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Applied Sciences
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Advanced Manufacturing Processes: Technologies and Applications
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Advanced Manufacturing Processes: Technologies and Applications

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 31 May 2025 | Viewed by 5355

Special Issue Editors

Dr. Gustavo H. S. F. L. Carvalho

E-Mail Website
Guest Editor
1. Department of Industrial Engineering, University of Florence, Via di Santa Marta 3, 50139 Firenze, Italy
2. CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788 Coimbra, Portugal
Interests: explosive welding; welding; additive manufacturing; WAAM; metallurgy; metallurgical characterization
Special Issues, Collections and Topics in MDPI journals
Dr. Ivan Galvão

E-Mail Website
Guest Editor
1. ISEL, Department of Mechanical Engineering, Polytechnic Institute of Lisbon, Rua Conselheiro Emídio Navarro, 1959-007 Lisboa, Portugal
2. CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788 Coimbra, Portugal
Interests: solid-state welding; friction stir welding; explosion welding; dissimilar materials welding; solid-state processing
Special Issues, Collections and Topics in MDPI journals
Dr. Rui Manuel Leal

E-Mail Website
Guest Editor
1. ESAD.CR, Polytechnic Institute of Leiria, Rua Isidoro Inácio Alves de Carvalho, 2500-321 Caldas da Rainha, Portugal
2. CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos, 3030-788 Coimbra, Portugal
Interests: welding technology; processing technology; microstructural and mechanical characterization; friction stir welding; explosion welding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The current advancement of all engineering fields and the emergence of individualized applications with stricter requirements increase the need to improve the current manufacturing processes or even develop new manufacturing processes capable of delivering the required features for each specific application. This development creates the need for new research areas addressing these novel and developing processes, which usually differ from current and conventional ones. Therefore, there is a need for specific research regarding these processes, not only from a process point of view, but also including research addressing material science and characterizations, corrosion properties, numerical simulations, case studies, and so on, related to these processes.

This Special Issue will publish high-quality, original research and review papers addressing manufacturing processes that have been developed more recently or that present new features or variations regarding conventional processes. Some examples include additive manufacturing technologies, solid-state welding processes (e.g., friction stir welding, explosive welding, and magnetic pulse welding), advanced fusion welding and coating processes, powder metallurgy, and machining, among others. Many aspects related to these processes may be addressed, such as process development, metallurgical characterization, machining, tool wear, corrosion resistance, industrial applications, case studies, improvements in energy efficiency, sustainability and environmental impact, heat treatment and post-processing, surface analysis, and numerical modeling and simulation.

Dr. Gustavo H. S. F. L. Carvalho
Dr. Ivan Galvão
Dr. Rui Manuel Leal
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • solid-state welding
  • impact welding processes
  • explosive welding
  • magnetic pulse welding
  • diffusion bonding
  • advanced fusion welding processes
  • powder metallurgy/sintering
  • machining, numerical modelling and simulation

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (5 papers)

