Journal of Manufacturing and Materials Processing

26 pages, 8811 KB

Open AccessArticle

Influence of Vibration-Assisted Dynamic Solidification on Microstructure and Mechanical Properties of Permanent Mold Cast Aluminum Alloy 2024 with Conformal Cooling

by Muhammad Waqas Ali Khan, Rauf Ahmad, Syed Masood Arif Bukhari, Muhammad Sultan, Naveed Husnain, Muhammad Tuoqeer Anwar, Umer Bin Nooman, Hassan Raza, Abid Latif, Sajjad Ahmad and Khurram Hasnain Bukhari

J. Manuf. Mater. Process. 2025, 9(12), 416; https://doi.org/10.3390/jmmp9120416 - 18 Dec 2025

Viewed by 308

Abstract

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 mechanical vibrations and conformal cooling, on the [...] Read more.

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 mechanical vibrations and conformal cooling, on the microstructural evolution and mechanical properties of permanent mold-cast AA2024. Mechanical vibrations were applied during solidification in the frequency range of 15–45 Hz and acceleration of 0.5–1.5 g. Process parameters, including pouring temperature, die temperature, vibration frequency, and acceleration, were optimized using an L9 orthogonal array based on the Taguchi method. Analysis of variance (ANOVA) was performed to determine the significance of the aforementioned process parameters. In addition, the alloy’s microstructure was observed through a microscope, which revealed a transition from dendritic to non-dendritic microstructure due to dynamic solidification. The average grain size of the alloy was significantly reduced by 40.9%. Moreover, the values of hardness and Ultimate Tensile Strength (UTS) of the alloy were improved by 13.5% and 10.6%, respectively. Optimal results were obtained at a pouring temperature of 750 °C, die temperature of 150 °C, frequency of 45 Hz, and acceleration of 1.0 g. Moreover, uncertainty analysis for all three responses was also performed. Full article

► Show Figures

Graphical abstract

14 pages, 1661 KB

Open AccessArticle

Influence of Cutting Parameters and Tool Surface Texturing on Surface Integrity in Face Milling of AISI 1050 Carbon Steel

by Serafino Caruso, Maria Rosaria Saffioti, Vincenzina Siciliani, Giulia Zaniboni, Domenico Umbrello, Leonardo Orazi and Luigino Filice

J. Manuf. Mater. Process. 2025, 9(12), 415; https://doi.org/10.3390/jmmp9120415 - 18 Dec 2025

Viewed by 302

Abstract

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 elevated material removal rates. The tool surface engineering approach, [...] Read more.

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 elevated material removal rates. The tool surface engineering approach, particularly laser-induced micro-texturing, comprises a promising route toward modifying the tribological conditions at the tool–chip interface, thus affecting friction, heat generation, chip formation and the resultant surface finish. This study investigates the combined effects of cutting speed, axial depth of cut and tool micro-texture orientation (parallel versus orthogonal to the chip flow direction) on machining performance under wet conditions. In addition to the experimental analysis of cutting forces, chip morphology and surface roughness, this work integrates a full factorial Design of Experiments, regression modeling, and ANOVA to quantify the statistical significance of each factor and to identify dominant interactions. The regression models show strong predictive capability across all measured responses, while the ANOVA confirms the axial depth of cut and tool texture orientation as the most influential parameters. Multi-objective optimization by Pareto analysis further underlines the superiority of orthogonal micro-texturing, which consistently reduces the cutting forces and improves surface quality while promoting controlled chip segmentation. The results provide quantitative and statistically validated evidence of the enhancement of lubrication effectiveness, reduction in interface friction, and stabilization in chip formation provided by the micro-textured tools. Overall, the findings contribute to the development of data-driven machining strategies and surface-engineered cutting tools in view of improved productivity, energy efficiency and surface integrity in advanced manufacturing applications. Full article

► Show Figures

Figure 1

20 pages, 3431 KB

Open AccessArticle

Effect of MEX Process Parameters on the Mechanical Response of PLA Structures for Orthopedic Applications

by Stelios Avraam, Demetris Photiou, Theodoros Leontiou and Loucas Papadakis

J. Manuf. Mater. Process. 2025, 9(12), 414; https://doi.org/10.3390/jmmp9120414 - 17 Dec 2025

Viewed by 219

Abstract

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 characterization of additively manufactured (AM) polymeric polylactic acid (PLA) components produced via Material Extrusion [...] Read more.

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 characterization of additively manufactured (AM) polymeric polylactic acid (PLA) components produced via Material Extrusion (MEX), commonly known as Fused Filament Fabrication (FFF). By optimizing geometric configurations and process parameters, these structures demonstrate enhanced flexibility, energy absorption, and load distribution, making them well-suited for orthopedic products and assistive devices. A comprehensive mechanical testing campaign was conducted to evaluate the elasticity, ductility, and strength of FFF-fabricated samples under tensile and three-point bending loads. Key process parameters, including nozzle diameter, layer thickness, and printing orientation, were systematically varied, and their influence on mechanical performance was recorded. The results reveal that these parameters affect mechanical properties in a complex, interdependent manner. To better understand these relationships, an automated routine was developed to calculate the experimental mechanical response, specifically, stiffness and strength. This methodology enables an automated evaluation of the output, considering parameter ranges for future applications. The outcome of the analysis of variance (ANOVA) of the experimental investigation reveals that the printing orientation has a strong impact on the mechanical anisotropy in FFF, while layer thickness and nozzle diameter demonstrate moderate-to-weak importance. Thereafter, the experimental findings were applied on an innovative orthopedic wrist splint design to be fabricated by means of FFF. The most suitable mechanical properties were selected to test the mechanical response of the designed components under operational bending loading by means of linear elastic finite element (FE) analysis. The computational results indicated the importance of employing the actual mechanical properties derived from the applied printing process parameters compared to data sheet values. Hereby, an additional parameter to adjust the mechanical response is the product’s design topology. Finally, this framework lays the foundation for future training of neural networks to optimize specific mechanical responses, reducing reliance on conventional trial-and-error processes and improving the balance between orthopedic product quality and manufacturing efficiency. Full article

► Show Figures

Graphical abstract

13 pages, 9752 KB

Open AccessArticle

Mechanism Governing the Effect of Roller Straightening of a Pure Magnesium Strip on the Tensile Stress–Strain Curve Shape

by Stanislav O. Rogachev, Viacheslav E. Bazhenov, Eugene S. Statnik, Vladimir A. Andreev, Anatoly E. Shelest and Nikita A. Ershov

J. Manuf. Mater. Process. 2025, 9(12), 413; https://doi.org/10.3390/jmmp9120413 - 17 Dec 2025

Viewed by 282

Abstract

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 straightening leads to the appearance of a kink in [...] Read more.

