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J. Manuf. Mater. Process., Volume 9, Issue 8 (August 2025) – 2 articles

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55 pages, 8888 KiB  
Article
Single, Multi-, and Many-Objective Optimization of Manufacturing Processes Using Two Novel and Efficient Algorithms with Integrated Decision-Making
by Ravipudi Venkata Rao and Joao Paulo Davim
J. Manuf. Mater. Process. 2025, 9(8), 249; https://doi.org/10.3390/jmmp9080249 - 22 Jul 2025
Abstract
Manufacturing processes are inherently complex, multi-objective in nature, and highly sensitive to process parameter settings. This paper presents two simple and efficient optimization algorithms—Best–Worst–Random (BWR) and Best–Mean–Random (BMR)—developed to solve both constrained and unconstrained optimization problems of manufacturing processes involving single, multi-, and [...] Read more.
Manufacturing processes are inherently complex, multi-objective in nature, and highly sensitive to process parameter settings. This paper presents two simple and efficient optimization algorithms—Best–Worst–Random (BWR) and Best–Mean–Random (BMR)—developed to solve both constrained and unconstrained optimization problems of manufacturing processes involving single, multi-, and many-objectives. These algorithms are free from metaphorical inspirations and require no algorithm-specific control parameters, which often complicate other metaheuristics. Extensive testing reveals that BWR and BMR consistently deliver competitive, and often superior, performance compared to established methods. Their multi- and many-objective extensions, named MO-BWR and MO-BMR, respectively, have been successfully applied to tackle 2-, 3-, and 9-objective optimization problems in advanced manufacturing processes such as friction stir processing (FSP), ultra-precision turning (UPT), laser powder bed fusion (LPBF), and wire arc additive manufacturing (WAAM). To aid in decision-making, the proposed BHARAT can be integrated with MO-BWR and MO-BMR to identify the most suitable compromise solution from among a set of Pareto-optimal alternatives. The results demonstrate the strong potential of the proposed algorithms as practical tools for intelligent decision-making in real-world manufacturing applications. Full article
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37 pages, 21436 KiB  
Review
An Overview of the Working Conditions of Laser–Arc Hybrid Processes and Their Effects on Steel Plate Welding
by Girolamo Costanza, Fabio Giudice, Severino Missori, Cristina Scolaro, Andrea Sili and Maria Elisa Tata
J. Manuf. Mater. Process. 2025, 9(8), 248; https://doi.org/10.3390/jmmp9080248 - 22 Jul 2025
Abstract
Over the past 20 years, laser beam–electric arc hybrid welding has gained popularity, enabling high quality and efficiency standards needed for steel welds in structures subjected to severe working conditions. This process enables single-pass welding of thick components, overcoming issues concerning the individual [...] Read more.
Over the past 20 years, laser beam–electric arc hybrid welding has gained popularity, enabling high quality and efficiency standards needed for steel welds in structures subjected to severe working conditions. This process enables single-pass welding of thick components, overcoming issues concerning the individual use of traditional processes based on an electric arc or laser beam. Therefore, thorough knowledge of both processes is necessary to combine them optimally in terms of efficiency, reduced presence of defects, corrosion resistance, and mechanical and metallurgical features of the welds. This article aims to review the technical and metallurgical aspects of hybrid welding reported in the scientific literature mainly of the last decade, outlining possible choices for system configuration, the inter-distance between the two heat sources, as well as the key process parameters, considering their effects on the weld characteristics and also taking into account the consequences for solidification modes and weld composition. Finally, a specific section has been reserved for hybrid welding of clad steel plates. Full article
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