Journal of Manufacturing and Materials Processing

13 pages, 6394 KB

Open AccessArticle

Effect of Rapid Solidification on the Structure and Properties of Ag–Cu–(Ti,Zr) Brazing Alloys for Metal–Ceramic Joining

by Sofya Terekhova, Alexander Ivannikov, Anton Abramov, Veronika Kirillova, Vladimir Mikhalchik, Alexander Bazhenov, Pavel Morokhov, Ivan Fedotov, Ivan Klyushin, Nikita Popov and Oleg Sevryukov

J. Manuf. Mater. Process. 2026, 10(3), 90; https://doi.org/10.3390/jmmp10030090 - 3 Mar 2026

Abstract

Four compositions of rapidly quenched ribbon brazing alloys based on Ag–Cu–Ti (Ag–26.5Cu–1.5Ti, Ag–25Cu–5Ti) and Ag–Cu–Zr (Ag–26.5Cu–1.5Zr, Ag–25Cu–5Zr) systems were produced. Initial ingots were synthesized by arc melting. Rapidly solidified ribbons, 50–100 μm thick, were then fabricated from homogenized ingots using a “Crystall-702” facility. [...] Read more.

Four compositions of rapidly quenched ribbon brazing alloys based on Ag–Cu–Ti (Ag–26.5Cu–1.5Ti, Ag–25Cu–5Ti) and Ag–Cu–Zr (Ag–26.5Cu–1.5Zr, Ag–25Cu–5Zr) systems were produced. Initial ingots were synthesized by arc melting. Rapidly solidified ribbons, 50–100 μm thick, were then fabricated from homogenized ingots using a “Crystall-702” facility. A comparative analysis of the microstructure and phase composition of both the ingots and ribbons was conducted using scanning electron microscopy and X-ray diffraction. The analysis revealed the presence of Cu₄Ti and CuTi intermetallic compounds in the Ag–Cu–Ti alloys, and AgCu₄Zr and Zr₂Cu in the Ag–Cu–Zr alloys. Rapid quenching was found to produce metastable structures and significantly refine the intermetallic phases. Microhardness measurements of the ingot and ribbon states demonstrated a substantial influence of the processing route on the mechanical properties. The tensile strength of the ingots was also evaluated. The wetting angles of the rapidly quenched alloy melts on 99% Al₂O₃ (alumina) ceramic substrates under vacuum were determined. All produced ribbons, except for the Ag–26.5Cu–1.5Zr composition, demonstrated adequate wettability. Thus, these materials are considered promising for further research into heat-resistant metal–ceramic joints. Full article

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17 pages, 26160 KB

Open AccessArticle

New Insight into Mechanical, Microstructural and Failure Features of Lap-Fillet Autogenous Laser-Welded Similar and Dissimilar Joints of Ultra-Thin Steel Sheets

by Mihaela Iordachescu, Patricia Santos, Andrés Valiente, Maricely de Abreu and Elena Scutelnicu

J. Manuf. Mater. Process. 2026, 10(3), 89; https://doi.org/10.3390/jmmp10030089 - 2 Mar 2026

Abstract

This research work addresses the mechanical and metallurgical characterisation, as well as the failure features, of two types of lap-fillet autogenous laser-welded joints made of ultra-thin sheets by applying an appropriate welding technology for producing sound welds and flawless joints. Both welded samples, [...] Read more.

This research work addresses the mechanical and metallurgical characterisation, as well as the failure features, of two types of lap-fillet autogenous laser-welded joints made of ultra-thin sheets by applying an appropriate welding technology for producing sound welds and flawless joints. Both welded samples, one made only of stainless steel (SS-SS) sheets, and the other made of stainless steel and carbon steel (SS-CS) plates, were subjected to tensile–shear loads that are representative of the in-service conditions. The experimental research was focused on determining, by the digital image correlation (VIC-2D) method, the strain field and the rotation angle of the welded joints that were developed during loading tests of the welded specimens. Comparing to the classical testing method applied to study the joint overall mechanical properties, the novelty of this research consists of local mechanical behaviour assessment of relevant zones from similar and dissimilar welded joints, by using the innovative technique VIC-2D. Based on the analysis of the experimental results, it was found that the maximum rotation angle is 2.5 times higher in the SS-SS similar welded joint, in comparison with the SS-CS dissimilar welded joint. Despite this finding, the SS-CS specimen failed in the CS base material, far from the weld, with the failure phenomenon being preceded by the material yielding and necking. This failure mode is consistent with the detected strength mismatch of the SS-CS joint, with respect to the CS base material. In contrast, the quasi-ductile fracture of the SS-SS welded joint occurred by plastic exhaustion at the boundary between the narrow Heat-Affected Zone (HAZ) of SS and the Fuzion Zone (FZ). These outcomes are consistent with the hardness profile, microstructural heterogeneities found in the lap-fillet welded joints, and the load versus elongation curves that are determined and discussed in this paper. This research provides new insight and original information on the materials’ response to the autogenous laser welding, which will contribute to improving the knowledge on the ultra-thin lap-fillet welded similar and dissimilar steels. Full article