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 straightening leads to the appearance of a kink in the specimen’s tensile stress–strain curve as well as an almost twofold decrease in the yield stress. This effect was observed only on longitudinal specimens. The conducted EBSD analysis confirmed the previously stated hypothesis about the influence of twinning on the change in the shape of the roller-straightened magnesium alloy specimen’s stress–strain curve. The tensile twins {

10 \bar{1} 2

} formed during roller straightening facilitate the detwinning process during subsequent tensile deformation, which, along with the basal sliding, is the reason for the decrease in yield stress. The scaling factor of the tensile specimens was investigated. Full article

► Show Figures

Figure 1

43 pages, 6068 KB

Open AccessReview

Fundamentals of Cooling Rate and Its Thermodynamic Interactions in Material Extrusion

by Ahmad Saeed Alzahrani, Muhammad Khan and Feiyang He

J. Manuf. Mater. Process. 2025, 9(12), 412; https://doi.org/10.3390/jmmp9120412 - 16 Dec 2025

Viewed by 588

Abstract

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 performance of ME-printed parts often remains suboptimal, primarily due to complex [...] Read more.

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 performance of ME-printed parts often remains suboptimal, primarily due to complex thermal phenomena that govern microstructural development during the printing process, which are key determinants of mechanical strength. As a result, optimizing thermodynamic printing parameters has become essential for improving the overall quality of the printed parts. Extensive research articles and reviews have been published to explore the effect of many ME printing parameter settings on the resultant product characteristics. Despite this focus, the effect of cooling rate, a critical thermodynamic parameter of the process, has been largely overlooked in current research when they are critically reviewed. Cooling rate plays a central role in determining the thermal history of printed material, which in turn influences polymer chain mobility and microstructural features of the extruded material, all of which are crucial to the mechanical integrity of the printed part. Thus, it has been concluded by this review that analytical and empirical investigations into the influence of cooling rate on the microstructural properties of ME parts represent a valuable and novel contribution to the academic field. Full article

► Show Figures

Figure 1

17 pages, 3062 KB

Open AccessArticle

Enhancing Geometric Deviation Prediction in Laser Powder Bed Fusion with Varied Process Parameters Using Conditional Generative Adversarial Networks

by Subigyamani Bhandari, Himal Sapkota and Sangjin Jung

J. Manuf. Mater. Process. 2025, 9(12), 411; https://doi.org/10.3390/jmmp9120411 - 15 Dec 2025

Viewed by 378

Abstract

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 remains a challenge. This work explores how [...] Read more.

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 remains a challenge. This work explores how changes in laser speed, laser power, and hatch spacing affect geometrical deviations in parts made using laser powder bed fusion (L-PBF) and emphasizes predicting geometrical defects in AM parts. Sliced images obtained from CAD designs and printed parts are utilized to capture the effects of various L-PBF process parameters and to generate a comprehensive data set. Conditional Generative Adversarial Networks (cGANs) are trained to predict images that accurately reflect actual geometrical deviations. In this study, the influence of L-PBF process parameters on geometric deviation is quantified, and the prediction results demonstrate the effectiveness of the proposed cGAN-based method in improving the predictability of geometric deviations in parts fabricated via L-PBF. This approach is expected to facilitate early correction of geometrical deviations during the L-PBF process. Full article

(This article belongs to the Special Issue Smart Manufacturing in the Era of Industry 4.0, 2nd Edition)

► Show Figures

Figure 1

22 pages, 3276 KB

Open AccessArticle

Deep Neural Network-Based Inverse Identification of the Mechanical Behavior of Anisotropic Tubes

by Zied Ktari, Pedro Prates and Ali Khalfallah

J. Manuf. Mater. Process. 2025, 9(12), 410; https://doi.org/10.3390/jmmp9120410 - 14 Dec 2025

Viewed by 360

Abstract

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) provides valuable experimental data for evaluating the elastoplastic response [...] Read more.

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) provides valuable experimental data for evaluating the elastoplastic response of anisotropic tubes in the hoop direction, but frictional effects often distort the measured force–displacement response. This study proposes a deep learning-based inverse identification framework to accurately recover the true hoop stress–strain behavior from RHTT data. Convolutional and recurrent neural network architectures, including CNN, long short term memory (LSTM), gated recurrent unit (GRU), bidirectional GRU (BiGRU), bidirectional LSTM (BiLSTM) and ConvLSTM, were trained using numerically generated datasets from finite element simulations. Data augmentation and hyperparameter tuning were applied to generalization. The hybrid ConvLSTM model achieved superior performance, with a minimum mean absolute error (MAE) of 0.08 and a coefficient of determination (R²) value of approximately 0.97, providing a close match to the Hill48 yield criterion. The proposed approach demonstrates the potential of deep neural networks as an efficient and accurate alternative to traditional inverse methods for characterizing anisotropic tubular materials. Full article

(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)

► Show Figures

Figure 1

22 pages, 5466 KB

Open AccessArticle

Induction-Heated, Unrestricted-Rotation Rectangular-Slot Hot End for FFF

by Miguel Rodríguez, David Blanco, Juan Antonio Martín, Pedro José Villegas, Alejandro Fernández and Pablo Zapico

J. Manuf. Mater. Process. 2025, 9(12), 409; https://doi.org/10.3390/jmmp9120409 - 13 Dec 2025

Viewed by 438

Abstract

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 design with an external coil that induces eddy-current heating in [...] Read more.

