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Topology Optimization Study of a Refrigeration Block Manufactured with Powder Bed Fusion Selective Laser Melting
Enhancing Fatigue Life of Metal Parts Produced by High-Speed Laser Powder Bed Fusion Through In Situ Surface Quality Improvement
Investigation of the Thermo-Mechanical Modeling of the Manufacturing of Large-Scale Wire Arc Additive Manufacturing Components with an Outlook Towards Industrial Applications
Physics-Informed Preform Design for Flashless 3D Forging via Material Point Backtracking and Finite Element Simulations

Journal Description

Journal of Manufacturing and Materials Processing

Journal of Manufacturing and Materials Processing is an international, peer-reviewed, open access journal on the scientific fundamentals and engineering methodologies of manufacturing and materials processing published monthly online by MDPI.

Open Access— free for readers, with article processing charges (APC) paid by authors or their institutions.
High Visibility: indexed within Scopus, ESCI (Web of Science), Inspec, CAPlus / SciFinder, Ei Compendex and other databases.
Journal Rank: JCR - Q2 (Engineering, Mechanical) / CiteScore - Q2 (Mechanical Engineering)
Rapid Publication: manuscripts are peer-reviewed and a first decision is provided to authors approximately 16.2 days after submission; acceptance to publication is undertaken in 3.6 days (median values for papers published in this journal in the first half of 2025).
Recognition of Reviewers: reviewers who provide timely, thorough peer-review reports receive vouchers entitling them to a discount on the APC of their next publication in any MDPI journal, in appreciation of the work done.
Journal Cluster of Mechanical Manufacturing and Automation Control: Aerospace, Automation, Drones, Journal of Manufacturing and Materials Processing, Machines, Robotics and Technologies.

Impact Factor: 3.3 (2024); 5-Year Impact Factor: 3.6 (2024)

Imprint Information Journal Flyer Open Access ISSN: 2504-4494

Latest Articles

17 pages, 6473 KB

Open AccessArticle

Design and Experimental Research for the Ultrasonic Burnishing System on Rods for Hydraulic Applications Surfaces

by Erbo Liu, Qingchun Li, Xufeng Song, Qingqing Lü, Xiaodong Liu, Liquan Yang, Qun Li, Yun Hu and Qianyang Zhao

J. Manuf. Mater. Process. 2025, 9(9), 291; https://doi.org/10.3390/jmmp9090291 - 26 Aug 2025

To explore the effects of ultrasonic burnishing strengthening technology on the surface morphology and mechanical properties of 40Cr rods for hydraulic applications, a conical transition composite amplitude transformer was designed using ANSYS (Workbench 2024 R1) finite element analysis software, with a frequency of [...] Read more.

To explore the effects of ultrasonic burnishing strengthening technology on the surface morphology and mechanical properties of 40Cr rods for hydraulic applications, a conical transition composite amplitude transformer was designed using ANSYS (Workbench 2024 R1) finite element analysis software, with a frequency of 18,158 Hz, an amplification factor (M_p) of 2.0, and a maximum stress of 122.9 MPa. The ultrasonic burnishing strengthening process was numerically simulated via ABAQUS finite element analysis software. Based on the single-factor analysis method, the influence of spindle speed, ultrasonic amplitude, and burnishing passes on the maximum residual compressive stress of the hydraulic rod was investigated, and key parameters such as surface roughness and microhardness of the rod before and after ultrasonic burnishing strengthening were comparatively analyzed. The results show that ultrasonic burnishing strengthening technology can reduce the surface roughness of the hydraulic rod, enhance its microhardness, and increase the depth of the plastic deformation layer. Ultrasonic amplitude and burnishing passes exert a significant influence on the maximum residual compressive stress on the rod surface, while the effect of spindle speed is relatively minor. When the ultrasonic amplitude is 10 μm, the spindle speed is 120 r/min, and the burnishing passes are 3, the surface residual compressive stress of the hydraulic rod reaches the maximum experimental value of 433.39 MPa. This study reveals the influence law of process parameters on the surface properties of rods for hydraulic applications, verifies the feasibility of the ultrasonic burnishing system, and provides a technical reference for improving the performance of rods for hydraulic applications. Full article

