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Processing, Manufacturing and Machining of Advanced Alloy Materials: Latest Advances and Prospects, Second Edition

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

Deadline for manuscript submissions: 20 December 2026 | Viewed by 2056

Special Issue Editors


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Guest Editor
Department of Production Engeneering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: magnesium alloys; milling; machinability indicators; machining
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of Production Engeneering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: surface roughness; surface topography; vibratory shot peening; finishing treatment; burnishing; microhardness
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, 12 Powstancow Warszawy Str., 35-959 Rzeszow, Poland
Interests: milling; turning, difficult-to-cut materials; sustainable machining; CNC programming; machining process optimization
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Institute of Machine Tools and Machine Building Technology, Lodz University of Technology, 90-924 Lodz, Poland
Interests: measurement; methrology; infrared camera; thermographic analyse; machining processes; engineering; materials science; metallurgy and metallurgical engineering

Special Issue Information

Dear Colleagues,

Advanced Alloy Materials include both titanium, nickel, and chromium alloys, as well as light alloys, including aluminum and magnesium alloys. Each material group finds different applications in various industries. For example, titanium or nickel alloys are used for components such as aircraft engines elements. On the other hand light alloys (e.g. magnesium alloys), characterised by insignificant weight and considerable strength, find increasingly wider application as weight-saving elements. In the case of magnesium alloys, properties such as are considered beneficial excellent electromagnetic shielding, advantageous casting properties, good machinability, the ability to damp vibrations, recyclability as well as accessibility.

Starting from the 1970s, attempts have been made to define recommended machinability parameters for different alloys, including difficult-to-machine materials and lights alloys. Problems occurring in the manufacturing and machining of various groups of materials may have various causes. For example the problems occurring in the milling of magnesium alloys can be classified depending on the type of machining (i.e., dry, wet, or with oil). In dry machining, the critical machinability indicator is the temperature in the cutting zone. However magnesium alloys have proven to be suitable for both rough, finish, and precision machining.

For the above reasons, it seems advisable to collect the most important information about this topic.

Dr. Ireneusz Zagórski
Dr. Agnieszka Skoczylas
Prof. Dr. Witold Habrat
Dr. Piotr Zgórniak
Guest Editors

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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

  • machinability
  • aviation alloys
  • difficult-to-machine materials
  • light alloys
  • machinability indicators
  • surface roughness
  • cutting forces
  • vibrations
  • temperature in the cutting area
  • structure after processing
  • microhardness

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Published Papers (4 papers)