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 design with an external coil that induces eddy-current heating in a thin-walled sleeve, threaded to the heat break and nozzle, reducing thermal mass and eliminating wired sensors across the rotating interface. A contactless infrared thermometer targets the nozzle tip; the temperature is regulated by frequency-modulating the inverter around resonance, yielding stable control. The hot end incorporates an LPBF-manufactured nozzle, which transitions from a circular inlet to a rectangular outlet to deposit broad, low-profile strands at constant layer height while preserving lateral resolution. The concept is validated on a desktop Cartesian platform retrofitted to coordinate yaw with XY motion. A twin-printer testbed compares the proposed hot end against a stock cartridge-heated system under matched materials and environments. With PLA, the induction-heated, rotating hot end enables printing at 170 °C with defect-free flow and delivers substantial reductions in job time (22–49%) and energy per part (9–39%). These results indicate that the proposed approach is a viable route to higher-throughput, lower-specific-energy material extrusion. Full article

► Show Figures

Figure 1

20 pages, 6897 KB

Open AccessArticle

Novel Development of FDM-Based Wrist Hybrid Splint Using Numerical Computation Enhanced with Material and Damage Model

by Loucas Papadakis, Stelios Avraam, Muhammad Zulhilmi Mohd Izhar, Keval Priapratama Prajadhiana, Yupiter H. P. Manurung and Demetris Photiou

J. Manuf. Mater. Process. 2025, 9(12), 408; https://doi.org/10.3390/jmmp9120408 - 12 Dec 2025

Viewed by 387

Abstract

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 framework, simulation-driven design plays a critical role in ensuring the structural reliability and performance [...] Read more.

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 framework, simulation-driven design plays a critical role in ensuring the structural reliability and performance of orthopedic supports before fabrication. This research study delineates the novel development of a wrist hybrid splint (WHS) which has a simulation-based design and was additively manufactured using fused deposition modeling (FDM). The primary material selected for this purpose was polylactic acid (PLA), recognized for its biocompatibility and structural integrity in medical applications. Prior to the commencement of the actual FDM process, an extensive pre-analysis was imperative, involving the application of nonlinear numerical models aiming at replicating the mechanical response of the WHS in respect to different deposition configurations. The methodology encompassed the evaluation of a sophisticated material model incorporating a damage mechanism which was grounded in experimental data derived from meticulous tensile and three-point bending testing of samples with varying FDM process parameters, namely nozzle diameter, layer thickness, and deposition orientation. The integration of custom subroutines with utility routines was coded with a particular emphasis on maximum stress thresholds to ensure the fidelity and reliability of the simulation outputs on small scale samples in terms of their elasticity and strength. After the formulation and validation of these computational models, a comprehensive simulation of a full-scale, finite element (FE) model of two WHS design variations was conducted, the results of which were aligned with the stringent requirements set forth by the product specifications, ensuring comfortable and safe usage. Based on the results of this study, the final force comparison between the numerical simulation and experimental measurements demonstrated a discrepancy of less than 2%. This high level of agreement highlights the accuracy of the employed methodologies and validates the effectiveness of the WHS simulation and fabrication approach. The research also concludes with a strong affirmation of the material model with a damage mechanism, substantiating its applicability and effectiveness in future manufacturing of the WHS, as well as other orthopedic support devices through an appropriate selection of FDM parameters. Full article

► Show Figures

Figure 1

33 pages, 6567 KB

Open AccessReview

Artificial Intelligence in Biomedical 3D Printing: Mapping the Evidence

by Maria Tănase, Cristina Veres and Dan-Alexandru Szabo

J. Manuf. Mater. Process. 2025, 9(12), 407; https://doi.org/10.3390/jmmp9120407 - 11 Dec 2025

Viewed by 900

Abstract

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 indexed in the Web of Science Core Collection (2018–2025) and [...] Read more.

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 indexed in the Web of Science Core Collection (2018–2025) and visualised in CiteSpace, identifies three interconnected research domains: AI-driven design and process optimisation, data-assisted bioprinting for tissue engineering, and the development of smart and adaptive materials enabling 4D functionalities. The results highlight a clear progression from algorithmic control of additive manufacturing parameters toward predictive modelling, deep learning, and autonomous fabrication systems. Leading contributors include China, India, and the USA, while journals such as Applied Sciences, Polymers, and Advanced Materials act as major dissemination platforms. Emerging clusters around “4D printing”, “deep learning”, and “shape memory polymers” indicate a shift toward intelligent, sustainable, and personalised biomanufacturing. In addition, a qualitative synthesis of the most influential papers complements the bibliometric mapping, providing interpretative depth on the scientific core driving this interdisciplinary evolution. Overall, the study reveals the consolidation of a multidisciplinary research ecosystem in which computational intelligence and biomedical engineering converge to advance the next generation of adaptive medical fabrication technologies. Full article

(This article belongs to the Special Issue Advances in 3D Printing Technologies: Materials, Processes, and Applications)

► Show Figures

Figure 1

24 pages, 1658 KB

Open AccessArticle

Statistical Correlation Analysis of Surface Roughness of Micromilled 316L Stainless Steel Components Fabricated by FDM–FFF Hybrid Manufacturing

by Ali Dinc, Suleiman Obeidat, Ali Mamedov, Murat Otkur and Kaushik Nag

J. Manuf. Mater. Process. 2025, 9(12), 406; https://doi.org/10.3390/jmmp9120406 - 10 Dec 2025

Viewed by 394

Abstract

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 surface roughness of the final part is affected by both 3D printing and [...] Read more.

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 surface roughness of the final part is affected by both 3D printing and micromachining parameters. The presented work has direct practical relevance because micromilled 316L stainless steel components are frequently used in applications such as lab-on-a-chip (LOC) devices and micro-electro-mechanical systems (MEMS), where fatigue behavior and the rheological behavior of fluid flow play critical roles. Both fluid flow and fatigue performance of micromilled components are highly dependent on surface integrity, including surface roughness, residual stresses, and microstructure. Specimens were produced using a 3D printer, under controlled layer thicknesses, raster angles, and fabrication directions, followed by a sintering process for the 3D-printed parts. The sintered parts are then micromilled at varying cutting directions (Angle Cut). Surface roughness (Ra) was measured with a profilometer, generating 34 experimental datasets analyzed through correlation and regression modeling. Cutting direction (Angle Cut) exhibited the strongest positive correlation with Ra (r = 0.486, p = 0.004), followed by layer thickness (r = 0.326, p = 0.060), whereas raster angle and fabrication direction had minimal influence. The multiple linear regression model accounted for 33.5% of Ra variance (R² = 0.335, p = 0.0158), highlighting that fine-layer deposition and alignment of tool paths with filament orientation significantly improve post-machined surface quality. Results confirm that additive-induced anisotropy persists after sintering, affecting chip formation and surface morphology during micromilling. The novelty of this work lies in its integrated hybrid framework, linking metal FFF process parameters, fabrication direction, and machining outcomes through a unified statistical approach. This foundation supports machine-learning-based prediction and hybrid process optimization in metal FFF systems, providing guidance for high-quality additive–subtractive manufacturing. Full article

(This article belongs to the Special Issue 3D Micro/Nano Printing Technologies and Advanced Materials)

► Show Figures

Figure 1

23 pages, 5542 KB

Open AccessReview

Influence of Dressing Methods on Chipping Size During Si and SiC Die Singulation: A Review

by Sergey N. Grigoriev, Anna A. Okunkova, Marina A. Volosova, Khaled Hamdy and Alexander S. Metel

J. Manuf. Mater. Process. 2025, 9(12), 405; https://doi.org/10.3390/jmmp9120405 - 9 Dec 2025

Viewed by 514

Abstract

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 the die edges [...] Read more.