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18 pages, 13090 KB

Open AccessArticle

Optimizing Laser Weldability of Heat-Treatable and Non-Heat-Treatable Aluminum Alloys: A Comprehensive Study

by Jean-Denis Béguin, Yannick Balcaen, Jade Pécune, Nathalie Aubazac and Joël Alexis

J. Manuf. Mater. Process. 2025, 9(9), 290; https://doi.org/10.3390/jmmp9090290 - 25 Aug 2025

Laser welding, a vital process in modern industry, offers significant technical and economic benefits, including improved part quality, precision, productivity, and cost reduction. This study significantly enhances our understanding of heat-treatable weldability (AA2024, AA2017, AA6061) and non-heat-treatable AA5083 aluminum alloys. It establishes a [...] Read more.

Laser welding, a vital process in modern industry, offers significant technical and economic benefits, including improved part quality, precision, productivity, and cost reduction. This study significantly enhances our understanding of heat-treatable weldability (AA2024, AA2017, AA6061) and non-heat-treatable AA5083 aluminum alloys. It establishes a “weldability window” based on power density and interaction time, identifying three key domains: insufficient penetration, full penetration with regular weld, and irregular weld or cutoff. The study’s findings reveal that heat-treatable alloys soften in the fusion zone due to the dissolution of reinforcing precipitates during welding. In contrast, non-heat-treatable alloys exhibit hardening due to a fine dendritic microstructure. The fusion zone features fine dendrites, and in the heat-affected zone (HAZ), coarse particles and liquation at the fusion line are observed, particularly in AA6061 and 2024 alloys. The study also shows that the joint efficiency, a measure of the weld’s load-bearing capacity, is approximately 90% for the AA5083 alloy and 80% for the heat-treatable alloys. These findings significantly contribute to our understanding of welding processes. They can be used to optimize laser welding processes, thereby ensuring the production of high-quality and reliable joints in industrial applications. Full article

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46 pages, 5042 KB

Open AccessReview

A Review of the Role of Modeling and Optimization Methods in Machining Ni-Cr Super-Alloys

by Shovon Biswas, Chinmoy Shekhar Saikat, Nafisa Anzum Sristi and Prianka Binte Zaman

J. Manuf. Mater. Process. 2025, 9(9), 289; https://doi.org/10.3390/jmmp9090289 - 25 Aug 2025

Ni-Cr alloys are some of the most important materials being utilized in the manufacturing industry. Their unique properties make them attractive for various applications, especially in the aerospace and automobile industries. Since machining these materials is challenging due to their properties, it is [...] Read more.

Ni-Cr alloys are some of the most important materials being utilized in the manufacturing industry. Their unique properties make them attractive for various applications, especially in the aerospace and automobile industries. Since machining these materials is challenging due to their properties, it is necessary to understand their machining processes and how to improve them. As a result, time and again, effort has been made to understand and model the machining of Ni-Cr alloys. In this action, different approaches, i.e., neural networks, fuzzy systems, simulations, etc., have been of great help. At the same time, efforts have been made to optimize the machining processes to find how to obtain the best outputs from the processes. Different methods, such as multi-criteria decision-making, meta-heuristic algorithms, desirability functions, etc., have been utilized in this respect. This work aims to prepare an exhaustive review of the methods used for modeling and optimization of the machining of Ni-Cr alloys. It considers five major machining operations and collects data on how these methods or algorithms have been used to improve the machining and to what extent. The use of newer advanced algorithms in manufacturing processes is on the rise, and this manuscript aims to record the methods used, their effectiveness, and their shortcomings. It also provides an insight into the methods and their compatibility. Suggestions for future work are also discussed at the end of this study. Full article

