Journal of Manufacturing and Materials Processing

15 pages, 1437 KiB

Open AccessArticle

Nanosecond Laser Cutting of Double-Coated Lithium Metal Anodes: Toward Scalable Electrode Manufacturing

by Masoud M. Pour, Lars O. Schmidt, Blair E. Carlson, Hakon Gruhn, Günter Ambrosy, Oliver Bocksrocker, Vinayakraj Salvarrajan and Maja W. Kandula

J. Manuf. Mater. Process. 2025, 9(8), 275; https://doi.org/10.3390/jmmp9080275 - 11 Aug 2025

Abstract

The transition to high-energy-density lithium metal batteries (LMBs) is essential for advancing electric vehicle (EV) technologies beyond the limitations of conventional lithium-ion batteries. A key challenge in scaling LMB production is the precise, contamination-free separation of lithium metal (LiM) anodes, hindered by lithium’s [...] Read more.

The transition to high-energy-density lithium metal batteries (LMBs) is essential for advancing electric vehicle (EV) technologies beyond the limitations of conventional lithium-ion batteries. A key challenge in scaling LMB production is the precise, contamination-free separation of lithium metal (LiM) anodes, hindered by lithium’s strong adhesion to mechanical cutting tools. This study investigates high-speed, contactless laser cutting as a scalable alternative for shaping double-coated LiM anodes. The effects of pulse duration, pulse energy, repetition frequency, and scanning speed were systematically evaluated using a nanosecond pulsed laser system on 30 µm LiM foils laminated on both sides of an 8 µm copper current collector. A maximum single-pass cutting speed of 3.0 m/s was achieved at a line energy of 0.06667 J/mm, with successful kerf formation requiring both a minimum pulse energy (> 0.4 mJ) and peak power (> 2.4 kW). Cut edge analysis showed that shorter pulse durations (72 ns) significantly reduced kerf width, the heat-affected zone (HAZ), and bulge height, indicating a shift to vapor-dominated ablation, though with increased spatter due to recoil pressure. Optimal edge quality was achieved with moderate pulse durations (261–508 ns), balancing energy delivery and thermal control. These findings define critical laser parameter thresholds and process windows for the high-speed, high-fidelity cutting of double-coated LiM battery anodes, supporting the industrial adoption of nanosecond laser systems in scalable LMB electrode manufacturing. Full article

20 pages, 4219 KiB

Open AccessArticle

Machine Learning-Based Prediction of EDM Material Removal Rate and Surface Roughness

by Isam Qasem and Amjad Alsakarneh

J. Manuf. Mater. Process. 2025, 9(8), 274; https://doi.org/10.3390/jmmp9080274 (registering DOI) - 11 Aug 2025

Abstract

Examining the electrical discharge machining (EDM) process is challenging in manufacturing technology due to the complexity of the physical events that take place in the gaps between electrodes. In this study, we examined the EDM process in detail and developed multiple machine learning [...] Read more.

Examining the electrical discharge machining (EDM) process is challenging in manufacturing technology due to the complexity of the physical events that take place in the gaps between electrodes. In this study, we examined the EDM process in detail and developed multiple machine learning (ML) models to describe the relationship between the EDM independent (process parameters) and dependent (responses) variables. The collected experimental data was used to train the machine learning models. According to the results, the GPR model outperformed other ML models across different materials, with average RMSE values of 0.9234 and 3.0216 for the material removal rate (MRR) and surface roughness (Sa), respectively, highlighting the effectiveness of ML tools at modeling complex machining processes, such as EDM. In addition, as a practical implication, this study opens the door to employing the developed ML models to predict the EDM process performance. Full article

(This article belongs to the Special Issue Mechanics Analysis and Predictive Modeling of Engineering Materials Involved in the Manufacturing of Parts and Components)

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23 pages, 17405 KiB

Open AccessArticle

Effect of Laser Shock Peening on the Fatigue Performance of Q355D Steel Butt-Welded Joints

by Dongdong You, Yongkang Li, Fenglei Li, Jianhua Wang, Yi Hou, Pengfei Sun and Shengguan Qu

J. Manuf. Mater. Process. 2025, 9(8), 273; https://doi.org/10.3390/jmmp9080273 - 11 Aug 2025

Abstract

This study investigated the effect of laser shock peening (LSP) treatment on the fatigue performance of Q355D steel butt-welded joints. The results demonstrate that LSP sig-nificantly enhances joint fatigue resistance through gradient hardening in surface lay-ers, introduction of high-magnitude residual compressive stress fields, [...] Read more.

This study investigated the effect of laser shock peening (LSP) treatment on the fatigue performance of Q355D steel butt-welded joints. The results demonstrate that LSP sig-nificantly enhances joint fatigue resistance through gradient hardening in surface lay-ers, introduction of high-magnitude residual compressive stress fields, and micro-structural refinement. Specifically, microhardness increased across all joint zones with gradient attenuation of strengthening effects within an approximately 700 μm depth. LSP effectively suppressed residual tensile stress concentration in regions beyond 4 mm on both sides of the weld. Fatigue tests confirmed that LSP substantially extended joint fatigue life: by 113–165% in the high-stress region (250–270 MPa) and 46–63% in the medium-low-stress region (230–240 MPa). Fractographic analysis further revealed reduced fatigue striation spacing and lower microcrack density in LSP-treated speci-mens, reflecting the synergistic effect of residual compressive stress fields and micro-structural refinement in retarding crack propagation. This work substantiates LSP as an effective method for enhancing fatigue resistance in Q355D steel welded joints. Full article

(This article belongs to the Special Issue Progress in Laser Materials Processing)

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18 pages, 2147 KiB

Open AccessArticle

Manufacturing Design and Analysis of Bending Technology by the Variation of the Initial Technological Parameters

by Sándor Bodzás and Gyöngyi Szanyi

J. Manuf. Mater. Process. 2025, 9(8), 272; https://doi.org/10.3390/jmmp9080272 - 11 Aug 2025

Abstract

The aim of this study is a detailed methodological analysis of the bending technology based on literature sources and the analysis of the correlation between the technological parameters. During this research the process of the determination of the technological parameters and their practical [...] Read more.