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 the die edges influences the final product quality. Reducing chipping size and width has been a scientific problem over the last few decades. Many techniques were proposed to solve it. The most practical solutions involved optimizing processing factors and cutting direction in accordance with the crystallographic structure of the wafers, since silicon and silicon carbide are hard and brittle materials with low fracture toughness, high hardness, and high thermal conductivity. Wear of the PCD saw blade is also a contributing factor to the formation of chipping and cracks. Dressing allows the bond material removal and diamond grain liberation, where grit size plays a critical role. Dressing techniques were divided into two groups depending on the nature of the exposure, and a combined technique of dressing–coating–redressing was also observed. The less significant chipping size effect was observed for the combined technique in dicing Si wafers when the effect of the techniques based on the mechanical and electrophysical exposures was more significant. Full article

(This article belongs to the Special Issue Advances in Machining Processes of Difficult-to-Machine Materials)

► Show Figures

Figure 1

23 pages, 9623 KB

Open AccessArticle

Process Optimization, Microstructure and Mechanical Properties of SiC + TiB₂/AlSi10Mg Composites Fabricated by Laser-Directed Energy Deposition

by Xin Zhang, Siyu Zhang, Yijie Peng, Long Geng, Chennuo Kang, Zhe Feng, Wei Fan, Hua Tan and Xin Lin

J. Manuf. Mater. Process. 2025, 9(12), 404; https://doi.org/10.3390/jmmp9120404 - 8 Dec 2025

Viewed by 513

Abstract

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) [...] Read more.

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 fabricated using the Laser-Directed Energy Deposition (LDED) technique. The effects of processing parameters on the microstructure evolution and mechanical properties were systematically investigated. Using areal energy density as the main variable, the experiments combined microstructural characterization and mechanical testing to elucidate the underlying strengthening and failure mechanisms. The results indicate that both 2 wt.% and 5 wt.% SiC + TiB₂/AlSi10Mg composites exhibit excellent formability, achieving a relative density of 98.9%. However, the addition of 5 wt.% SiC leads to the formation of brittle Al₄C₃ and TiC phases within the matrix. Compared with the LDED-fabricated AlSi10Mg alloy, the tensile strength of the TiB₂/AlSi10Mg composite increased by 21.4%. In contrast, the tensile strengths of the 2 wt.% and 5 wt.% SiC + TiB₂/AlSi10Mg composites decreased by 3.7% and 2.6%, respectively, mainly due to SiC particle agglomeration and the consumption of TiB₂ particles caused by TiC formation. Nevertheless, their elastic moduli were enhanced by 9% and 16.3%, respectively. Fracture analysis revealed that the composites predominantly exhibited ductile fracture characteristics. However, pores larger than 10 μm and SiC/TiB₂ clusters acted as crack initiation sites, inducing stress concentration and promoting the propagation of secondary cracks. Full article

► Show Figures

Figure 1

19 pages, 5991 KB

Open AccessArticle

Precipitation, Deformation, and Superplastic Behavior of Novel Crossover Al-Zn-Mg-Cu-Y(Er)-Zr-Cr-Ti-Fe-Si Alloys

by Maria V. Glavatskikh, Ruslan Yu. Barkov, Maxim G. Khomutov, Olga A. Yakovtseva and Andrey V. Pozdniakov

J. Manuf. Mater. Process. 2025, 9(12), 403; https://doi.org/10.3390/jmmp9120403 - 7 Dec 2025

Viewed by 434

Abstract

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 with Er/Y and Fe/Si impurities alloys have been studied. The [...] Read more.

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 with Er/Y and Fe/Si impurities alloys have been studied. The microstructure of the alloys with nano-sized precipitates and micron-sized particles allows obtaining a micrograin stable microstructure. The spherical D0₂₃-Al₃(Er,Zr) precipitates with a diameter of about 20 nm and rod-like crystalline and qusicrystalline E (Al₁₈Mg₃Cr₂) precipitates with a thickness of about 20 nm and length of about 150–200 nm were identified by transmission electron microscopy. The superplastic deformation behaviors were investigated under different temperatures of 460–520 °C and different strain rates of 3 × 10⁻⁴ to 3 × 10⁻³ s⁻¹. The microstructure observation shows that uniform and equiaxed grains can be obtained by dynamic recrystallization before superplastic deformation. The alloy with Y exhibits inferior superplastic properties, while the alloy with Er has an elongation of more than 350% at a rate of 1 × 10⁻³ s⁻¹ and a temperature of 510 °C. Full article

(This article belongs to the Special Issue Deformation and Mechanical Behavior of Metals and Alloys)

► Show Figures

Figure 1

12 pages, 1568 KB

Open AccessArticle

Technological Assurance of Surface Roughness of Ti-6Al-4V Parts Made Using Additive and Conventional Manufacturing Methods

by Artis Kromanis, Arturs Vevers, Gatis Muiznieks, Jyothi Prasad Gandreddi and Arturs Korenkovs

J. Manuf. Mater. Process. 2025, 9(12), 402; https://doi.org/10.3390/jmmp9120402 - 5 Dec 2025

Viewed by 436

Abstract

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. Nevertheless, the same AM parts require post-processing using conventional machining [...] Read more.