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Research

29 pages, 5472 KB  
Article
Chip Temperature in Dry Rough Milling of Magnesium Alloys Using Different Rake-Angle Tools
by Ireneusz Zagórski, Piotr Zgórniak, Monika Kulisz and Witold Habrat
Appl. Sci. 2026, 16(4), 1750; https://doi.org/10.3390/app16041750 - 10 Feb 2026
Viewed by 319
Abstract
This study examines how variations in cutting parameters and end mill rake-angle affect chip-temperature in the cutting zone. This study describes a method involving end mills with varying rake angles to measure the temperature of chips in the cutting zone during the dry [...] Read more.
This study examines how variations in cutting parameters and end mill rake-angle affect chip-temperature in the cutting zone. This study describes a method involving end mills with varying rake angles to measure the temperature of chips in the cutting zone during the dry rough milling of magnesium alloys. The chip temperature is determined by infrared spectroscopy. The influence of milling parameters (i.e., cutting speed, feed per tooth, and depth-of-cut) on the maximum chip temperature was analyzed. Box plots, bar charts, and 2D graphs are used to display the chip temperatures. We address issues that come up while recording a signal with an average emissivity coefficient value and how to resolve them. The tests yielded chip temperatures that were not higher than 366 °C. Thus, for a variety of machining parameters, the dry roughing milling procedure using carbide tools with different rake angles can be deemed safe. The proposed approach to detecting the chip temperature and processing findings constitutes a novel and efficient way for evaluating safety in the dry milling of magnesium alloys. Full article
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19 pages, 5836 KB  
Article
Assessment of the Influence of Electro Slag Remelting on the Purity and Mechanical Properties of Structural Steel
by Josef Walek, Petr Opěla, František Vrána and Radim Kocich
Appl. Sci. 2026, 16(3), 1366; https://doi.org/10.3390/app16031366 - 29 Jan 2026
Viewed by 426
Abstract
Electro slag remelting steel is a technology of tertiary metallurgy that can be used in the production of special structural steels where high purity is required to influence the quality of the final products. This work deals with the evolution of steel purity [...] Read more.
Electro slag remelting steel is a technology of tertiary metallurgy that can be used in the production of special structural steels where high purity is required to influence the quality of the final products. This work deals with the evolution of steel purity comparing vacuum degassing (VD) and electro slag remelting (ESR) technologies in terms of the chemical composition of non-metallic inclusions and their morphology. The present work primarily studies the creep behavior of special structural steel at two different initial material states (VD and ESR steel) tested in the range from 450 to 650 °C. A rather unique plastometric experimental methodology of accelerated creep testing, which consists of a slow plastic deformation of a material under long-term stress at an elevated temperature, was used to study the behavior of the prepared specimens. The results show that, after remelting the steel, there was an increase in micropurity due to a reduction in the average size and, in particular, a reduction in the maximum size of non-metallic inclusions. The results of creep behavior show a particular difference at 600 °C, where ESR steel shows higher relaxation phase stress values as well as higher creep strength factor values compared with VD steel. Full article
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25 pages, 8139 KB  
Article
Explicit FEM Analysis of Soil–Disc Interaction for APS-Coated Notched Harrow Discs in Representative Agricultural Soils
by Corneliu Munteanu, Ana Tufescu, Fabian Cezar Lupu, Bogdan Istrate, Marcelin Benchea, Iurie Melnic, Vitali Vișanu and Vlad Nicolae Arsenoaia
Appl. Sci. 2026, 16(1), 395; https://doi.org/10.3390/app16010395 - 30 Dec 2025
Viewed by 508
Abstract
The present work develops an explicit dynamic finite element model of soil–disc interaction for a notched harrow disc, aiming to quantify how APS coatings, soil type and disc–soil friction influence stresses in the disc and surrounding soil. The model reproduces a four-gang offset [...] Read more.
The present work develops an explicit dynamic finite element model of soil–disc interaction for a notched harrow disc, aiming to quantify how APS coatings, soil type and disc–soil friction influence stresses in the disc and surrounding soil. The model reproduces a four-gang offset harrow operating at 7 km/h, 0.15 m working depth, with 18°disc angle and 15° tilt angle, and compares an uncoated steel disc with three APS-coated variants (P1 Metco 71NS, P2 Metco 136F, P3 Metco 45C-NS). Mechanical properties of the substrate and coatings are obtained from micro-indentation tests and introduced via a bilinear steel model and Johnson–Cook plasticity for the coatings, while disc–soil friction coefficients are calibrated from microscratch measurements. Soil behaviour is described using the AUTODYN Granular model for four representative agricultural soils, spanning sandy loam to saturated heavy clay. Results show that the uncoated disc develops von Mises stresses in the disc–soil contact region of ≈150–220 MPa, with intermediate-stiffness soils being most critical. APS coatings significantly alter both the level and distribution of stresses: P2, the stiffest ceramic, yields the highest stresses (≈421–448 MPa), P1 keeps stresses near the baseline while shielding the substrate through extended plastic zones, and P3 provides an intermediate, more uniformly distributed stress regime. Increasing disc–soil friction systematically amplifies von Mises stresses in the contact region, especially for P2. Overall, the calibrated explicit model captures the coupled influence of soil properties, coating stiffness and friction, and indicates that P1 is better suited for light-to-medium soils, P3 offers the most balanced response in medium-to-stiff soils, whereas P2 should be reserved for highly abrasive conditions and used with caution in cohesive soils. Full article
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23 pages, 3622 KB  
Article
Influence of Dispersed Phase Reinforcement on Performance and Wear Mechanism of Ceramic Tools in Rough Milling of Inconel 718
by Paweł Piórkowski and Wojciech Borkowski
Appl. Sci. 2026, 16(1), 62; https://doi.org/10.3390/app16010062 - 20 Dec 2025
Viewed by 506
Abstract
Machining nickel-based superalloys, such as Inconel 718, poses a significant technological challenge due to their high-temperature strength and low thermal conductivity, leading to rapid tool wear. This paper presents a comprehensive comparative analysis of two roughing strategies: high-feed milling and plunge milling, utilizing [...] Read more.
Machining nickel-based superalloys, such as Inconel 718, poses a significant technological challenge due to their high-temperature strength and low thermal conductivity, leading to rapid tool wear. This paper presents a comprehensive comparative analysis of two roughing strategies: high-feed milling and plunge milling, utilizing a unique custom-designed milling head. The primary objective was to evaluate the impact of tool material reinforcement on the process by comparing SiC whisker-reinforced ceramic inserts (CW100) with non-reinforced inserts (CS300). The experiment involved measuring cutting force components, power consumption, and analyzing tool wear progression (VBB) and mechanisms. Results showed that the presence of the reinforcing phase is critical for reducing the axial force component (Fz), particularly in plunge milling, where CW100 inserts achieved a 30–35% force reduction and avoided the catastrophic failure observed in non-reinforced ceramics. Microscopic analysis confirmed that composite inserts undergo predictable abrasive wear, whereas CS300 inserts are prone to brittle fracture and spalling. Multi-criteria optimization using Grey Relational Analysis (GRA) identified high-feed milling with reinforced inserts as the most efficient strategy, while also positioning plunge milling with composites as a competitive, less energy-intensive alternative. Full article
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