The aim of this study is a detailed methodological analysis of the bending technology based on literature sources and the analysis of the correlation between the technological parameters. During this research the process of the determination of the technological parameters and their practical interpretation is given special attention. We analyze the technological process in a clear and understandable way using our own prepared figures to assist industrial and educational usage. This work contributes to a deeper understanding of bending technology and supports the basis of the technological decision. Furthermore four experiments will be conducted to find a correlation between the actual variable technological parameter (more variables will be selected) and the received technological parameters to analyze the function between these influential factors. This study can help industrial engineers and university students to understand the complexity of this technology, design all of the technological parameters that are needed to execute this technology for the manufacturing process, and enhance the quality of this metal forming process. Full article

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26 pages, 4117 KiB

Open AccessArticle

Defect Detection via Through-Transmission Ultrasound Using Neural Networks and Domain-Specific Feature Extraction

by Gary LeMay and Enkhsaikhan Boldsaikhan

J. Manuf. Mater. Process. 2025, 9(8), 271; https://doi.org/10.3390/jmmp9080271 - 11 Aug 2025

Abstract

Defect detection in acoustically matched media remains a significant challenge, particularly when defects, such as fiberglass and polyamide residues, exhibit properties that match those of fiber-reinforced composite laminates as the base material. Techniques, such as through-transmission ultrasound (TTU), often miss subtle residues as [...] Read more.

Defect detection in acoustically matched media remains a significant challenge, particularly when defects, such as fiberglass and polyamide residues, exhibit properties that match those of fiber-reinforced composite laminates as the base material. Techniques, such as through-transmission ultrasound (TTU), often miss subtle residues as defects with the use of conventional amplitude-based TTU detection alone. There is a noticeable research gap in properly identifying such subtle residues in composites using TTU inspection. This study investigated the use of neural networks (NNs) to identify subtle defects in composites based on domain-specific feature extraction from TTU signals. Each signal waveform of each spatial TTU inspection is used as a discrete sample to obtain a larger dataset for each specimen. Domain-specific features were extracted separately from the time, frequency, and wavelet domains, resulting in independent feature vectors to emphasize the signal characteristics. The NN classification used 70% of the overall dataset for training and 30% for testing. Results reveal the features of the time- and frequency domains perform well, achieving macro-F1 scores of 0.96 and 0.97, respectively, while wavelet domain features perform lower with a macro-F1 score of 0.62. Wavelet-domain features perhaps need machine learning methods like recurrent NNs to correctly recognize subtle time-dependent signal variations. Full article

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

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21 pages, 4954 KiB

Open AccessArticle

Direct Ink Writing and Characterization of ZrC-Based Ceramic Pellets for Potential Nuclear Applications

by Narges Malmir, Guang Yang, Thomas Poirier, Nathaniel Cavanaugh, Dong Zhao, Brian Taylor, Nikhil Churi, Tiankai Yao, Jie Lian, James H. Edgar, Dong Lin and Shuting Lei

J. Manuf. Mater. Process. 2025, 9(8), 270; https://doi.org/10.3390/jmmp9080270 - 11 Aug 2025

Abstract

Developing advanced nuclear fuel technologies is critical for high-performance applications such as nuclear thermal propulsion (NTP). This study explores the feasibility of direct ink writing (DIW) for fabricating ceramic pellets for potential nuclear applications. Zirconium carbide (ZrC) is used as a matrix material [...] Read more.

Developing advanced nuclear fuel technologies is critical for high-performance applications such as nuclear thermal propulsion (NTP). This study explores the feasibility of direct ink writing (DIW) for fabricating ceramic pellets for potential nuclear applications. Zirconium carbide (ZrC) is used as a matrix material and vanadium carbide (VC) is used as a surrogate for uranium carbide (UC) in this study. A series of ink formulations were developed with varying concentrations of VC and nanocrystalline cellulose (NCC) to optimize the rheological properties for DIW processing. Post-sintering analysis revealed that conventionally sintered samples at 1750 °C exhibited high porosity (>60%), significantly reducing the compressive strength compared to dense ZrC ceramics. However, increasing VC content improved densification and mechanical properties, albeit at the cost of increased shrinkage and ink flow challenges. Spark plasma sintering (SPS) achieved near-theoretical density (~97%) but introduced geometric distortions and microcracking. Despite these challenges, this study demonstrates that DIW offers a viable route for fabricating ZrC-based ceramic structures, provided that sintering strategies and ink rheology are further optimized. These findings establish a baseline for DIW of ZrC-based materials and offer valuable insights into the porosity control, mechanical stability, and processing limitations of DIW for future nuclear fuel applications. Full article

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52 pages, 5052 KiB

Open AccessReview

A Comprehensive Review of Sustainable and Green Additive Manufacturing: Technologies, Practices, and Future Directions

by Sudip Dey Dipta, Md. Mahbubur Rahman, Md. Jonaet Ansari and Md. Nizam Uddin

J. Manuf. Mater. Process. 2025, 9(8), 269; https://doi.org/10.3390/jmmp9080269 - 9 Aug 2025

Viewed by 57

Abstract

Additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative technology across various industries due to its potential for design flexibility, material efficiency, and reduced production lead times. As global attention increasingly shifts toward environmental sustainability, there is a growing [...] Read more.

Additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative technology across various industries due to its potential for design flexibility, material efficiency, and reduced production lead times. As global attention increasingly shifts toward environmental sustainability, there is a growing need to evaluate the ecological implications and opportunities associated with AM. This comprehensive review explores the current state of sustainable and green additive manufacturing (SGAM) technologies and practices, highlighting innovations that reduce energy consumption, minimize material waste, and incorporate renewable or recyclable materials. This study focuses on the utilization of recyclable thermoplastics combined with biodegradable polymers, exploring sustainable source materials, cold fabrication techniques, and cyclic lifecycle strategies integrated with renewable energy systems. Despite its potential, SGAM faces key challenges such as material compatibility, scalability of manufacturing processes, mechanical property optimization, and the need for standardized production protocols. Nevertheless, this work finds that SGAM devices are effective in minimizing environmental impact across the entire manufacturing process, aligning with predominant research trends that emphasize strategic predictive models to guide future developments in AM system implementation. The review concludes with future directions and research opportunities to enhance the environmental performance of AM technologies, ultimately contributing to a more sustainable manufacturing landscape. Full article

(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)

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9 pages, 1119 KiB

Open AccessArticle

Effects of Ultrasonic Vibration Intensity and Initial Powder Amount in the Hopper on Powder Dispensing Rate in Binder Jetting Additive Manufacturing

by Mostafa Meraj Pasha, Zhijian Pei, Yi-Tang Kao and Ken Dubovick

J. Manuf. Mater. Process. 2025, 9(8), 268; https://doi.org/10.3390/jmmp9080268 - 9 Aug 2025

Viewed by 50

Abstract

In binder jetting additive manufacturing (BJAM), parts are fabricated layer by layer by depositing a liquid binder on selected regions of the powder bed. Powder particles in the hopper of the printer are dispensed onto the powder bed to form a layer of [...] Read more.

In binder jetting additive manufacturing (BJAM), parts are fabricated layer by layer by depositing a liquid binder on selected regions of the powder bed. Powder particles in the hopper of the printer are dispensed onto the powder bed to form a layer of powder. Powder dispensing rate affects material usage and print quality. Too high dispensing rates can cause excessive powder dispensing, increasing powder waste, while too low dispensing rates may result in incomplete layer formation, leading to reduced density of printed parts. The present study investigates how ultrasonic vibration intensity and initial powder amount in the hopper affect powder dispensing rate in BJAM when using a bimodal powder. A set of experiments with full factorial design were conducted using three levels of ultrasonic vibration intensity (50%, 75%, and 100%) and three levels of initial powder amount (600 g, 1000 g, and 1400 g) in the hopper. The results show that both ultrasonic vibration intensity and initial powder amount, as well as their interaction, significantly influence powder dispensing rate. Powder dispensing rate was higher when ultrasonic vibration intensity was higher or initial powder amount was smaller. Increasing initial powder amount from 600 to 1400 g, resulted in a much bigger decrease in powder dispensing rate when ultrasonic vibration intensity was 50% than when ultrasonic vibration intensity was 100%. Full article

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18 pages, 10856 KiB

Open AccessArticle

Influence of Structural Components on Thermal Deformations in Large Machine Tools

by Álvaro Sáinz de la Maza García, Leonardo Sastoque Pinilla and Luis Norberto López de Lacalle Marcaide

J. Manuf. Mater. Process. 2025, 9(8), 267; https://doi.org/10.3390/jmmp9080267 - 8 Aug 2025

Viewed by 122

Abstract

In sectors that require large components with tight tolerances, the control of machine thermal deformations as a result of ambient temperature variations, motor consumption, and heating of moving components is essential. There are many alternatives for modelling and trying to compensate for this [...] Read more.

In sectors that require large components with tight tolerances, the control of machine thermal deformations as a result of ambient temperature variations, motor consumption, and heating of moving components is essential. There are many alternatives for modelling and trying to compensate for this deformation, but structural components are rarely analysed independently to study their influence on positioning errors. This study analysed component temperature and deformation measurements using 49 thermocouples and 14 integral deformation sensors (IDS) installed on a large-scale machine tool. The effect of each heat source on component deformations was studied and those with a predominant effect were identified. The results can ease thermal effect prediction models development and new machine design process to maximise accuracy by focusing effort on the most critical components and most important heat sources. It was found that ambient temperature variations lead to greater but more uniform deformations than internal heat sources, reaching a 60% of total deformations with smaller temperature changes (8.7 °C, against 15–35 °C due to internal heat sources). These deformations are localized mainly in the machine bed (100

μ

m in X direction and 170

μ

m in the Y direction) and column (150

μ

m in the Z direction) and in the axis ball screw bearings (reaching 55 °C). Consequently, it is concluded that improving bearing and motor refrigeration could significantly reduce thermally-induced deformations. Full article

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Graphical abstract

14 pages, 2146 KiB

Open AccessArticle

Method for Determining the Contact and Bulk Resistance of Aluminum Alloys in the Initial State for Resistance Spot Welding

by Andreas Fezer, Stefan Weihe and Martin Werz

J. Manuf. Mater. Process. 2025, 9(8), 266; https://doi.org/10.3390/jmmp9080266 - 7 Aug 2025

Viewed by 160

Abstract

In resistance spot welding (RSW), the total electrical resistance (dynamic resistance) as the sum of bulk and contact resistance is a key variable. Both of these respective resistances influence the welding result, but the exact ratio to the total resistance of a real [...] Read more.