(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding, 2nd Edition)

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14 pages, 3444 KB

Open AccessArticle

Scan-Strategy Dependent Microstructural Modulation in L-PBF Ti-6Al-4V Components Through Selective Rescanning

by Kalyan Nandigama, Bharath Bhushan Ravichander, Yash Parikh and Golden Kumar

J. Manuf. Mater. Process. 2026, 10(3), 88; https://doi.org/10.3390/jmmp10030088 - 2 Mar 2026

Abstract

Laser Powder Bed Fusion (L-PBF) can enable in situ microstructural tailoring of metallic components by precisely controlling the layer-wise processing parameters. Layer rescanning is one such strategy used to induce localized microstructural modification. In this study, we investigated the effect of a lattice-based [...] Read more.

Laser Powder Bed Fusion (L-PBF) can enable in situ microstructural tailoring of metallic components by precisely controlling the layer-wise processing parameters. Layer rescanning is one such strategy used to induce localized microstructural modification. In this study, we investigated the effect of a lattice-based selective rescanning approach applied to different base scan strategies for Ti-6Al-4V samples. The lattice regions were selectively rescanned at 50% reduced laser power relative to the initial scan along the same laser path. Relative density, porosity, martensitic α′ morphology, phase fraction, and Vickers microhardness were compared with those of non-rescanned reference counterparts. Different scan strategies, including unidirectional, stripes, and chess, exhibited distinct responses to selective rescanning, resulting in localized variations in martensitic phase formation and hardness values. The extent of localized microstructural modification and hardness enhancement was strongly governed by the underlying scan strategy. Selective rescanning using the stripes strategy yielded the largest contrast between non-rescanned and rescanned regions. The unidirectional strategy showed strong effects of rescanning, but the heat-affected zones extended to the non-rescanned regions. In contrast, the chess strategy exhibited comparatively moderate changes owing to its inherent thermal-management characteristics. These findings demonstrate that selective rescanning can provide an effective, localized approach for tailoring microstructure and hardness enhancement in L-PBF Ti-6Al-4V, with its effectiveness strongly dependent on the underlying scan strategy. Full article

(This article belongs to the Special Issue Advances in Metal Additive Manufacturing: Processes, Materials, and Applications)

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39 pages, 31180 KB

Open AccessArticle

A Segmental Joining Method for Large-Scale Additive Components: Case Study on a Fan Blade

by Ronald Bastovansky, Matus Veres, Rudolf Madaj, Robert Kohar and Peter Weis

J. Manuf. Mater. Process. 2026, 10(3), 87; https://doi.org/10.3390/jmmp10030087 - 27 Feb 2026

Abstract

This study presents a case-specific joining method for modular, large-scale components manufactured using Selective Laser Sintering (SLS). A T-slot joint reinforced with a pultruded carbon fiber rod was developed to enable the segmental assembly of polymer fan blades that exceed the build volume [...] Read more.

This study presents a case-specific joining method for modular, large-scale components manufactured using Selective Laser Sintering (SLS). A T-slot joint reinforced with a pultruded carbon fiber rod was developed to enable the segmental assembly of polymer fan blades that exceed the build volume of common SLS printers. Through an iterative design process, five joint variations were investigated, focusing on the optimization of slot geometry (fillet radii and wall thickness) and the integration of carbon fiber reinforcements to create a high-strength hybrid connection. The experimental findings were validated using a non-linear finite element analysis (FEA) utilizing an iteratively calibrated Young’s modulus of 710 MPa, which accounts for the 50/50 virgin-to-reused PA2200 powder ratio employed in the study. The numerical model identified that the primary sites for crack initiation were the fillet radii of the female slot, where localized equivalent plastic strains reached critical levels of up to 84% in tension and 78% in bending. The final design achieved an average tensile strength of 27.6 MPa, exceeding the design threshold of 21.9 MPa with a safety factor of 2.5. While unreinforced joints showed a 73.4% reduction in bending strength compared to solid specimens, the addition of an 8 mm carbon rod increased performance by 238.7%, restoring over 90% of the monolithic material’s strength. Numerical results confirmed that the reinforcement assumed the primary load-bearing role, effectively mitigating stresses in the polymer matrix below the ultimate tensile strength. Failure analysis clarified that the observed audible failure originated from internal fiber breakage within the rod at stresses between 900–1050 MPa. This work demonstrates that a segmental, reinforcement-based joining method can effectively overcome size constraints in polymer additive manufacturing, providing a robust and repeatable solution for rotating components subject to complex loading conditions. Full article

(This article belongs to the Special Issue Advanced Design and Materials for Additive Manufacturing)

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16 pages, 2560 KB

Open AccessArticle

Investigation of Wire EDM Dressing of Metal-Bond Diamond Grinding Wheels and Its Impact on Grinding Performance

by Jan Wittenburg, Marcel Olivier, Tim Herrig, Timm Petersen, Thomas Bergs, Christian Wrobel, Rainer Harter and Eugen Großmann

J. Manuf. Mater. Process. 2026, 10(3), 86; https://doi.org/10.3390/jmmp10030086 - 27 Feb 2026

Abstract

Grinding wheel conditioning is critical for maintaining cutting efficiency and surface quality, yet conventional mechanical dressers struggle with metal-bonded superabrasive wheels. In this study, wire electrical discharge machining (WEDM) dressing was evaluated on metal-bond diamond wheels of two grit sizes (D54 and D91) [...] Read more.