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. Nevertheless, the same AM parts require post-processing using conventional machining methods such as turning which is the subject of this study. This study provides a comparative analysis of the technological assurance of Ti-6Al-4V parts made via AM using selective laser melting (SLM) and conventional manufacturing methods. The effects of machining parameters such as cutting speed, depth of cut, and feed on the surface roughness of machined Ti-6Al-4V parts are studied. The study concluded that at low feed (0.12 mm/rev.) and low and average depth of cut (0.3 mm and 0.5 mm), the best surface roughness was obtained on the 3D printed samples rather than on the samples obtained using the conventional manufacturing method. In addition, an alternative surface roughness measurement scheme is proposed, which not only allows for measuring the surface roughness, including multiple aspects, but also for identifying possible surface defects in AM parts. Full article

► Show Figures

Figure 1

45 pages, 11101 KB

Open AccessReview

Processing and Development of Porous Titanium for Biomedical Applications: A Comprehensive Review

by Mayank Kumar Yadav, Akshay Yarlapati, Yarlapati Naga Aditya, Praveenkumar Kesavan, Vaibhav Pandey, Chandra Shekhar Perugu, Amit Nain, Kaushik Chatterjee, Satyam Suwas, Jayamani Jayaraj and Konda Gokuldoss Prashanth

J. Manuf. Mater. Process. 2025, 9(12), 401; https://doi.org/10.3390/jmmp9120401 - 4 Dec 2025

Viewed by 973

Abstract

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 robustness. These alloys effectively overcome several limitations of conventional metallic implants, [...] Read more.

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 robustness. These alloys effectively overcome several limitations of conventional metallic implants, such as 316L stainless steel and Co-Cr alloys, particularly with respect to corrosion, fatigue performance, and biological response. However, dense Ti alloys possess a relatively high elastic modulus, which can cause stress shielding in load-bearing applications. This challenge has motivated significant research toward engineered porous Ti structures that exhibit a reduced and bone-matched modulus while preserving adequate mechanical integrity. This review provides a comprehensive examination of powder metallurgy and additive manufacturing approaches used to fabricate porous Ti and Ti-alloy scaffolds, including additive manufacturing and different powder metallurgy techniques. Processing routes are compared in terms of achievable porosity, pore size distribution, microstructural evolution, mechanical properties, and biological outcomes, with emphasis on the relationship between processing parameters, pore architecture, and functional performance. The reported findings indicate that optimized powder-metallurgy techniques can generate interconnected pores in the 100–500 μm range suitable for osseointegration while maintaining compressive strengths of 50–300 MPa, whereas additive manufacturing enables the precise control of hierarchical architectures but requires careful post-processing to remove adhered powder, stabilize microstructures, and ensure corrosion and wear resistance. In addition, this review integrates fundamental aspects of bone biology and bone implant interaction to contextualize the functional requirements of porous Ti scaffolds. Full article

► Show Figures

Graphical abstract

23 pages, 6136 KB

Open AccessArticle

A Bidirectional Digital Twin System for Adaptive Manufacturing

by Klaas Maximilian Heide, Berend Denkena and Martin Winkler

J. Manuf. Mater. Process. 2025, 9(12), 400; https://doi.org/10.3390/jmmp9120400 - 4 Dec 2025

Viewed by 702

Abstract

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 milling that emphasizes real-time bidirectional coupling between a real machine [...] Read more.

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 milling that emphasizes real-time bidirectional coupling between a real machine and a virtual counterpart as well as the use of machine-native signals. The architecture comprises a physical space defined by a five-axis machining center, a virtual space implemented via a dexel-based technological simulation environment, and a digital thread for continuous data exchange between those. A full-factorial simulation study investigated the influence of dexel density and cycle time on engagement accuracy and runtime, yielding an optimal configuration that minimizes discretization errors while maintaining real-time feasibility. Latency measurements confirmed a mean response time of 34.2 ms, supporting process-parallel decision-making. Two application scenarios in orthopedic implant milling validated the DTS: process force monitoring enabled an automatic machine halt within 28 ms of anomaly detection, while adaptive feed rate control reduced predicted form error by 20 µm. These findings demonstrate that the DTS extends beyond passive monitoring by actively intervening in machining processes; enhancing process reliability and part quality; and establishing a foundation for scalable, interpretable digital twins in regulated manufacturing. Full article

(This article belongs to the Special Issue Digital Twinning for Manufacturing)

► Show Figures

Graphical abstract

17 pages, 4812 KB

Open AccessArticle

Turn Milling of Inconel 718 Produced via Additive Manufacturing Using HVOF and DMLS Methods

by Michal Povolný, Michal Straka, Miroslav Gombár, Jan Hnátík, Jan Kutlwašer, Josef Sklenička and Jaroslava Fulemová

J. Manuf. Mater. Process. 2025, 9(12), 399; https://doi.org/10.3390/jmmp9120399 - 4 Dec 2025

Viewed by 511

Abstract

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 for nickel-based superalloys such as Inconel 718. This study presents the design [...] Read more.

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 for nickel-based superalloys such as Inconel 718. This study presents the design and topology optimisation of a cutting tool with a linear cutting edge, capable of operating in turn-milling or turning modes, offering a viable alternative to conventional grinding. A non-optimised tool served as a baseline for comparison with a topology-optimised variant improving cutting-force distribution and stiffness-to-mass ratio. Finite element analyses and experimental turn-milling trials were performed on DMLS and HVOF Inconel 718 using carbide and CBN inserts. The optimised tool achieved significantly reduced roughness values: for DMLS, Ra decreased from 0.514 ± 0.069 µm to 0.351 ± 0.047 µm, and for HVOF from 0.606 ± 0.069 µm to 0.407 ± 0.069 µm. Rz was similarly improved, decreasing from 4.234 ± 0.343 µm to 3.340 ± 0.439 µm (DMLS) and from 5.349 ± 0.552 µm to 4.521 ± 0.650 µm (HVOF). The lowest measured Ra, 0.146 ± 0.030 µm, was obtained using CBN inserts at the highest tested cutting speed. All improvements were statistically significant (p < 0.005). No measurable tool wear was observed due to the small engagement and the use of a fresh cutting edge for each pass. The resulting surface quality was comparable to grinding and clearly superior to conventional turning. These findings demonstrate that combining topology optimisation with a linear-edge tool provides a practical and efficient finishing approach for additively manufactured and thermally sprayed Inconel 718 components. Full article

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

► Show Figures

Figure 1

17 pages, 2039 KB

Open AccessArticle

The Effects of Melting Methods and In-House Recycled Content on Climate Effects

by Anders E. W. Jarfors

J. Manuf. Mater. Process. 2025, 9(12), 398; https://doi.org/10.3390/jmmp9120398 - 1 Dec 2025

Viewed by 431

Abstract

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 crashworthiness all increase, and the foundry’s readiness for this varies and is [...] Read more.