In resistance spot welding (RSW), the total electrical resistance (dynamic resistance) as the sum of bulk and contact resistance is a key variable. Both of these respective resistances influence the welding result, but the exact ratio to the total resistance of a real existing sheet is not known. Due to the high scatter in the RSW of aluminum alloys compared to steel, it is of interest to be able to explicitly determine the individual resistance components in order to gain a better understanding of the relationship between the initial state and the lower reproducibility of aluminum welding in the future. So far, only the total resistance and the bulk resistance could be determined experimentally. Due to the different sample shapes, it was not possible to consistently determine the contact resistance from the measurements. In order to realize this, a method was developed that contains the following innovations with the aid of simulation: determination of the absolute bulk resistance at room temperature (RT), determination of the absolute contact resistance at RT and determination of the ratio of bulk and contact resistance. This method makes it possible to compare the resistances of the bulk material and the surface in the initial state quantitatively. This now allows the comparison of batches regarding the surface resistance, especially for welding processes. For the aluminum sheets (EN AW-5182-O, EN AW-6014-T4) investigated, the method showed that the contact resistance dominates and the bulk resistance is less than 20%. These data can also be used to make predictions about the weldability of the alloy using artificial intelligence (AI). If experimental data are available, the method can also be applied to higher temperatures. Full article

(This article belongs to the Special Issue Recent Advances in Welding and Joining Metallic Materials)

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16 pages, 6254 KiB

Open AccessArticle

Influence of Alpha/Gamma-Stabilizing Elements on the Hot Deformation Behaviour of Ferritic Stainless Steel

by Andrés Núñez, Irene Collado, Marta Muratori, Andrés Ruiz, Juan F. Almagro and David L. Sales

J. Manuf. Mater. Process. 2025, 9(8), 265; https://doi.org/10.3390/jmmp9080265 - 6 Aug 2025

Viewed by 146

Abstract

This study investigates the hot deformation behaviour and microstructural evolution of two AISI 430 ferritic stainless steel variants: 0A (basic) and 1C (modified). These variants primarily differ in chemical composition, with 0A containing higher austenite-stabilizing elements (C, N) compared to 1C, which features [...] Read more.

This study investigates the hot deformation behaviour and microstructural evolution of two AISI 430 ferritic stainless steel variants: 0A (basic) and 1C (modified). These variants primarily differ in chemical composition, with 0A containing higher austenite-stabilizing elements (C, N) compared to 1C, which features lower interstitial content and slightly higher Si and Cr. This research aimed to optimize hot rolling conditions for enhanced forming properties. Uniaxial hot compression tests were conducted using a Gleeble thermo-mechanical system between 850 and 990 °C at a strain rate of 3.3 s⁻¹, simulating industrial finishing mill conditions. Analysis of flow curves, coupled with detailed microstructural characterization using electron backscatter diffraction, revealed distinct dynamic restoration mechanisms influencing each material’s response. Thermodynamic simulations confirmed significant austenite formation in both materials within the tested temperature range, notably affecting their deformation behaviour despite their initial ferritic state. Material 0A consistently exhibited a strong tendency towards dynamic recrystallization (DRX) across a wider temperature range, particularly at 850 °C. DRX led to a microstructure with a high concentration of low-angle grain boundaries and sharp deformation textures, actively reorienting grains towards energetically favourable configurations. However, under this condition, DRX did not fully complete the recrystallization process. In contrast, material 1C showed greater activity of both dynamic recovery and DRX, leading to a much more advanced state of grain refinement and recrystallization compared to 0A. This indicates that the composition of 1C helps mitigate the strong influence of the deformation temperature on the crystallographic texture, leading to a weaker texture overall than 0A. Full article

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12 pages, 4963 KiB

Open AccessArticle

Effect of Bias Voltage and Cr/Al Content on the Mechanical and Scratch Resistance Properties of CrAlN Coatings Deposited by DC Magnetron Sputtering

by Shahnawaz Alam, Zuhair M. Gasem, Nestor K. Ankah and Akbar Niaz

J. Manuf. Mater. Process. 2025, 9(8), 264; https://doi.org/10.3390/jmmp9080264 - 6 Aug 2025

Viewed by 140

Abstract

Chromium–aluminum nitride (CrAlN) coatings were deposited on polished H13 tool steel substrates using direct current (DC) magnetron sputtering. The Cr/Al composition in the target was varied by inserting either four or eight chromium (Cr) plugs into cavities machined into an aluminum (Al) plate [...] Read more.

Chromium–aluminum nitride (CrAlN) coatings were deposited on polished H13 tool steel substrates using direct current (DC) magnetron sputtering. The Cr/Al composition in the target was varied by inserting either four or eight chromium (Cr) plugs into cavities machined into an aluminum (Al) plate target. Nitrogen was introduced as a reactive gas to facilitate the formation of the nitride phase. Coatings were deposited at substrate bias voltages of −30 V, −50 V, and −60 V to study the combined effects of composition and ion energy on coating properties. Compositional analysis of coatings deposited at a −50 V bias revealed Cr/Al ratios of approximately 0.8 and 1.7 for the 4- and 8-plug configurations, respectively. This increase in the Cr/Al ratio led to a 2.6-fold improvement in coating hardness. Coatings produced using the eight-Cr-plug target exhibited a nearly linear increase in hardness with increasing substrate bias voltage. Cross-sectional scanning electron microscopy revealed a uniform bilayer structure consisting of an approximately 0.5 µm metal interlayer beneath a 2–3 µm CrAlN coating. Surface morphology analysis indicated the presence of coarse microdroplets in coatings with the lower Cr/Al ratio. These microdroplets were significantly suppressed in coatings with higher Cr/Al content, especially at increased bias voltages. This suppression is likely due to enhanced ion bombardment associated with the increased Cr content, attributed to Cr’s relatively higher atomic mass compared to Al. Coatings with lower hardness exhibited greater scratch resistance, likely due to the influence of residual compressive stresses. The findings highlight the critical role of both Cr/Al content and substrate bias in tailoring the tribo-mechanical performance of PVD CrAlN coatings for wear-resistant applications. Full article

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31 pages, 17555 KiB

Open AccessArticle

Evaluating Performance of Friction Stir Lap Welds Made at Ultra-High Speeds

by Todd Lainhart, Joshua Sheffield, Jeremy Russell, Jeremy Coyne and Yuri Hovanski

J. Manuf. Mater. Process. 2025, 9(8), 263; https://doi.org/10.3390/jmmp9080263 - 6 Aug 2025

Viewed by 259

Abstract

Friction stir lap welding has been utilized across research and industry for over a decade. However, difficulties in welding in the lap configuration without an interface-related defect have prevented the process from moving beyond low feed rates (generally less than 1.5 m per [...] Read more.