Grinding wheel conditioning is critical for maintaining cutting efficiency and surface quality, yet conventional mechanical dressers struggle with metal-bonded superabrasive wheels. In this study, wire electrical discharge machining (WEDM) dressing was evaluated on metal-bond diamond wheels of two grit sizes (D54 and D91) and compared to standard mechanical dressing. Dressing was performed on a WEDM machine using varied discharge currents, open-circuit voltages, and duty factors; subsequently, each wheel ground twelve grooves in tungsten carbide under identical parameters. Performance was assessed via maximum spindle power, tangential and normal forces, surface roughness (Ra), radial wheel wear, and edge radius. WEDM-dressed wheels exhibited up to 56% lower peak spindle power and 40–50% lower forces than mechanically dressed wheels. Compared to mechanically dressed wheels, WEDM-conditioned wheels exhibited markedly lower radial wear and maintained substantially sharper, more stable edge radii throughout the grinding cycles. Surface roughness converged after an initial break-in, matching mechanical methods. By selectively eroding the bond without damaging grains, WEDM dressing extends dressing intervals by approximately fivefold and reduces maintenance. Full article

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19 pages, 5217 KB

Open AccessArticle

Experimental Characterization and Numerical Optimization of 3D-Printed PA6-CF External Fixator Rings

by Ion Badea, Tudor-George Alexandru, Diana Popescu and Florin Baciu

J. Manuf. Mater. Process. 2026, 10(3), 85; https://doi.org/10.3390/jmmp10030085 - 27 Feb 2026

Abstract

This research investigated the feasibility of 3D-printed external fixator (EF) rings made from carbon fiber reinforced polyamide 6 (PA6-CF) as an alternative to the conventional metallic counterpart. The study integrated tensile testing with digital image correlation (DIC) in as-printed and cold plasma-sterilized conditions, [...] Read more.

This research investigated the feasibility of 3D-printed external fixator (EF) rings made from carbon fiber reinforced polyamide 6 (PA6-CF) as an alternative to the conventional metallic counterpart. The study integrated tensile testing with digital image correlation (DIC) in as-printed and cold plasma-sterilized conditions, finite-element analysis (FEA) under wire loading, topology optimization for material and energy reduction, and evaluation of printability limits for large PA6-CF rings. The average Young’s modulus was 4.76 GPa and the maximum tensile strength was 60.5 MPa for as-printed samples, decreasing by 6.4% and 10.4% after sterilization, respectively. Using these properties as model inputs, FEA predicted safety factors larger than 1.42 for all configurations under 1000 N wire pretension, while topology optimization targeted up to 50% mass reduction without compromising ring stiffness. The study also revealed challenges in the printability of PA6-CF for large and thin components, including dimensional contraction, significant warping and moisture-induced defects, requiring an experienced 3D printer operator. Full article

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21 pages, 8264 KB

Open AccessArticle

Defects, Microstructure, and Hardness of As-Built and Heat-Treated 13 Hot Work Tool Steel and 17-4 PH Stainless Steel Obtained by Fused Filament Fabrication

by Morgane Mokhtari, Chirag Khandivar, Yannick Balcaen, David López-Bolaños, Miren Aristizabal and Joël Alexis

J. Manuf. Mater. Process. 2026, 10(3), 84; https://doi.org/10.3390/jmmp10030084 - 27 Feb 2026

Abstract

Fused Filament Fabrication (FFF) is a low-cost additive manufacturing process that produces metallic parts from printing with a metal-polymer filament, followed by a debinding–sintering process. It presents an opportunity for the tooling sector to improve performance by geometrical optimization while keeping costs low. [...] Read more.

Fused Filament Fabrication (FFF) is a low-cost additive manufacturing process that produces metallic parts from printing with a metal-polymer filament, followed by a debinding–sintering process. It presents an opportunity for the tooling sector to improve performance by geometrical optimization while keeping costs low. This study investigates the possibility of producing a molding core for plastic injection by FFF technology. This research aimed to characterize 17-4 PH stainless steel and H13 hot work tool steels produced through this process. Their heat treatment behavior was investigated using dilatometry, which led to the obtention of a Continuous Cooling Transformation (CCT) diagram. Results show that for as-sintered materials, martensitic steel with some residual austenite is present in 17-4 PH, and a pearlitic microstructure is observed in H13. Porosity (around 4%) falls within the reported range in the literature and can be removed by hot isostatic pressing. CCT diagrams do not show significant differences with conventional materials. The low hardness of as-sintered H13 (around 175 HV1) is improved (>500 HV1) by suitable heat treatment. Finally, both materials meet the requirements for this specific industrial application, and demonstrators were produced. Full article

