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

September 2025 - 37 articles

Cover Story: This study investigates how stirring pin geometry influences weld quality and microstructure in wire-based friction-stir additive manufacturing (W-FSAM) of EN AW-6063 aluminium. Using a custom tool, four probe configurations (0–3 pins) were tested. The two-stirring-probe design achieved the best layer adhesion and a smooth, pore-free surface. A five-layer wall fabricated with this setup showed strong metallurgical bonding and grain refinement to about one quarter of the substrate grain size, indicating dynamic recrystallisation. Mechanical tests revealed tensile strengths up to 147 MPa (≈77% of filler wire strength) with 10% elongation. These findings demonstrate the potential of W-FSAM to produce high-quality, lightweight aluminium components with refined microstructures and reliable performance. View this paper
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Articles (37)

  • Article
  • Open Access
711 Views
16 Pages

This study introduces an integrated framework combining Artificial Neural Networks (ANN) and Genetic Algorithms (GA) to optimize quality in multi-component product assemblies. The novelty of this work lies in its closed-loop structure: ANN is used to...

  • Article
  • Open Access
776 Views
16 Pages

Refined Cost Calculation Framework for FDM Parts

  • Bálint Leon Seregi and
  • Péter Ficzere

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) technology, favored for its design flexibility and suitability for low-volume production. However, precise cost estimation remains a critical challenge, particularly in indu...

  • Article
  • Open Access
790 Views
18 Pages

Upcycling of Copper Scrap into High-Quality Powder for Additive Manufacturing: Processing, Characterization, and Sustainability Assessment

  • Mattia Cabrioli,
  • María Silva Colmenero,
  • Sepideh Gholamzadeh,
  • Matteo Vanazzi,
  • Sasan Amirabdollahian,
  • Matteo Perini,
  • Wojciech Łacisz and
  • Bartosz Kalicki

Copper is a critical material for energy transition and green technologies, making its sustainable use increasingly important. Its superior thermal and electrical conductivity make it highly well-suited for additive manufacturing (AM). In this study,...

  • Article
  • Open Access
551 Views
15 Pages

The unique cutting–burnishing coupling effect in BTA deep hole drilling generates a high-hardness and -brittleness white layer (ultrafine martensitic layer), which will degrade component performance and accelerate tool wear. This work investiga...

  • Article
  • Open Access
554 Views
15 Pages

Injection Performance of UHMWPE in Micro-Discs for Prosthetic Applications Using SLA Molds

  • Rossella Surace,
  • Francesco Modica,
  • Vito Basile,
  • Vincenzo Bellantone and
  • Irene Fassi

Ultra-high molecular weight polyethylene (UHMWPE) is widely used in orthopedic and prosthetic applications due to its excellent wear resistance and biocompatibility. However, its high molecular weight presents significant challenges in terms of proce...

  • Article
  • Open Access
492 Views
23 Pages

In this study, the maximum achievable weldable thickness in spot welding with pinless tools was investigated by welding multiple stacks of 1 mm thick high-strength steel HC420LA. This approach allowed for the evaluation of heat dissipation during the...

  • Article
  • Open Access
573 Views
20 Pages

Increasing the Wear Resistance of Stainless Steel Products by Depositing Modifying Coatings Based on Zirconium Nitride with the Addition of Niobium, Hafnium, and Titanium

  • Sergey Grigoriev,
  • Marina Volosova,
  • Catherine Sotova,
  • Filipp Milovich,
  • Anton Seleznev,
  • Kirill Makarevich,
  • Pavel Potapov and
  • Alexey Vereschaka

To increase wear resistance, (Zr,Nb)N, ZrN and (Zr,Hf)N coatings with columnar structures and (Zr,Ti)N and (Zr,Nb,Hf)N coatings with nanolayer structures were deposited on an AISI 321 stainless steel substrate. The samples with (Zr,Nb)N and ZrN coati...

  • Article
  • Open Access
742 Views
15 Pages

Thermomechanical Properties of Sustainable Polymer Composites Incorporating Agricultural Wastes

  • Emmanuel Kwaku Aidoo,
  • Abubakar Sumaila,
  • Maryam Jahan,
  • Guoqiang Li and
  • Patrick Mensah

Polymer matrix composites have been used extensively in the aerospace and automotive industries. Nevertheless, the growing demand for composites raises concerns about the thermal stability, cost, and environmental impacts of synthetic fillers like gr...

  • Article
  • Open Access
891 Views
26 Pages

This study investigates multi-objective optimization of end-milling parameters for AISI D2 cold-worked tool steel using GC1130-coated carbide inserts under wet machining, focusing on cutting speed and feed rate per tooth values beyond manufacturer re...

  • Article
  • Open Access
2,862 Views
17 Pages

Microfluidic device prototyping demands rapid, cost-effective, and high-precision mould fabrication, yet ultrashort pulsed laser structuring of polymer inserts remains underexplored. This study presents a novel method for fabricating microfluidic mou...

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J. Manuf. Mater. Process. - ISSN 2504-4494Creative Common CC BY license