Friction stir lap welding has been utilized across research and industry for over a decade. However, difficulties in welding in the lap configuration without an interface-related defect have prevented the process from moving beyond low feed rates (generally less than 1.5 m per minute). As a means of making a huge leap in welding productivity, this study will evaluate friction stir welds made at 10 m per minute (mpm), detailing the changes to tool geometries and weld parameters that result in fully consolidated welds. Characterization of the subsequent material properties, namely through optical microscopy, CT scanning, microhardness testing, tensile and fatigue testing, hermetic seal pressure tests, and electron backscattered diffraction, is presented as a means of demonstrating the quality and repeatability of friction stir lap welds made at 10 mpm. Fully consolidated welds were produced at spindle speeds 5.5% faster and 2.9% slower than nominal values and weld depths ranging from 1% shallower to 8.2% deeper than nominal values. Additionally, the loading direction of the weld had a significant impact on tensile properties, with the advancing side of the weld measured to be 16% stronger in lap-shear tensile and 289% fatigue life improvement under all loading conditions measured when compared to the retreating side. Full article

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17 pages, 2287 KiB

Open AccessArticle

Compressive Strength Impact on Cut Depth of Granite During Abrasive Water Jet Machining

by Isam Qasem, La’aly A. Al-Samrraie and Khalideh Al Bkoor Alrawashdeh

J. Manuf. Mater. Process. 2025, 9(8), 262; https://doi.org/10.3390/jmmp9080262 - 5 Aug 2025

Viewed by 255

Abstract

Background: Compared to the conventional method of machining granite, abrasive water jet machining (AWJM) offers several benefits, including flexible cutting mechanisms and machine efficiency, among other possible advantages. The high-speed particles carried by water remove the materials, preventing heat damage and maintaining the [...] Read more.

Background: Compared to the conventional method of machining granite, abrasive water jet machining (AWJM) offers several benefits, including flexible cutting mechanisms and machine efficiency, among other possible advantages. The high-speed particles carried by water remove the materials, preventing heat damage and maintaining the granite’s structure. Methods: Three types of granite with different compressive strengths are investigated in terms of the effects of pump pressure (P), traverse speed (T), and abrasive mass flow (A) on the cutting depth. Results: The results of the study demonstrated that the coarse-grained granite negatively affected the penetration depth, while the fine-grained granite produced a higher cutting depth. The value of an optimal depth of penetration was also generated; for example, the optimum depth obtained for Black Galaxy Granite, M1 (32.27 mm), was achieved at P = 300 MPa, T = 100 mm/min, and A = 180.59 g/min. Conclusions: In terms of processing parameters, the maximum penetration depth can be achieved in granite with a higher compressive strength. Full article

(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)

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20 pages, 7843 KiB

Open AccessArticle

Effect of Ageing on a Novel Cobalt-Free Precipitation-Hardenable Martensitic Alloy Produced by SLM: Mechanical, Tribological and Corrosion Behaviour

by Inés Pérez-Gonzalo, Florentino Alvarez-Antolin, Alejandro González-Pociño and Luis Borja Peral-Martinez

J. Manuf. Mater. Process. 2025, 9(8), 261; https://doi.org/10.3390/jmmp9080261 - 4 Aug 2025

Viewed by 348

Abstract

This study investigates the mechanical, tribological, and electrochemical behaviour of a novel precipitation-hardenable martensitic alloy produced by selective laser melting (SLM). The alloy was specifically engineered with an optimised composition, free from cobalt and molybdenum, and featuring reduced nickel content (7 wt.%) and [...] Read more.

This study investigates the mechanical, tribological, and electrochemical behaviour of a novel precipitation-hardenable martensitic alloy produced by selective laser melting (SLM). The alloy was specifically engineered with an optimised composition, free from cobalt and molybdenum, and featuring reduced nickel content (7 wt.%) and 8 wt.% chromium. It has been developed as a cost-effective and sustainable alternative to conventional maraging steels, while maintaining high mechanical strength and a refined microstructure tailored to the steep thermal gradients inherent to the SLM process. Several ageing heat treatments were assessed to evaluate their influence on microstructure, hardness, tensile strength, retained austenite content, dislocation density, as well as wear behaviour (pin-on-disc test) and corrosion resistance (polarisation curves in 3.5%NaCl). The results indicate that ageing at 540 °C for 2 h offers an optimal combination of hardness (550–560 HV), tensile strength (~1700 MPa), microstructural stability, and wear resistance, with a 90% improvement compared to the as-built condition. In contrast, ageing at 600 °C for 1 h enhances ductility and corrosion resistance (Rp = 462.2 kΩ; Ecorr = –111.8 mV), at the expense of a higher fraction of reverted austenite (~34%) and reduced hardness (450 HV). This study demonstrates that the mechanical, surface, and electrochemical performance of this novel SLM-produced alloy can be effectively tailored through controlled thermal treatments, offering promising opportunities for demanding applications requiring a customised balance of strength, durability, and corrosion behaviour. Full article

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23 pages, 20324 KiB

Open AccessArticle

Hyperparameter Tuning of Artificial Neural Network-Based Machine Learning to Optimize Number of Hidden Layers and Neurons in Metal Forming

by Ebrahim Seidi, Farnaz Kaviari and Scott F. Miller

J. Manuf. Mater. Process. 2025, 9(8), 260; https://doi.org/10.3390/jmmp9080260 - 3 Aug 2025

Viewed by 283

Abstract

Cold rolling is widely recognized as a key industrial process for enhancing the mechanical properties of materials, particularly hardness, through strain hardening. Despite its importance, accurately predicting the final hardness remains a challenge due to the inherently nonlinear nature of the deformation. While [...] Read more.