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20 pages, 5349 KB

Open AccessArticle

The Effect of Si and Zr on the Formation of Al₃X and V-Phase in a 6005A Alloy with Sc—Part 1: Alloy Design and Heat Treatment Selection

by Eli Harma, Timothy Langan and Paul Sanders

J. Manuf. Mater. Process. 2026, 10(3), 83; https://doi.org/10.3390/jmmp10030083 - 27 Feb 2026

Abstract

Adding Sc to 6xxx series alloys has led to inconsistent results due to the formation of the high-temperature, thermodynamically stable V-phase (AlSc₂Si₂). Thermo-Calc single-axis equilibrium and phase diagram calculations were employed to identify V-phase formation with varying Si and [...] Read more.

Adding Sc to 6xxx series alloys has led to inconsistent results due to the formation of the high-temperature, thermodynamically stable V-phase (AlSc₂Si₂). Thermo-Calc single-axis equilibrium and phase diagram calculations were employed to identify V-phase formation with varying Si and Zr concentrations, indicating that increasing Zr and decreasing Si lowered the V-phase equilibrium volume fraction. Increasing Zr also shifted the V-phase equilibrium to higher Si concentrations. To access real-world influences of Zr and Si, four compositions were cast with different Si and Zr concentrations: a high-Si, low-Zr alloy; a medium-Si, medium-Zr alloy; a low-Si, high-Zr alloy; and a baseline alloy without Zr and Sc. The compositions were DC-cast followed by multi-step isochronal and isothermal heat treatments, which revealed that increasing Zr concentration did not influence the formation of V-phase but did result in higher hardness at high temperatures, likely due to Al₃Zr precipitation. In contrast, higher Si and lower Zr concentrations produced higher hardness in the peak-aged condition but lower hardness at homogenization temperatures in the 400 °C to 520 °C range. Given these conclusions, a new alloy and a multi-step homogenization process are proposed to further develop Sc- and Zr-containing 6xxx extrusion alloys. Full article

(This article belongs to the Special Issue Design and Manufacturing of Lightweight Materials Process and Structures)

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17 pages, 5996 KB

Open AccessArticle

Optimization of the Operating Behavior of Spur Gears Through Machine Hammer Peening

by Mohammad Dadgar, Sebastian Sklenak, Martina Müller, Tim Herrig, René Greschert, Dieter Mevissen, Christian Brecher and Thomas Bergs

J. Manuf. Mater. Process. 2026, 10(3), 82; https://doi.org/10.3390/jmmp10030082 - 26 Feb 2026

Abstract

Gear systems operate under high mechanical and tribological loads, making their surfaces vulnerable to wear and fatigue. Improving surface durability requires finishing processes that improve near-surface properties and extend service life. Since machine hammer peening (MHP) offers such potential, this study investigates its [...] Read more.

Gear systems operate under high mechanical and tribological loads, making their surfaces vulnerable to wear and fatigue. Improving surface durability requires finishing processes that improve near-surface properties and extend service life. Since machine hammer peening (MHP) offers such potential, this study investigates its influence on the performance of case-hardened spur gears and evaluates its suitability as an alternative to shot peening as a conventional finishing method. Analog specimens with simplified geometries were treated using various MHP parameters to identify effective process settings. These optimized settings were then applied to real spur gears to assess performance under practical conditions. The experiments showed that MHP can significantly modify surface integrity, achieving surface roughness reductions of up to 55%, surface hardness increases of up to 30%, and compressive residual stresses exceeding −1400 MPa with stability to depths of 200 µm. These modifications resulted in improved wear and fatigue performance, with increases in load cycle number in the tooth flank up to 99% and an increase in load amplitude in the tooth root of more than 5%. For comparison, specimens were also treated with shot peening. Although MHP induced stronger surface integrity modifications, shot peening achieved higher overall load-carrying capacity because several critical areas could not be fully accessed by MHP, limiting its effectiveness. Overall, MHP shows promise as a finishing process, but its full potential depends on overcoming accessibility limitations in complex gear geometries. Full article

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15 pages, 1668 KB

Open AccessArticle

Dynamic Reuleaux Venturi with Boundary-Imposed Swirl

by Lorenzo Albanese

J. Manuf. Mater. Process. 2026, 10(3), 81; https://doi.org/10.3390/jmmp10030081 - 26 Feb 2026

Abstract

In-line cavitation is relevant to many continuous processes; however, its intensity depends on flow rate, available pressure, temperature, fluid properties, and plant conditions, complicating the maintenance of a repeatable regime within a prescribed band. This paper presents the DVRA, an actuated Venturi module [...] Read more.