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 crashworthiness all increase, and the foundry’s readiness for this varies and is challenging. At the same time, the carbon footprint needs to be reduced, meaning that recycled, secondary aluminium usage is required, making the challenge of attaining the required component performance significantly more difficult. The current paper examined the conditions and requirements to manage and reach the required targets, both from a material standpoint as well as from a climate impact and resource-efficiency perspective. Full article

► Show Figures

Graphical abstract

26 pages, 7466 KB

Open AccessArticle

Investigation of Air Quality and Particle Emission During Wet Granite Edge Finishing on Machine Tool with Half-Beveled and Ogee Profile Tools

by Wael Mateur, Victor Songmene, Ali Bahloul, Mohamed Nejib Saidi and Jules Kouam

J. Manuf. Mater. Process. 2025, 9(12), 397; https://doi.org/10.3390/jmmp9120397 - 1 Dec 2025

Viewed by 398

Abstract

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 particles (UFP, <100 nm) containing crystalline silica are emitted, posing [...] Read more.

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 particles (UFP, <100 nm) containing crystalline silica are emitted, posing health risks such as silicosis and pulmonary or cardiovascular diseases. This study investigates particle emissions during CNC edge finishing of black (containing 0% quartz) and white granites (containing 41% quartz) using two industrially relevant profile tools: Half-Beveled (HB) and Ogee (OG). A full factorial design evaluated the effects of granite type, tool geometry, abrasive grit size, spindle speed, and feed rate. Particle concentrations were measured with Aerodynamic and Scanning Mobility Particle Sizers. Results show that spindle speed (N) is the dominant factor, explaining up to 92% of variance in emissions, whereas feed rate (V_f) played a minor role. Tool geometry had a pronounced effect on UFP release: sharp-edged geometries (HB) promoted localized micro-fracturing and higher emissions, while curved geometries (OG) distributed stresses and reduced particle detachment. White granite generated higher mass emissions due to its high quartz content, while black granite exhibited more stable emission behavior. These findings highlight the dual necessity of optimizing cutting kinematics and selecting appropriate tool profiles to balance surface quality and occupational health in granite processing. Full article

► Show Figures

Figure 1

16 pages, 6563 KB

Open AccessArticle

Additive Manufacturing of 6061 Aluminum by Filament Based Material Extrusion (MEX): Process Development and Mechanical Characterization

by Sihan Zhang, Hassan Soltani, Kameswara Pavan Kumar Ajjarapu, Shokoufeh Ghasemimotlagh, Harish Irrinki, Sundar Atre and Kunal Kate

J. Manuf. Mater. Process. 2025, 9(12), 396; https://doi.org/10.3390/jmmp9120396 - 1 Dec 2025

Viewed by 671

Abstract

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 stable flow and shear-thinning behavior with a [...] Read more.

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 stable flow and shear-thinning behavior with a measured viscosity of 710.9 ± 3.2 Pa·s. Filaments produced from this material had a consistent diameter of 1.74 ± 0.0064 mm and were used to print specimens at extrusion multipliers of 0.9, 0.95, and 1.0. Debinding and sintering procedures, guided by thermal analysis, resulted in a peak density over 97% of the theoretical value. Among the conditions tested, the 0.95 extrusion multiplier produced the most favorable mechanical properties, with an ultimate tensile strength of 153.5 ± 3 MPa, a yield strength of 68.2 ± 11.7 MPa, and elongation reaching 28 ± 3%, which aligns with values reported for annealed Al-6061. Fractographic analysis showed a ductile fracture mode, confirming good interlayer adhesion and consistent sintering. These results show that MEX is a reliable method for fabricating Al-6061 parts with complex geometries and stable mechanical performance. Full article

(This article belongs to the Special Issue Advances in 3D Printing Technologies: Materials, Processes, and Applications)

► Show Figures

Figure 1

16 pages, 5189 KB

Open AccessArticle

Effects of Multiple Quenching Treatments on Microstructure and Hardness of O2, D2, and D3 Tool Steels

by Emanuele Ghio, Matteo Felci and Rinaldo Garziera

J. Manuf. Mater. Process. 2025, 9(12), 395; https://doi.org/10.3390/jmmp9120395 - 1 Dec 2025

Viewed by 451

Abstract

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 were applied to assess the influence of repeated [...] Read more.

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 were applied to assess the influence of repeated austenitization on grain refinement, carbide dissolution, martensitic transformation, and retained austenite. The microstructure was investigated by optical and SEM observations, supported with XRD analyses. The results were correlated with Rockwell and Vickers hardness measurements. In AISI O2, the mean austenitic grain size decreased from (6.5 ± 0.8) μm to (4.3 ± 0.4) μm, accompanied by an increase in hardness from ~800 HV1 to ~950 HV1 (63 HRC), mainly due to the progressive carbide dissolution and a reduction in retained austenite. In AISI D2 and D3, repeated AQ cycles led to a marked reduction in carbide size and volume fraction (up to 25%), with D2 showing partial coarsening beyond the third cycle and D3 exhibiting continuous dissolution owing to higher carbide stability. A linear correlation between the carbide volume fraction and Rockwell hardness was established. Compared with conventional single-step treatments, the multi-cycle AQ approach also promote spheroidization of small carbides. Full article

► Show Figures

Figure 1

33 pages, 6561 KB

Open AccessReview

Evolution of Microstructures and Mechanical Properties of Laser-Welded Maraging Steel for Aerospace Applications: The Past, Present, and Future Prospect

by Bharat Behl, Yu Dong, Alokesh Pramanik and Tapas Kumar Bandyopadhyay

J. Manuf. Mater. Process. 2025, 9(12), 394; https://doi.org/10.3390/jmmp9120394 - 30 Nov 2025

Viewed by 800

Abstract

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 minimal instances of wider heat-affected zones (HAZs), precipitate accumulation, [...] Read more.