Cold rolling is widely recognized as a key industrial process for enhancing the mechanical properties of materials, particularly hardness, through strain hardening. Despite its importance, accurately predicting the final hardness remains a challenge due to the inherently nonlinear nature of the deformation. While several studies have employed artificial neural networks to predict mechanical properties, architectural parameters still need to be investigated to understand their effects on network behavior and model performance, ultimately supporting the design of more effective architectures. This study investigates hyperparameter tuning in artificial neural networks trained using Resilient Backpropagation by evaluating the impact of varying number of hidden layers and neurons on the prediction accuracy of hardness in 70-30 brass specimens subjected to cold rolling. A dataset of 1000 input–output pairs, containing dimensional and hardness measurements from multiple rolling passes, was used to train and evaluate 819 artificial neural network architectures, each with a different configuration of 1 to 3 hidden layers and 4 to 12 neurons per layer. Each configuration was tested over 50 runs to reduce the influence of randomness and enhance result consistency. Enhancing the network depth from one to two hidden layers improved predictive performance. Architectures with two hidden layers achieved better performance metrics, faster convergence, and lower variation than single-layer networks. Introducing a third hidden layer did not yield meaningful improvements over two-hidden-layer architectures in terms of performance metrics. While the top three-layer model converged in fewer epochs, it required more computational time due to increased model complexity and weight elements. Full article

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15 pages, 3316 KiB

Open AccessArticle

Experimental Study on the Electromagnetic Forming Behavior of Pre-Painted Al 99.0 Sheet

by Dorin Luca, Vasile Șchiopu and Dorian D. Luca

J. Manuf. Mater. Process. 2025, 9(8), 259; https://doi.org/10.3390/jmmp9080259 - 3 Aug 2025

Viewed by 255

Abstract

Development of forming methods for surface-coated metals is a current concern due to their economic and environmental advantages. For a successful forming operation, it is necessary that both components, the substrate and the coating, are able to withstand stress without damage until the [...] Read more.

Development of forming methods for surface-coated metals is a current concern due to their economic and environmental advantages. For a successful forming operation, it is necessary that both components, the substrate and the coating, are able to withstand stress without damage until the final shape and dimensions are reached. This goal can be achieved through good knowledge of the elastic and plastic properties of the substrate and the coating, the compatibility between them, the appropriate surface treatment, and the rigorous control of technological forming parameters. Our study was carried out with flat specimens of pre-painted Al 99.0 sheet that were electromagnetically formed by bulging. Forming behavior was investigated as depending on the initial thickness of the substrate, on the aluminum sheet pretreatment, as well as on the plastic deformation path of the metal–paint structure. To verify the damage to the paint layer, tests with increasing strains were performed, and the interface between the metal and the coating layer was investigated by scanning electron microscopy. The obtained results indicate that electromagnetic forming of pre-painted sheets can be a feasible method for specific applications if the forming degree of the substrate is tightly correlated with the type of desired coating and with the pretreatment method used for the metal surface. Full article

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19 pages, 4156 KiB

Open AccessArticle

Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters

by Emin O. Bastekeli, Haci A. Tasdemir, Adil Yucel and Buse Ortac Bastekeli

J. Manuf. Mater. Process. 2025, 9(8), 258; https://doi.org/10.3390/jmmp9080258 - 1 Aug 2025

Viewed by 262

Abstract

In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber [...] Read more.

In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber laser (λ = 1064 nm, spot size = 0.05 mm) was used, and Ø1.6 mm × 20 mm cylindrical rods were processed under ambient conditions without auxiliary cooling. The experimental framework systematically evaluated the influence of scanning speed, pulse frequency, and the number of laser passes on dimensional accuracy and material removal efficiency. The results indicate that a maximum diameter reduction of 0.271 mm was achieved at a scanning speed of 3200 mm/s and 50 kHz, whereas 0.195 mm was attained at 6400 mm/s and 200 kHz. A robust second-order polynomial correlation (R² = 0.99) was established between diameter reduction and the number of passes, revealing the high predictability of the process. Crucially, when the scanning speed was doubled, the effective fluence was halved, considerably influencing the ablation characteristics. Despite the low fluence, evidence of material evaporation at elevated frequencies due to the incubation effect underscores the complex photothermal dynamics governing the process. This work constitutes the first comprehensive quantification of pass-dependent diameter modulation in DLBT and introduces a transformative, noncontact micromachining strategy for hard-to-machine alloys. The demonstrated precision, repeatability, and thermal control position DLBT as a promising candidate for next-generation manufacturing of high-performance miniaturized components. Full article

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32 pages, 5560 KiB

Open AccessArticle

Design of Reconfigurable Handling Systems for Visual Inspection

by Alessio Pacini, Francesco Lupi and Michele Lanzetta

J. Manuf. Mater. Process. 2025, 9(8), 257; https://doi.org/10.3390/jmmp9080257 - 31 Jul 2025

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Abstract

Industrial Vision Inspection Systems (VISs) often struggle to adapt to increasing variability of modern manufacturing due to the inherent rigidity of their hardware architectures. Although the Reconfigurable Manufacturing System (RMS) paradigm was introduced in the early 2000s to overcome these limitations, designing such [...] Read more.