In-line cavitation is relevant to many continuous processes; however, its intensity depends on flow rate, available pressure, temperature, fluid properties, and plant conditions, complicating the maintenance of a repeatable regime within a prescribed band. This paper presents the DVRA, an actuated Venturi module with a Reuleaux triangular cross-section for in-operation regulation of hydrodynamic cavitation through device configuration. The novelty lies in combining two degrees of freedom—an in-operation adjustable hydraulic throat and boundary-imposed swirl forcing—within a compact in-line device: all rotation is confined to the module, and no rotation of the process line is required. The hydraulic throat is tuned via an actuated elastomeric liner, while swirl is generated by external end collars. Reproducible operational conventions are introduced together with a normalized input set and a configuration-space formalism that distinguishes admissible from achievable configurations. Regulation is cast as a control-oriented inverse mapping given a target band for an in-line estimated cavitation indicator and standard industrial measurements of flow rate, pressure, and temperature; configuration commands are selected to keep the indicator within bounds. The contribution is methodological and provides an implementable basis; comprehensive validation and performance benchmarking are outside the scope of this paper and will be reported separately. Full article

(This article belongs to the Special Issue Technological Advances and Industrial Applications in Intelligent Manufacturing)

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16 pages, 1868 KB

Open AccessArticle

Effects of Dispense Delay and Recoat Speed on Green Part Density and Powder Bed Density in Binder Jetting Additive Manufacturing

by Fahim Khan, Zhijian Pei, Md Shakil Arman, Steven Kuntzendorf and Yi-Tang Kao

J. Manuf. Mater. Process. 2026, 10(3), 80; https://doi.org/10.3390/jmmp10030080 - 26 Feb 2026

Abstract

This study investigates the effects of two process parameters (dispense delay and recoat speed) on green part density and powder bed density in binder jetting additive manufacturing using silicon carbide powder. These two process parameters control the amount of powder dispensed on the [...] Read more.

This study investigates the effects of two process parameters (dispense delay and recoat speed) on green part density and powder bed density in binder jetting additive manufacturing using silicon carbide powder. These two process parameters control the amount of powder dispensed on the powder bed for each powder layer. Experiments were conducted at three levels of dispense delay (0.2, 1, and 5 s) and three levels of recoat speeds (5, 10, and 20 mm/s). The one-way Analysis of Variance (ANOVA) results reveal that both dispense delay and recoat speed have statistically significant effects on green part density and powder bed density. Experimental results show that increasing dispense delay or decreasing recoat speed leads to higher green part density and powder bed density. These findings provide useful insights into optimizing binder jetting additive manufacturing process parameters to achieve the desired green part density without employing powder bed compaction. Full article

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23 pages, 3596 KB

Open AccessArticle

Analysis and Characterization of Axially Joined Friction-Welded Ti6Al4V Alloy Rods

by Mthobisi Zulu, Peter Madindwa Mashinini, Tshepo Ntsoane, Andrew Venter, Ryno van der Merwe and Deon Marais

J. Manuf. Mater. Process. 2026, 10(3), 79; https://doi.org/10.3390/jmmp10030079 - 26 Feb 2026

Abstract

The effect of process inputs in the friction welding of Ti6Al4V alloy rods was investigated through the analysis of residual stresses, microstructure, chemical phases and hardness testing of the weld joints. The rods were welded using different combinations of process inputs. The results [...] Read more.

The effect of process inputs in the friction welding of Ti6Al4V alloy rods was investigated through the analysis of residual stresses, microstructure, chemical phases and hardness testing of the weld joints. The rods were welded using different combinations of process inputs. The results revealed variations in residual stresses, hardness and microstructure of the weld joints when weld inputs were varied. Peak compressive residual stresses were obtained at the centre of the weld interface, where the grains were very fine. The joints with a greater volume fraction of martensitic grains had elevated residual stress values. The maximum compressive residual stress values were obtained at the weld interface, with high hardness results. A further investigation was conducted to study the relationship between the residual stresses, microstructure and mechanical properties of the weld joint. Full article

(This article belongs to the Special Issue Advances in Additive Manufacturing of Metal Alloys: Microstructure, Mechanical Behavior, and Surface Performance)

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16 pages, 8594 KB

Open AccessArticle

Microstructure and Mechanical Properties of Aluminum Alloy Studs Using Wire–Laser Directed Energy Deposition

by Fawu Xiang, Jiangang Wang, Likun Yang, Hui Gao, Yingying Huang and Haihe Jiang

J. Manuf. Mater. Process. 2026, 10(3), 78; https://doi.org/10.3390/jmmp10030078 - 25 Feb 2026

Abstract

In this study, an annular laser beam shaping optics and a wire feeding system are used for additive manufacturing. A discrete concentric layering trajectory strategy (DCL-TS) and a continuous deposition trajectory strategy (CD-TS) for the laser-directed energy deposition (WL-DED) of aluminum alloy stud [...] Read more.