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Research

16 pages, 6973 KiB  
Article
Optimization of the Tool Influence Function for Small Tool Polishing Based on the Control of Polishing Pressure Distribution
by Qixin Li, Zhen Ma, Yongsheng Yao, Jiaoteng Ding and Xiangmin Jiang
Appl. Sci. 2025, 15(6), 3044; https://doi.org/10.3390/app15063044 - 11 Mar 2025
Viewed by 587
Abstract
In ultra-precision optical components polishing, the shape of the Tool Influence Function (TIF) is an important factor that affects the processing efficiency and processing accuracy of optical components. For a self-rotating small tool polishing device commonly used in computer-controlled optical surfacing (CCOS), its [...] Read more.
In ultra-precision optical components polishing, the shape of the Tool Influence Function (TIF) is an important factor that affects the processing efficiency and processing accuracy of optical components. For a self-rotating small tool polishing device commonly used in computer-controlled optical surfacing (CCOS), its TIF deviates from the Gaussian shape, and the processing is prone to cause surface figure divergence. Inspired by the theory of eccentric compression, this paper proposes a method to optimize the shape of the TIF based on pressure distribution control. Based on the finite element method, a contact pressure distribution model is established. The influence of different positions of the pressure contact points on the contact pressure distribution is analyzed, and the position of the pressure application point that makes the TIF close to the Gaussian shape is determined. On this basis, a new type of small tool polishing device that can realize the above optimization method is designed. The optimized actual TIF is obtained, and an aspheric mirror processing experiment is completed. After three rounds of processing, the value of PV of the surface form error converged from 1861.180 nm to 64.875 nm, with a convergence rate of 96.5%. The value of RMS converged from 299.857 nm to 6.043 nm, with a convergence rate of 97.9%. The surface figure accuracy has reached the expected goal with the root mean square value less than 10 nm, which verifies the feasibility and effectiveness of this optimization method. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes: Technologies and Applications)
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13 pages, 3590 KiB  
Article
Study on the Ablation Behavior of High-Intensity Lasers in Vacuum
by Heyan Gao, Ying Wang, Jifei Ye, Bangdeng Du, Diankai Wang, Sai Li, Qianqian Cui, Sibo Wang and Tengfei Zhang
Appl. Sci. 2025, 15(2), 848; https://doi.org/10.3390/app15020848 - 16 Jan 2025
Viewed by 1003
Abstract
Laser ablation has been extensively studied by researchers due to its high precision, high efficiency processing capabilities, and wide range of application potentials. However, in a vacuum environment, due to the complexity of experimental conditions, specific application scenarios, and interdisciplinary interferences, more in-depth [...] Read more.
Laser ablation has been extensively studied by researchers due to its high precision, high efficiency processing capabilities, and wide range of application potentials. However, in a vacuum environment, due to the complexity of experimental conditions, specific application scenarios, and interdisciplinary interferences, more in-depth research on the ablation behavior of high-intensity lasers in vacuum is still insufficient. In response to such issues, experiments were conducted on titanium alloy perforation using a nanosecond laser in a vacuum environment. The variations in ablation depth and volume as functions of pulse energy, pulse number, and defocus were investigated. Both the depth and volume ablation efficiencies were calculated, and the three-dimensional morphology of the ablation holes was captured. Additionally, the ablation plume was observed to support the research conclusions. The results indicate that within the number of high-intensity laser pulses, the ablation depth per pulse can be increased by more than four times, and the average ablation volume per pulse can reach 0.97 µm3/µJ. The enhanced sputtering of molten material during the multi-pulse laser ablation process in a vacuum environment is identified as the primary factor contributing to the increased ablation efficiency. With the advancement of science and technology and the growing demand for applications, this research is crucial for the further development of fields such as space exploration and technology, advanced manufacturing technology, and basic scientific research. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes: Technologies and Applications)
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17 pages, 7903 KiB  
Article
Analysis of Crack Initiation in Hot Forging Process with the Support of the Digital Image Correlation System
by Łukasz Lisiecki, Paulina Lisiecka-Graca and Nikolaos E. Karkalos
Appl. Sci. 2025, 15(1), 408; https://doi.org/10.3390/app15010408 - 4 Jan 2025
Viewed by 825
Abstract
The limits of plastic deformation without failure are considered to be a measure of formability and can be estimated by the standard tests. However, the mechanical states observed during commonly used compression tests are similar to those observed in many bulk deformation processes, [...] Read more.
The limits of plastic deformation without failure are considered to be a measure of formability and can be estimated by the standard tests. However, the mechanical states observed during commonly used compression tests are similar to those observed in many bulk deformation processes, with an additional advantage of those tests having the possibility of applying large deformations without the risk of the appearance of necking (in tension) or material reorientation (in torsion). Thus, this study presents the results of modified compression tests under conditions of a real forging process, since knowledge of the geometrical parameters of the tools and samples makes it possible to determine the areas of stress concentration which contribute to the formation of controlled cracks. The digital image correlation system (DIC) was used to analyze the deformation parameters that lead to achieving the critical values of fracture criterion; simulations were additionally performed to confirm the reliability of predicting the location and the critical moment just before failure in the forging process under consideration. After the accuracy of the model was verified, this approach was applied to a case of backward extrusion, also correctly predicting the locations with high probability of fracture. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes: Technologies and Applications)
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16 pages, 15909 KiB  
Article
Microstructure Evolution and Forming Characteristics of Post-Weld Composite Treatment of 6061 Aluminum Alloy Tailor Welded Blanks
by Xiaonan Dong, Gang Song and Liming Liu
Appl. Sci. 2024, 14(19), 8998; https://doi.org/10.3390/app14198998 - 6 Oct 2024
Viewed by 1229
Abstract
The mechanical properties and cross-sectional geometric dimensions of the fusion zone (FZ), heat affected zone (HAZ), and base metal (BM) of 6xxx series aluminum alloys are inconsistent after filler wire welding, which reduces the formability of aluminum alloy tailor welded blanks (TWBs). This [...] Read more.
The mechanical properties and cross-sectional geometric dimensions of the fusion zone (FZ), heat affected zone (HAZ), and base metal (BM) of 6xxx series aluminum alloys are inconsistent after filler wire welding, which reduces the formability of aluminum alloy tailor welded blanks (TWBs). This paper proposes a post-weld cold rolling-solution heat treatment (PWCR-SHT) composite process, and the effects of weld excess metal, plastic deformation, and SHT on the formability of aluminum alloy TWBs are studied. The results show that the PWCR-SHT composite process eliminates the weld excess metal and internal pores, reduces the stress concentration at the weld toe, eliminates the local strain hardening behavior, and causes recrystallization in the FZ region. The cupping value of aluminum alloy TWBs using SHT is 105% of BM, in comparison, the cupping value of aluminum alloy TWBs using the PWCR-SHT composite process is 119% of BM, which is the result of the combined effect of geometric dimensions consistency and mechanical properties consistency. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes: Technologies and Applications)
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20 pages, 3756 KiB  
Article
Research on Critical Quality Feature Recognition and Quality Prediction Method of Machining Based on Information Entropy and XGBoost Hyperparameter Optimization
by Dongyue Qu, Chaoyun Gu, Hao Zhang, Wenchao Liang, Yuting Zhang and Yong Zhan
Appl. Sci. 2024, 14(18), 8317; https://doi.org/10.3390/app14188317 - 15 Sep 2024
Viewed by 1207
Abstract
To address the problem of predicting machining quality for critical features in the manufacturing process of mechanical products, a method that combines information entropy and XGBoost (version 2.1.1) hyperparameter optimization is proposed. Initially, machining data of mechanical products are analyzed based on information [...] Read more.
To address the problem of predicting machining quality for critical features in the manufacturing process of mechanical products, a method that combines information entropy and XGBoost (version 2.1.1) hyperparameter optimization is proposed. Initially, machining data of mechanical products are analyzed based on information entropy theory to identify critical quality characteristics. Subsequently, a quality prediction model for these critical features is established using the XGBoost machine learning framework. The model’s hyperparameters are then optimized through Bayesian optimization. This method is applied as a case study to a medium-speed marine diesel engine piston. After the critical quality characteristics in the machining process are identified, the machining quality of these vital characteristics is predicted, and the results are compared with those obtained from a machine learning model without hyperparameter optimization. The findings demonstrate that the proposed method effectively predicts the machining quality of mechanical products. Full article
(This article belongs to the Special Issue Advanced Manufacturing Processes: Technologies and Applications)
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