Industrial Vision Inspection Systems (VISs) often struggle to adapt to increasing variability of modern manufacturing due to the inherent rigidity of their hardware architectures. Although the Reconfigurable Manufacturing System (RMS) paradigm was introduced in the early 2000s to overcome these limitations, designing such reconfigurable machines remains a complex, expert-dependent, and time-consuming task. This is primarily due to the lack of structured methodologies and the reliance on trial-and-error processes. In this context, this study proposes a novel theoretical framework to facilitate the design of fully reconfigurable handling systems for VISs, with a particular focus on fixture design. The framework is grounded in Model-Based Definition (MBD), embedding semantic information directly into the 3D CAD models of the inspected product. As an additional contribution, a general hardware architecture for the inspection of axisymmetric components is presented. This architecture integrates an anthropomorphic robotic arm, Numerically Controlled (NC) modules, and adaptable software and hardware components to enable automated, software-driven reconfiguration. The proposed framework and architecture were applied in an industrial case study conducted in collaboration with a leading automotive half-shaft manufacturer. The resulting system, implemented across seven automated cells, successfully inspected over 200 part types from 12 part families and detected more than 60 defect types, with a cycle below 30 s per part. Full article

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14 pages, 1863 KiB

Open AccessArticle

Advancements in Hole Quality for AISI 1045 Steel Using Helical Milling

by Pedro Mendes Silva, António José da Fonseca Festas, Robson Bruno Dutra Pereira and João Paulo Davim

J. Manuf. Mater. Process. 2025, 9(8), 256; https://doi.org/10.3390/jmmp9080256 - 31 Jul 2025

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Abstract

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, [...] Read more.

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, remains underexplored in the literature. This study addresses this gap by systematically evaluating the influence of key process parameters—cutting speed (V_c), axial depth of cut (a_p), and tool diameter (D_t)—on hole quality attributes, including surface roughness, burr formation, and nominal diameter accuracy. A full factorial experimental design (2³) was employed, coupled with analysis of variance (ANOVA), to quantify the effects and interactions of these parameters. The results reveal that, with a higher V_c, it is possible to reduce surface roughness (R_a) by 30% to 40%, while an increased a_p leads to a 50% increase in R_a. Additionally, D_t emerged as the most critical factor for nominal diameter accuracy, reducing geometrical errors by 1% with a larger D_t. Burr formation was predominantly observed at the lower end of the hole, highlighting challenges specific to this technique. These findings provide valuable insights into optimizing helical milling for low-carbon steels, offering a foundation for broader industrial adoption and further research. Full article

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16 pages, 3072 KiB

Open AccessArticle

Process Development to Repair Aluminum Components, Using EHLA and Laser-Powder DED Techniques

by Adrienn Matis, Min-Uh Ko, Richard Kraft and Nicolae Balc

J. Manuf. Mater. Process. 2025, 9(8), 255; https://doi.org/10.3390/jmmp9080255 - 31 Jul 2025

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Abstract

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. [...] Read more.

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. To optimize the process parameters, single-track depositions were analyzed for both laser-powder DED (feed rate of 2 m/min) and EHLA (feed rate 20 m/min) for AlSi10Mg and Al6061 powders. The cross-sections of single tracks revealed the bonding characteristics and provided laser-powder DED, a suitable parameter selection for the repair. Three damage types were identified on the Al component to define the specification of the repair process and to highlight the capabilities of laser-powder DED and EHLA in repairing intricate surface scratches and dents. Our research is based on variation of the powder mass flow and beam power, studying the influence of these parameters on the weld bead geometry and bonding quality. The evaluation criteria include bonding defects, crack formation, porosity, and dilution zone depth. The bidirectional path planning strategy was applied with a fly-in and fly-out path for the hatching adjustment and acceleration distance. Samples were etched for a qualitative microstructure analysis, and the HV hardness was tested. The novelty of the paper is the new process parameters for laser-powder DED and EHLA deposition strategies to repair large Al components (6061 T6), using AlSi10Mg and Al6061 powder. Our experimental research tested the defect-free deposition and the compatibility of AlSi10Mg on the Al6061 substrate. The readers could replicate the method presented in this article to repair by laser-powder DED/EHLA large Al parts and avoid the replacement of Al components with new ones. Full article

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21 pages, 4865 KiB

Open AccessArticle

Impact of Laser Power and Scanning Speed on Single-Walled Support Structures in Powder Bed Fusion of AISI 316L

by Dan Alexander Gallego, Henrique Rodrigues Oliveira, Tiago Cunha, Jeferson Trevizan Pacheco, Oksana Kovalenko and Neri Volpato

J. Manuf. Mater. Process. 2025, 9(8), 254; https://doi.org/10.3390/jmmp9080254 - 30 Jul 2025

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Abstract

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing [...] Read more.

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing processes, L-PBF stands out, paving the way for the execution of part designs with geometries previously considered unfeasible. Despite offering several advantages, parts with overhang features require the use of support structures to provide dimensional stability of the part. Support structures achieve this by resisting residual stresses generated during processing and assisting heat dissipation. Although the scientific community acknowledges the role of support structures in the success of L-PBF manufacturing, they have remained relatively underexplored in the literature. In this context, the present work investigated the impact of laser power and scanning speed on the dimensioning, integrity and tensile strength of single-walled block type support structures manufactured in AISI 316L stainless steel. The method proposed in this work is divided in two stages: processing parameter exploration, and mechanical characterization. The results indicated that support structures become more robust and resistant as laser power increases, and the opposite effect is observed with an increment in scanning speed. In addition, defects were detected at the interfaces between the bulk and support regions, which were crucial for the failure of the tensile test specimens. For a layer thickness corresponding to 0.060 mm, it was verified that the combination of laser power and scanning speed of 150 W and 500 mm/s resulted in the highest tensile resistance while respecting the dimensional deviation requirement. Full article

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

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22 pages, 3504 KiB

Open AccessArticle

Improving Geometric Formability in 3D Paper Forming Through Ultrasound-Assisted Moistening and Radiative Preheating for Sustainable Packaging

by Heike Stotz, Matthias Klauser, Johannes Rauschnabel and Marek Hauptmann

J. Manuf. Mater. Process. 2025, 9(8), 253; https://doi.org/10.3390/jmmp9080253 - 26 Jul 2025

Viewed by 379

Abstract

In response to increasing sustainability demands, the packaging industry is shifting toward paper-based alternatives to replace polymer packaging. However, achieving complex, three-dimensional geometries comparable to plastics remains challenging due to the limited stretchability of paper. This study investigates advanced preconditioning techniques to enhance [...] Read more.