In this study, an annular laser beam shaping optics and a wire feeding system are used for additive manufacturing. A discrete concentric layering trajectory strategy (DCL-TS) and a continuous deposition trajectory strategy (CD-TS) for the laser-directed energy deposition (WL-DED) of aluminum alloy stud structures are developed. Initially, combinations of parameters, such as laser power, transverse speed, and wire feeding speed, which lead to a process that produces a single-layer structure with good morphology and no visible pores and cracks, are identified. Then, DCL-TS and CD-TS manufacturing strategies are used to produce aluminum alloy studs of similar dimensions. The EBSD results indicate that the CD-TS produces finer grains in the aluminum alloy studs compared to the DCL-TS; correspondingly, mechanical testing reveals superior microhardness and tensile strength in the circularly fabricated studs. The latter tensile value testing verifies that aluminum alloy studs using WL-DED on the substrate can meet the requirements for practical application in mobile phones, computers, etc. This research method enhances the mechanical properties of additively manufactured items. Consequently, manufacturing efficiency is significantly improved, providing a promising solution for rapid production. Full article

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17 pages, 6482 KB

Open AccessArticle

Effect of Post-Build Annealing on the Microstructure and Mechanical Properties of LPBF-Processed AlSn10Pb10 Alloy

by Kirill O. Akimov, Alexander L. Skorentsev, Nikolay M. Rusin, Vadim E. Likharev, Dmitry P. Il’yashchenko and Andrey I. Dmitriev

J. Manuf. Mater. Process. 2026, 10(3), 77; https://doi.org/10.3390/jmmp10030077 - 24 Feb 2026

Abstract

The work studied the effect of high-temperature annealing on the phase composition, microstructure, and mechanical properties of an AlSn10Pb10 vol.% alloy obtained by laser powder bed fusion (LPBF). For this purpose, a series of anneals was carried out in the temperature range of [...] Read more.

The work studied the effect of high-temperature annealing on the phase composition, microstructure, and mechanical properties of an AlSn10Pb10 vol.% alloy obtained by laser powder bed fusion (LPBF). For this purpose, a series of anneals was carried out in the temperature range of 200–500 °C with a duration of 30 min. Using X-ray diffraction, it was determined that the annealed samples had a three-phase structure consisting of Al, β-Sn, and α-Pb phases, with a gradual decrease in their lattice elastic strain and dislocation density as the heating temperature increased. Analysis of the obtained SEM images revealed that these changes were accompanied by the coarsening of Sn and Pb inclusions and growth of the pure aluminum areas. As a result of the described structural changes with increasing annealing temperature, the ultimate compressive strength of the alloy monotonically decreased from 108 MPa (in the as-built state) to 75 MPa after annealing at 500 °C. The alloy’s ductility (strain at peak stress) also improved and reached a maximum of 26% after annealing at 400 °C. Compression test results showed that the optimal combination of ductility and strength of the LPBF-processed AlSn10Pb10 alloy was observed after annealing at 400 °C. Full article

(This article belongs to the Special Issue Advances in Additive Manufacturing of Metal Alloys: Microstructure, Mechanical Behavior, and Surface Performance)

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23 pages, 9159 KB

Open AccessArticle

Tribological Analysis of Laser-Cladded Martensitic and Mixed-Alloy Coatings: Correlating Microstructure, Hardness, and Wear Response

by Stavros K. Chionopoulos and Antonios Spyridakos

J. Manuf. Mater. Process. 2026, 10(2), 76; https://doi.org/10.3390/jmmp10020076 - 23 Feb 2026

Abstract

High-strength quenched and tempered steels such as EN 42CrMo4, widely used for marine shaft applications due to their high strength, toughness, and fatigue resistance, are nevertheless susceptible to surface degradation under severe dry sliding conditions. To enhance surface integrity and tribological performance, this [...] Read more.

High-strength quenched and tempered steels such as EN 42CrMo4, widely used for marine shaft applications due to their high strength, toughness, and fatigue resistance, are nevertheless susceptible to surface degradation under severe dry sliding conditions. To enhance surface integrity and tribological performance, this study investigates laser-cladded AISI 410L and mixed AISI 410L/AISI 4140 (50/50 wt.%) coatings deposited on EN 42CrMo4 steel using a high-power diode laser (HPDL). Two-layer coatings were produced, and selected specimens underwent post-cladding stress-relief heat treatment to mitigate residual stresses and temper as-solidified microstructures. Microstructural characterization revealed refined dendritic and martensitic morphologies, while the mixed-alloy coatings showed increased carbide formation and improved hardness homogeneity. The mixed AISI 410L/AISI 4140 coatings achieved significantly higher microhardness values (≈530–555 HV) compared to single-alloy 410L coatings (≈310–420 HV). Tribological testing under dry sliding conditions (Al₂O₃ counterbody, 5 N load, 0.5 m/s sliding speed) demonstrated that the mixed-alloy coatings exhibited substantially lower steady-state friction coefficients (μ ≈ 0.65–0.69) and markedly reduced specific wear rates (≈11–17 × 10⁻¹⁴ m³/Nm) compared to the 410L coatings (≈150–175 × 10⁻¹⁴ m³/Nm). Post-cladding heat treatment further stabilized friction behaviour and reduced wear in the mixed-alloy system by tempering martensite and alleviating localized stress concentrations. Wear mechanism analysis revealed a transition from severe abrasive wear with fatigue-induced delamination in the 410L coatings to predominantly mild abrasive wear in the mixed-alloy coatings, accompanied by localized plastic deformation. Overall, the results establish clear correlations between microstructure, hardness, and tribological response, demonstrating that mixed-alloy laser cladding is an effective strategy for enhancing the dry sliding performance of EN 42CrMo4 steel in demanding marine applications. Full article