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

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19 pages, 6809 KB

Open AccessArticle

Balancing Strength and Flexibility: Mechanical Characterization of Carbon Fiber-Reinforced PLA Composites in FDM 3D Printing

by Boston Blake, Ryan Mendenhall and Babak Eslami

J. Manuf. Mater. Process. 2025, 9(9), 288; https://doi.org/10.3390/jmmp9090288 - 22 Aug 2025

Fused Deposition Modeling (FDM) is a commonly used 3D printing process characterized by its versatility in material selection; however, FDM’s layer-by-layer process often leads to lower strength properties. This study explores the mechanical properties of FDM 3D-printed composite materials printed with varying nozzle [...] Read more.

Fused Deposition Modeling (FDM) is a commonly used 3D printing process characterized by its versatility in material selection; however, FDM’s layer-by-layer process often leads to lower strength properties. This study explores the mechanical properties of FDM 3D-printed composite materials printed with varying nozzle diameters, specifically on the influence of Carbon Fiber-reinforced Polylactic Acid (PLA-CF) on tensile and flexural strength when reinforcing Polylactic Acid (PLA) parts. Composite samples were printed with varying ratios of PLA and PLA-CF, ranging from 0% to 100% PLA-CF in 20% increments, with layer groups stacked vertically, while also using three different nozzle diameters (0.4 mm, 0.6 mm, and 0.8 mm). Tensile testing revealed a proportional increase in strength as PLA-CF content increased, indicating that carbon fiber reinforcement significantly enhances tensile performance. However, flexural testing demonstrated a decrease in bending strength with higher PLA-CF content, suggesting a trade-off between stiffness and flexibility. Mid-range ratios (40–60% PLA-CF) provided a balance between tensile and flexural properties. Finally, atomic force microscopy was utilized to provide a better understanding of the microscale morphology and surface properties of PLA and PLA-CF thin films. The results highlight the potential of PLA-CF/PLA composites to allow for more direct control over the tensile–flexural trade-off during the printing process, as opposed to manufacturing filaments with fixed fiber percentages. These results provide a path for tailoring the mechanical behavior of printed parts without requiring specialized filaments. Full article

(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing: 2nd Edition)

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15 pages, 5119 KB

Open AccessArticle

The Effect of Substrate Bias Voltage on the Mechanical and Tribological Properties of (TiAlZrTaNb)N_x High-Entropy Nitride Coatings

by Juan Pablo González, Ingrid González, Oscar Piamba, Jhon Olaya, Leonardo Velasco and Gilberto Bejarano

J. Manuf. Mater. Process. 2025, 9(9), 287; https://doi.org/10.3390/jmmp9090287 - 22 Aug 2025

We investigate TiAlZrTaNb nitride coatings deposited on Haynes 282 nickel superalloy substrates via high-power impulse magnetron sputtering (HiPIMS) under varying substrate bias voltages (0 V to −75 V). The influence of substrate bias on the microstructure, morphology, hardness, and wear resistance was systematically [...] Read more.

We investigate TiAlZrTaNb nitride coatings deposited on Haynes 282 nickel superalloy substrates via high-power impulse magnetron sputtering (HiPIMS) under varying substrate bias voltages (0 V to −75 V). The influence of substrate bias on the microstructure, morphology, hardness, and wear resistance was systematically analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), nanoindentation, and ball-on-disk tribometry. The coatings exhibited a near equiatomic chemical composition with a face-centered cubic (FCC) crystal structure preferentially oriented along the (200) and (111) planes. Increasing the bias voltage reduced the grain size (3.65 nm to 2.84 nm) and lattice parameter (0.442 nm to 0.440 nm); meanwhile, the hardness (>45 GPa) and wear resistance were improved. The interplay between the deposition parameters and coating-substrate interactions are discussed in order to optimize HiPIMS-derived coatings for industrial applications. Full article

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21 pages, 2258 KB

Open AccessReview

Linking Process Parameters, Structure, and Properties in Material Extrusion Additive Manufacturing of Polymers and Composites: A Review

by Attila Debreceni, Zsolt Buri and Sándor Bodzás

J. Manuf. Mater. Process. 2025, 9(9), 286; https://doi.org/10.3390/jmmp9090286 - 22 Aug 2025

This review investigates how process parameters and material choices influence the mechanical performance of parts produced by material extrusion additive manufacturing, with a particular focus on Material Extrusion (ME). Through a systematic bibliometric analysis of literature between 2015 and 2025, the study identifies [...] Read more.