In response to increasing sustainability demands, the packaging industry is shifting toward paper-based alternatives to replace polymer packaging. However, achieving complex, three-dimensional geometries comparable to plastics remains challenging due to the limited stretchability of paper. This study investigates advanced preconditioning techniques to enhance the formability of paper materials for deep-draw packaging applications. A custom-built test rig was developed at Syntegon Technology GmbH to systematically evaluate the effects of ultrasound-assisted moistening and segmented radiative heating. Under optimized conditions, 2.67 s moistening, 70.00 °C punch temperature, and 2999 W radiation power, maximum stretchability increased from 13.00% to 26.93%. The results confirm the effectiveness of ultrasound in accelerating moisture uptake and radiation heating in achieving uniform thermal distribution across the paper substrate. Although prototype constraints, such as the absence of inline conditioning and real-time measurement, limit process stability and scalability, the findings provide a strong foundation for developing industrial 3D paper forming processes that support sustainable packaging innovation. Full article

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21 pages, 4393 KiB

Open AccessArticle

Lightweight and Sustainable Steering Knuckle via Topology Optimization and Rapid Investment Casting

by Daniele Almonti, Daniel Salvi, Emanuele Mingione and Silvia Vesco

J. Manuf. Mater. Process. 2025, 9(8), 252; https://doi.org/10.3390/jmmp9080252 - 24 Jul 2025

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Abstract

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing [...] Read more.

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing and manufacturing a MacPherson steering knuckle using topology optimization (TO), additive manufacturing, and rapid investment casting (RIC). Static structural simulations confirmed the mechanical integrity of the optimized design, with stress and strain values remaining within the elastic limits of the SG A536 iron alloy. The TO process achieved a 30% reduction in mass, resulting in lower material use and production costs. Additive manufacturing of optimized geometry reduced resin consumption by 27% and printing time by 9%. RIC simulations validated efficient mold filling and solidification, with porosity confined to removable riser regions. Life cycle assessment (LCA) demonstrated a 27% reduction in manufacturing environmental impact and a 31% decrease throughout the component life cycle, largely due to vehicle lightweighting. The findings highlight the potential of integrated TO and advanced manufacturing techniques to produce structurally efficient and environmentally sustainable automotive components. This workflow offers promising implications for broader industrial applications that aim to balance mechanical performance with ecological responsibility. Full article

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22 pages, 11182 KiB

Open AccessArticle

Application of Laser Thermal Deformation Sintering in the Manufacture of Drum-Type Diamond Tools

by Oleksii Kaglyak, Leonid Golovko, Oleksii Goncharuk, Svitlana Voloshko, Oleksandr Kapustynskyi and Nikolaj Višniakov

J. Manuf. Mater. Process. 2025, 9(8), 251; https://doi.org/10.3390/jmmp9080251 - 24 Jul 2025

Viewed by 395

Abstract

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological [...] Read more.

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological parameters of the laser irradiation process are characterized, which determine the range of laser processing modes within which no oxidation and crack formation occur, and a high-quality composite with specified geometrical parameters is formed. It has been proven that composites consisting of synthetic diamond grains and a metal bond do not lose strength under the condition that the temperature during laser heating does not exceed 1600 °C and the exposure time is 0.3 s. Electron microscopy and X-ray diffractometry were used for experimental studies of the microstructure and phase composition of the sintered layers. A new design and manufacturing method for a drum-type abrasive tool with replaceable diamond inserts for grinding large-sized aircraft and shipbuilding products are proposed. Components of a laser technological complex for the implementation of the process of sintering the diamond-containing layer of the abrasive inserts of the drum have been developed. Full article

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19 pages, 2311 KiB

Open AccessArticle

Stochastic Optimization of Quality Assurance Systems in Manufacturing: Integrating Robust and Probabilistic Models for Enhanced Process Performance and Product Reliability

by Kehinde Afolabi, Busola Akintayo, Olubayo Babatunde, Uthman Abiola Kareem, John Ogbemhe, Desmond Ighravwe and Olanrewaju Oludolapo

J. Manuf. Mater. Process. 2025, 9(8), 250; https://doi.org/10.3390/jmmp9080250 - 23 Jul 2025

Viewed by 439

Abstract

This research integrates stochastic optimization techniques with robust modeling and probabilistic modeling approaches to enhance photovoltaic cell manufacturing processes and product reliability. The study employed an adapted genetic algorithm to tackle uncertainties in the manufacturing process, resulting in improved operational efficiency. It consistently [...] Read more.

This research integrates stochastic optimization techniques with robust modeling and probabilistic modeling approaches to enhance photovoltaic cell manufacturing processes and product reliability. The study employed an adapted genetic algorithm to tackle uncertainties in the manufacturing process, resulting in improved operational efficiency. It consistently achieved optimal fitness, with values remaining at 1.0 over 100 generations. The model displayed a dynamic convergence rate, demonstrating its ability to adjust performance in response to process fluctuations. The system preserved resource efficiency by utilizing approximately 2600 units per generation, while minimizing machine downtime to 0.03%. Product reliability reached an average level of 0.98, with a maximum value of 1.02, indicating enhanced consistency. The manufacturing process achieved better optimization through a significant reduction in defect rates, which fell to 0.04. The objective function value fluctuated between 0.86 and 0.96, illustrating how the model effectively managed conflicting variables. Sensitivity analysis revealed that changes in sigma material and lambda failure had a minimal effect on average reliability, which stayed above 0.99, while average defect rates remained below 0.05. This research exemplifies how stochastic, robust, and probabilistic optimization methods can collaborate to enhance manufacturing system quality assurance and product reliability under uncertain conditions. Full article

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55 pages, 8888 KiB

Open AccessArticle

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

Viewed by 732

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

Open AccessReview

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

Viewed by 441

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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J. Manuf. Mater. Process., Volume 9, Issue 8 (August 2025) – 28 articles

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