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23 pages, 3484 KB

Open AccessArticle

A Predictive Crater-Overlap Model for EDM Finishing Relevant to AISI 304 Welded Joints

by Mohsen Forouzanmehr, Mohammad Reza Dashtbayazi and Mahmoud Chizari

J. Manuf. Mater. Process. 2026, 10(2), 75; https://doi.org/10.3390/jmmp10020075 - 21 Feb 2026

Abstract

Electrical Discharge Machining (EDM) enables precision post-weld finishing of AISI 304 stainless steel, but stochastic spark overlaps make the fatigue-critical maximum peak-to-valley height (R_max) difficult to predict. This study develops a validated physics-based framework quantifying how crater overlap governs R [...] Read more.

Electrical Discharge Machining (EDM) enables precision post-weld finishing of AISI 304 stainless steel, but stochastic spark overlaps make the fatigue-critical maximum peak-to-valley height (R_max) difficult to predict. This study develops a validated physics-based framework quantifying how crater overlap governs R_max evolution. Experiments on unwelded AISI 304 cylinders—proxying weld metal while excluding heat-affected zone (HAZ) effects—used Central Composite Design (20 trials, 900–9380 μJ discharge energies). Profilometry and scanning electron microscopy (SEM) correlated the crater size, overlap intensity, micro-cracking, and R_max escalation from 18 to 85 μm. Primary and secondary crater formation under minimum and maximum overlap configurations were simulated using a 2D axisymmetric finite element model with Gaussian heat flux and temperature-dependent thermophysical properties. The predictive metric R_max,num = (d_initial + d_secondary)/2 achieved 11–19% average error against the experimental R_max,exp, with complementary valley depth (R_v) validation at 13% error. The Specimen 7 outlier (~50% error) reveals the limitations of deterministic modelling under stochastic debris accumulation and plasma instability at intermediate energies. Crater overlap generates secondary dimples, sharp inter-crater peaks, and rim micro-crack networks, driving the 4.7-fold R_max increase—approaching International Institute of Welding (IIW) fatigue thresholds (<25 μm for high-cycle categories). The framework explicitly links the discharge energy, plasma channel radius (R_pc), and overlap geometry to surface topography, enabling process optimization (I·t_on < 60 A·s maintains R_max < 25 μm). Mesh independence (<2.5% convergence) and six centre-point replicates (CV = 4.2%) confirm robustness. This validated upper-bound R_max predictor supports the digital co-optimization of welding and EDM parameters for aerospace/energy applications, with planned extensions to stochastic 3D models incorporating adaptive remeshing and real weld topographies. Full article

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

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23 pages, 1772 KB

Open AccessArticle

Experimental Study on Drilling Performance of Bio-Waste-Based Corn Husk Fiber Reinforced Epoxy Composites for Green Applications

by Karthick Rasu, Ashwin Prabhu Gnanasekaran, Sudarsan Deenadayalan, Kuntanahal Rajashekhara, Kamalakannan Ranganathan and Joao Paulo Davim

J. Manuf. Mater. Process. 2026, 10(2), 74; https://doi.org/10.3390/jmmp10020074 - 21 Feb 2026

Abstract

This study focuses on the machinability optimization of bio-waste corn husk fiber–reinforced epoxy composites during drilling, with the objective of minimizing delamination and improving hole quality required for mechanical fastening applications. While natural fiber composites have been widely investigated, systematic statistical optimization of [...] Read more.

This study focuses on the machinability optimization of bio-waste corn husk fiber–reinforced epoxy composites during drilling, with the objective of minimizing delamination and improving hole quality required for mechanical fastening applications. While natural fiber composites have been widely investigated, systematic statistical optimization of drilling parameters for corn husk fiber composites remains limited. The novelty of this work lies in identifying the dominant drilling parameter and establishing a clear damage-control strategy using a Taguchi L16 design coupled with ANOVA. Drilling experiments were conducted by varying spindle speed (1000, 1500, 2000, and 2500 rpm), drill diameter (6, 8, 10, and 12 mm), feed rate (00.05, 0.10, 0.15, and 0.20 mm/rev), and point angle (90°, 100°, 110°, and 120°). The results show that the drill diameter is the governing factor affecting delamination, contributing 73.52% of the total variation, followed by spindle speed (22.68%), whereas feed rate (3.14%) and point angle (0.38%) have minimal influence. The optimal condition (2500 rpm, 6 mm drill diameter, and 0.05 mm/rev feed rate) produced the lowest delamination and improved surface integrity. Microscopic observations confirmed reduced fiber pull-out and matrix cracking under these conditions. The main advantage of the proposed approach is the clear identification of parameter priority, enabling the industry to control drilling damage by primarily selecting appropriate drill diameter and spindle speed. The findings provide practical machining guidelines for the use of corn husk fiber composites in lightweight panels, automotive interior parts, and secondary structural components where reliable bolted joints are required. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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15 pages, 4548 KB