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 minimal instances of wider heat-affected zones (HAZs), precipitate accumulation, and other benefits. However, it should also be noted that their severe effect is still evident in terms of the tensile strength and fatigue strength of laser-welded maraging steel. This paper provides a critical review of the evolution of microstructural features and mechanical properties of laser-welded maraging steel, including corresponding factors in terms of microstructures and the formation of reverted austenite, as well as precipitation hardening from various studies on maraging steels. We examined the influence of precipitation, reverted austenite, welding, and post-weld heat treatment on mechanical properties like hardness, tensile strength, yield strength, elongation, and fatigue strength of laser-welded maraging steel. It is worth mentioning that the laser welding process is generally insufficient for welding sheets with a thickness over 10 mm or those requiring multi-pass welding. The reheating process becomes unfavorable for maraging steel in the multi-pass welding process since it may induce localized heat treatment. Although hybrid welding may resolve an arising thickness issue, the reversion of austenite and complexity are still difficult to overcome due to the dual nature of welding processes, resulting from the use of both arc and laser. Furthermore, maraging steel produced via additive manufacturing tends to avoid austenite reversion with effective heat treatment prior to any welding process. Post-weld heat treatment and cryogenic treatment have been found to be favorable for desired reverted austenite formation. Finally, the proposed constructive framework specifically applies to the welding process of maraging steel, particularly for aerospace applications. Full article

► Show Figures

Figure 1

29 pages, 4781 KB

Open AccessArticle

Optimization of Injection Molding Parameters for Warpage Reduction on Polypropylene Plates

by Jorge Jiménez-Armendáriz, Andrea Guevara-Morales, Ulises Figueroa-López, Mariel Alfaro-Ponce, José Martínez-Trinidad and Moises Jimenez-Martinez

J. Manuf. Mater. Process. 2025, 9(12), 393; https://doi.org/10.3390/jmmp9120393 - 29 Nov 2025

Viewed by 643

Abstract

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 comprehensive factorial design and ANOVA to evaluate the simultaneous effects of the [...] Read more.

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 comprehensive factorial design and ANOVA to evaluate the simultaneous effects of the injection temperature, packing pressure, packing time, and specimen orientation on the warpage, hardness, tensile, and flexural properties of polypropylene plates. The results demonstrate that the injection temperature and packing pressure are the dominant factors affecting the hardness and ultimate tensile strength, whereas warpage is mainly governed by the injection temperature and orientation. Under the tested conditions, certain combinations of injection temperature and packing pressure led to an improved mechanical performance; however, these adjustments also produced reductions in other properties, indicating that the balance among parameters depends on the targeted application rather than a single optimal set. Conversely, the parameter combination that produced the lowest warpage still yielded a significant increase in

E_{s e c}

, indicating that reducing the warpage does not necessarily compromise the tensile stiffness. Interestingly, variations in the stress distribution between the tensile and bending tests suggest that the solidification-induced structure of the material influences its mechanical response, with specimens that showed a lower tensile strength exhibiting a comparatively higher resistance under bending. These findings provide new insights into the trade-offs between dimensional accuracy and mechanical performance and offer practical guidelines for optimizing polypropylene injection molding processes. Full article

► Show Figures

Figure 1

57 pages, 5240 KB

Open AccessArticle

An Explainable Lightweight Framework for Process Control and Fault Detection in Additive Manufacturing

by Vijay Gurav, Ashwini Upadhyay and Hitesh Sakhare

J. Manuf. Mater. Process. 2025, 9(12), 392; https://doi.org/10.3390/jmmp9120392 - 28 Nov 2025

Viewed by 514

Abstract

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, which remain undetected and, thus, give rise to product defects, [...] Read more.

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, which remain undetected and, thus, give rise to product defects, waste generation, and safety issues. Most of the existing fault detection methods suffer from limited accuracy, poor adaptability within different printing conditions, and a lack of real-time monitoring capability. These factors critically limit their effectiveness in practical deployment. To address these limitations, the current study proposes a novel process control approach for additive manufacturing with the integration of advanced segmentation, detection, and monitoring strategies. The implemented framework involves segmentation of layer regions using MaskLab-CRFNet, integrating Mask R-CNN, DeepLabv3, and Conditional Random Fields for precise defect location; detection is performed by MoShuResNet, hybridizing MobileNetV3, ShuffleNet, and Residual U-Net for lightweight yet robust fault classification; and monitoring is done by BLC-MonitorNet, which incorporates Bayesian deep networks, ConvAE-LSTM, and convolutional autoencoders together for reliable real-time anomaly detection. Experimental evaluation demonstrates superior performance, with the achievement of 99.31% accuracy and 97.73% sensitivity. This work presents a reliable and interpretable process control framework for additive manufacturing that will improve safety, efficiency, and sustainability. Full article

► Show Figures

Figure 1

25 pages, 3855 KB

Open AccessArticle

The Effects of Tool Wear on the Accuracy of Complex Geometry in Sheet Blanking

by Ümit Aldemir, Orhan Çakır and C. Erdem İmrak

J. Manuf. Mater. Process. 2025, 9(12), 391; https://doi.org/10.3390/jmmp9120391 - 27 Nov 2025

Viewed by 735

Abstract

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 example [...] Read more.

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 example considers the effect of tool wear when using a cutting die with a 3% clearance value. The volume loss and the improvement in punch-tip rounding of parts with complex geometries and sharp corners in thin steel sheets are obtained and compared. It is shown that punch wear changes according to the surface roughness of the cut piece and the burr height on sharp corners, radii, and flat surfaces. A strategy for calculating tool wear is also proposed. It was found that a die clearance of 5% provides much better results than a 3% clearance for soft sheets with a thickness of 0.50 mm in terms of minimizing tool wear and maximizing the clearance value. Full article

► Show Figures

Figure 1

21 pages, 8090 KB

Open AccessArticle

Research on Milling Burrs of ALSI304 Stainless Steel with Consideration of Tool Eccentricity

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

J. Manuf. Mater. Process. 2025, 9(12), 390; https://doi.org/10.3390/jmmp9120390 - 27 Nov 2025

Viewed by 424

Abstract

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 coupled model for slot milling was constructed based on an explicit [...] Read more.

