hydroforming is a versatile forming process widely used in lightweight structural applications, where accurate characterization of the hoop mechanical behavior is crucial for reliable design and simulation. The ring hoop tensile test (RHTT) prov...

This work presents a fused-filament fabrication (FFF) hot end that combines an unrestricted-rotation C-axis with a rectangular-slot nozzle and an induction-heated melt sleeve. The architecture replaces the popular resistive cartridge and heater block...

Additive manufacturing has increasingly become a transformative approach in the design and fabrication of personalized medical devices, offering improved adaptability, reduced production time, and enhanced patient-specific functionality. Within this...

This study provides an integrated synthesis of Artificial Intelligence (AI) applications in Biomedical 3D Printing, mapping the conceptual and structural evolution of this rapidly emerging field. The bibliometric analysis, based on 229 publications i...

This study evaluates the surface roughness of micromilled 316L stainless steel parts fabricated via fused filament fabrication (FFF) and sintering, establishing statistical links between additive manufacturing and post-machining parameters. The surfa...

The review is intended to systematize the latest achievements and the most promising methods in polycrystalline diamond saw blade dressing used for dicing Si and SiC wafers. Dicing, or die singulation, is important in IC assembly, and the quality of...

In this study, TiB₂/AlSi10Mg, 2 wt.% SiC + TiB₂/AlSi10Mg, and 5 wt.% SiC + TiB₂/AlSi10Mg composite powders were prepared via high-energy ball milling. For the first time, TiB₂ and SiC hybrid particle-reinforced aluminum matrix composites (AMCs) were...

This research focuses on the investigation of microstructure, deformation, and superplastic behavior in wide range of strain rates of novel crossover Al-Zn-Mg-Cu alloy with Y/Er. The precipitation and superplastic behavior of the Al-Zn-Mg-Cu-Zr-Cr-Ti...

Additive manufacturing (AM) is finding increasing application in engineering, especially in manufacturing. As a result, new designs and machines not previously possible due to the restrictions of conventional manufacturing methods may be made. Nevert...

Titanium (Ti) and its alloys are widely used in orthopedic applications, including total hip and knee replacements, bone plates, and dental implants, because of their superior biocompatibility, bioactivity, corrosion resistance, and mechanical robust...

Digital Twin Systems (DTSs) are increasingly recognized as enablers of data-driven manufacturing, yet many implementations remain limited to monitoring or visualization without closed-loop control. This study presents a fully integrated DTS for CNC m...

Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging...

Large functionally integrated casting and electrification are rapidly changing the high-pressure die-casting industry. The requirements for these new castings differ from those of the previous ones. Load-bearing capability, fatigue, ductility, and cr...

Granite wet edge finishing is widely adopted to improve surface durability and aesthetics while reducing dust dispersion compared to dry processes. However, even under flooded lubrication, fine particles (FP, 0.5–20 µm) and ultrafine part...

This work examines how feedstock composition and process settings influence the performance of Al-6061 parts made through material extrusion (MEX). A feedstock with 57 vol% (78 wt%) solids loading was selected based on torque rheometry, showing stabl...

The effects of multiple austenitizing and quenching (AQ) thermal cycles on the microstructure and hardness of AISI O2 (90MnCrV8), D2 (X153CrMoV12), and D3 (X210Cr13) tool steels were systematically investigated. Up to four consecutive AQ treatments w...

Maraging steels encounter tremendous aerospace applications, such as in landing gears, rocket motor casing, pressure vessels, satellite launch vehicles, etc. Laser welding is considered one of the most effective manufacturing processes due to its min...

Injection molding is a high-volume manufacturing process widely used for producing polymer components; however, its process parameters strongly influence residual stress, warpage, and the resulting mechanical performance. This work presents a compreh...

Additive manufacturing has emerged as one of the revolutionary technologies of today, enabling quick prototyping, customized production, and reduced material waste. However, its reliability is often weakened due to faults arising during printing, whi...

The effects of tool wear on the accuracy of complex geometry in thin-sheet blanking are examined. Two illustrative examples are given. The first example considers the effect of tool wear when using a cutting die with a 5% clearance value. The second...

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical couple...

The formation of rivet holes is a critical step in aeronautical assembly, as hole quality directly influences the fatigue resistance and structural reliability of riveted joints. Nickel-based alloys, such as Inconel 625, present additional challenges...

This article presents the effects of novel electron beam hardening (EBH) process parameters in terms of residual stresses (RSs) and microstructure modification in as-received C45 cylindrical specimens. The EBH was performed using continuous irradiati...

This study fabricated AA2024-T4 aluminum alloy components using Additive Friction Stir Deposition (AFSD) to systematically investigate the effects of tool rotational speed (100–400 rpm) on the macroscopic morphology, microstructure, and mechani...

Drilling is fundamental to the assembly of aerospace structures, where millions of fastening holes must meet stringent structural and geometric requirements. Despite significant technological advances, hole quality remains sensitive to nonlinear and...

Over the last decade, laser powder bed fusion (LPBF) received increased attention as a method of producing complex-shaped products from various materials. Recent results indicate the potential of this technology for the production of intermetallic Ni...

Additive manufacturing (AM) of polyetheretherketone (PEEK) offers a promising route for producing lightweight, biocompatible, and patient-specific medical implants with complex geometries. This study investigates and optimizes fused deposition modeli...

This study develops a Bayesian optimization framework to calibrate two discrete element method (DEM) parameters—the cohesion-related surface energy coefficient (k) and the rolling resistance coefficient (μ_r)—based on experimental void...

This study explores the enhancement of mechanical and adhesive properties of unsaturated polyester resins (UPR) through the incorporation of bio-derived chitin nanowhiskers (CNWs) into the polymer matrix. CNWs are high-performance nanoparticles extra...