Open AccessArticle

Influence Mechanism of Process Parameters on Nanosecond Laser Polishing Quality of Ti6Al4V Titanium Alloy

by Xulin Wang and Jianwei Ma

J. Manuf. Mater. Process. 2026, 10(2), 73; https://doi.org/10.3390/jmmp10020073 - 20 Feb 2026

Abstract

This study presents a novel numerical framework that elucidates the critical, yet previously underexplored, role of Marangoni vortex dynamics in determining the final surface quality during the laser polishing of Ti6Al4V (TC4). TC4 titanium alloy is widely used in aerospace, biomedicine, and other [...] Read more.

This study presents a novel numerical framework that elucidates the critical, yet previously underexplored, role of Marangoni vortex dynamics in determining the final surface quality during the laser polishing of Ti6Al4V (TC4). TC4 titanium alloy is widely used in aerospace, biomedicine, and other high-precision applications due to its excellent specific strength, corrosion resistance, and biocompatibility. However, its surface quality directly affects the fatigue life and service performance of parts, and traditional polishing methods suffer from low efficiency and high pollution. As a non-contact, controllable surface treatment technology, nanosecond laser polishing has demonstrated unique advantages in balancing processing efficiency and surface quality. This study systematically discussed the influence of key process parameters (spot overlap rate, laser power, and scanning times) on the nanosecond laser polishing of TC4 titanium alloy. It revealed the internal physical mechanism by analyzing the temperature and velocity fields and vortex dynamics during molten-pool evolution. It is found that the polishing effect is determined by the process parameters, which adjust the thermal–fluid coupling physical field (temperature distribution, melt flow, and vortex structure) in the molten pool. There is an optimal combination of parameters (spot overlap rate of 79%, laser power of 0.8 W, scanning speed of 5 m/min, scanning 3 times) that can place the molten pool in an optimal dynamic balance state and achieve effective flatness. The experimental results show that, under this parameter, the surface roughness of the specimen with an initial roughness of 1.223 μm is reduced by about 32%. The research further clarified the mechanism by which the initial roughness of the base metal influences the molten pool: the greater the initial roughness, the more pronounced the “peak shaving and valley filling” effect. Under the same parameters, the improvement rate of the specimen with the initial roughness of 1.623 μm could reach about 40%. This study not only establishes the optimized process window but also reveals the essential relationship between “process parameters–bath behavior–surface quality” from the level of the physical field of the molten pool. The findings provide a practical guideline for parameter optimization, directly applicable to the high-precision laser finishing of critical titanium components in the aerospace and biomedical industries. Full article

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19 pages, 4477 KB

Open AccessArticle

Geometry-Driven Distortion Mechanisms in Thin-Walled Rotating Shells Fabricated by Laser Beam Powder Bed Fusion

by Mingyuan Tang, Chengcheng Liu, Lei Zhong, Junfeng He, Shilong Che and Xufei Lu

J. Manuf. Mater. Process. 2026, 10(2), 72; https://doi.org/10.3390/jmmp10020072 - 19 Feb 2026

Abstract

Laser beam powder bed fusion (PBF-LB) enables the fabrication of complex rotational metallic components for aerospace applications, such as engine exhaust nozzles and combustion liners, but the localized thermal cycles inherent to the process often lead to residual stress accumulation and geometry-dependent distortion, [...] Read more.

Laser beam powder bed fusion (PBF-LB) enables the fabrication of complex rotational metallic components for aerospace applications, such as engine exhaust nozzles and combustion liners, but the localized thermal cycles inherent to the process often lead to residual stress accumulation and geometry-dependent distortion, particularly in low-stiffness and open structures. This study investigates the thermo-mechanical response of three representative 316L stainless steel rotational geometries—dumbbell-shaped, cylindrical, and drum-shaped—in both closed and open configurations using a transient, fully coupled thermo-mechanical finite element model validated by high-resolution three-dimensional deformation measurements. The results reveal pronounced geometry- and size-dependent distortion mechanisms: for closed structures, the drum-shaped geometry exhibits the largest radial contraction and stress concentration due to its larger characteristic size and lower stiffness, with a maximum deformation of approximately 0.14 mm, whereas the dumbbell-shaped and cylindrical geometries show smaller and more uniform deformations of about 0.09 mm and 0.12 mm; open configurations experience substantially amplified distortion, with both the magnitude and vertical location of bulging governed by geometric stiffness and substrate constraint, and the open drum-shaped structure reaching a maximum displacement of approximately 1.6 mm. These findings clarify how geometric size and stiffness control stress relaxation and shape stability in PBF-LB-fabricated rotational components and provide transferable guidance for geometry-informed design and distortion mitigation in high-precision additive manufacturing. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Additive Manufacturing)

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