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 coupled model for slot milling was constructed based on an explicit dynamics model. Combining the Johnson–Cook (J-C) constitutive model with the J-C shear failure criterion, simulations were conducted to obtain burr dimensions, cutting temperature distributions, and cutting force waveforms under different tool eccentricity directions and magnitudes. Results: As the eccentricity increases, the temperature of the top burr rises, and both the width of the top burr and the thickness of the exit side burr significantly increase. Under simulated conditions, the width of the top burr in down milling side increased by up to 70%. The burr dimensions under different eccentricity directions can differ by approximately 40%. Groove milling experiments revealed similar burr shapes between experimental and simulated results. Furthermore, the simulated cutting force waveforms aligned with those in the literature, indicating the reliability of the simulation outcomes. Based on these findings, it can be concluded that tool eccentricity significantly affects the dimensions of top burrs and exit side burrs. The width of top burrs and the thickness of exit side burrs are positively correlated with the tool eccentricity distance, while exit bottom burrs remain unaffected by eccentricity. These research results provide valuable reference for burr suppression in practical machining operations. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology, 2nd Edition)

► Show Figures

Figure 1

23 pages, 3805 KB

Open AccessArticle

Sustainable Drilling Strategies for Rivet Hole Formation in Nickel-Based Alloys for Aeronautical Applications

by José Manuel Sáenz de Pipaón, Amabel García-Domínguez, Juan Claver and Eva María Rubio

J. Manuf. Mater. Process. 2025, 9(12), 389; https://doi.org/10.3390/jmmp9120389 - 25 Nov 2025

Viewed by 582

Abstract

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 due to their poor machinability and the stringent [...] Read more.

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 due to their poor machinability and the stringent surface integrity requirements imposed by the aerospace sector. This study investigates innovative and sustainable drilling strategies for rivet hole preparation, focusing on the comparative performance of two environmentally friendly cooling and lubrication methods: minimum quantity lubrication with an eco-friendly fluid (MQL-Eco) and cold compressed air (CCA). A comprehensive experimental campaign was carried out to analyze the combined effects of spindle speed, S, feed rate, f, and cooling method, R, on hole surface roughness parameters (Ra and Rz). These values are measured inside the drilled hole using optical scanner 3D equipment. Statistical tools, including analysis of variance (ANOVA) and response surface methodology (RSM), were employed to identify the most significant factors and optimize cutting conditions. The results reveal that the interaction between spindle speed and coolant type is the dominant contributor to surface roughness variability, with MQL-Eco consistently achieving values within the aeronautical standard range (Ra = 0.8–1.6 µm), and the coolant factor is the second cause of variability in both roughness Ra and Rz. Moreover, correlations between roughness parameters and tool wear confirm the relevance of sustainable cooling methods in extending tool life while maintaining compliance with aerospace quality requirements. The findings demonstrate that innovative eco-friendly drilling approaches can effectively replace conventional lubrication, offering a viable pathway towards greener manufacturing practices in metal forming and joining technologies. Full article

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

► Show Figures

Figure 1

29 pages, 20424 KB

Open AccessArticle

Effects of Electron Beam Hardening Parameters on the Residual Stresses and Microstructures in C45 Steel Cylindrical Specimens

by Galya Duncheva, Vladimir Dunchev, Milka Atanasova, Vladimir Todorov, Yaroslav Argirov, Marieta Ivanova and Boris Petkov

J. Manuf. Mater. Process. 2025, 9(12), 388; https://doi.org/10.3390/jmmp9120388 - 24 Nov 2025

Viewed by 442

Abstract

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 irradiation with power in the range of [...] Read more.

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 irradiation with power in the range of

720 - 2070 W

on an Evobeam µEBW Cube 400 machine. A distinctive feature of the novel surface hardening process is the linear scanning mode in the axial direction of the treated cylindrical surface, which makes it suitable for machining shafts and axles. Using a one-factor-at-a-time technique, the individual effects of the electron beam current

I_{b}

, workpiece peripheral velocity

v_{p}

, scanning frequency (SF), and focal length (FL) on the RSs and microstructure in surface layers were evaluated. The X-ray diffraction results, scanning electron microscopy (SEM) images, and phase analyses confirmed the significant potential of the EBH process for forming compressive RSs due to martensitic transformation in the surface zone and gradient microstructure in terms of structure and phase composition. The measured maximum compressive axial and hoop RSs of

- 289.5

and

- 345 M P a

, respectively, and compressive zone at a depth of approximately 0.3 mm correlate with the phase transformation region at a depth of approximately 0.2 mm. Based on the results for RSs and microstructure modification, the limitations with respect to the suitable operating parameter values were established. After excluding these operating parameter values, the following suitable ranges of the operating parameters were determined:

I_{b} \in (16, 36) m A, v_{p} \in (18, 45) m m / s

,

S F \in (5000, 20,000) H z

, and

F L \in (+ 5, - 5) m m

. The specified ranges are the basis for conducting a planned experiment on the novel EBH process. Full article

► Show Figures

Figure 1

18 pages, 9329 KB

Open AccessArticle

Fabrication of Al-Cu Alloy via Additive Friction Stir Deposition

by Qi Wen, Long Wan and Zeyu Zhang

J. Manuf. Mater. Process. 2025, 9(12), 387; https://doi.org/10.3390/jmmp9120387 - 24 Nov 2025

Viewed by 575

Abstract

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 mechanical properties of the deposited layers. The results demonstrate that defect-free, fully dense [...] Read more.

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 mechanical properties of the deposited layers. The results demonstrate that defect-free, fully dense deposits with good surface quality were successfully achieved across the entire speed range under a constant traverse speed. The deposition zone exhibited a homogeneous, fine equiaxed grain structure with an average grain size of 2.01 μm. As the rotational speed decreased from 400 rpm to 200 rpm, the ultimate tensile strength in the longitudinal direction increased from 340 MPa to 390 MPa, indicating that a moderate reduction in rotational speed enhances both the strength and ductility of AFSD-fabricated AA2024. This research provides the first revelation of the bidirectional material flow behavior and the mechanisms underlying regional property variations in AA2024 during AFSD. Furthermore, the contributions of different strengthening mechanisms were quantified using a multi-mechanism strength model. These findings offer a significant foundation and theoretical support for the solid-state additive manufacturing of high-performance Al-Cu alloy components. Full article

► Show Figures

Figure 1

Journal Menu

Journal Browser

J. Manuf. Mater. Process., Volume 9, Issue 12 (December 2025) – 35 articles

Further Information

Guidelines

MDPI Initiatives

Follow MDPI