This review investigates how process parameters and material choices influence the mechanical performance of parts produced by material extrusion additive manufacturing, with a particular focus on Material Extrusion (ME). Through a systematic bibliometric analysis of literature between 2015 and 2025, the study identifies key factors affecting mechanical strength, anisotropy, and structural reliability, including printing temperature, speed, orientation, layer thickness, and interlayer bonding. Emphasis is placed on emerging techniques such as 4D printing, fiber-reinforced composites, and novel monitoring methods like real-time vibration sensing and thermal imaging, which offer promising pathways to improve part performance and process stability. Three research questions guide the analysis: (1) how printing parameters affect micro- to macrostructure and failure behavior, (2) how optimization strategies enhance part quality, and (3) how material and process selection aligns with functional requirements. The review highlights both advances and persistent limitations in process control, material compatibility, and anisotropic strength. It concludes with a call for further integration of predictive modeling, hybrid material systems, and closed-loop process monitoring to unlock the full potential of additive manufacturing in high-performance engineering applications. Full article

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

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28 pages, 1673 KB

Open AccessReview

Advancement of 3D Bioprinting Towards 4D Bioprinting for Sustained Drug Delivery and Tissue Engineering from Biopolymers

by Maryam Aftab, Sania Ikram, Muneeb Ullah, Shahid Ullah Khan, Abdul Wahab and Muhammad Naeem

J. Manuf. Mater. Process. 2025, 9(8), 285; https://doi.org/10.3390/jmmp9080285 - 21 Aug 2025

The transition from three-dimensional (3D) to four-dimensional (4D)-bioprinting marks a significant advancement in tissue engineering and drug delivery. 4D-bioprinting offers the potential to more accurately mimic the adaptive qualities of living tissues due to its dynamic flexibility. Structures created with 4D-bioprinting can change [...] Read more.

The transition from three-dimensional (3D) to four-dimensional (4D)-bioprinting marks a significant advancement in tissue engineering and drug delivery. 4D-bioprinting offers the potential to more accurately mimic the adaptive qualities of living tissues due to its dynamic flexibility. Structures created with 4D-bioprinting can change shape in response to internal and external stimuli. This article reviews the background, key concepts, techniques, and applications of 4D-bioprinting, focusing on its role in tissue scaffolding and drug delivery. We discuss the limitations of traditional 3D-bioprinting in providing customized and sustained medication release. Shape memory polymers and hydrogels are examples of new responsive materials enabled by 4D-bioprinting that can enhance drug administration. Additionally, we provide a thorough analysis of various biopolymers used in drug delivery systems, including cellulose, collagen, alginate, and chitosan. The use of biopolymers in 4D-printing significantly increases material responsiveness, allowing them to react to stimuli such as temperature, light, and humidity. This capability enables complex designs with programmable shape and function changes. The expansion and contraction of hydrogels in response to temperature changes offer a practical method for controlled drug release. 4D-bioprinting has the potential to address significant challenges in tissue regeneration and medication administration, spurring ongoing research in this technology. By providing precise control over cell positioning and biomaterial integration, traditional 3D-bioprinting has evolved into 4D-bioprinting, enhancing the development of tissue constructs. 4D-bioprinting represents a paradigm shift in tissue engineering and biomaterials, offering enhanced possibilities for creating responsive, adaptive structures that address clinical needs. Researchers can leverage the unique properties of biopolymers within the 4D-printing framework to develop innovative approaches for tissue regeneration and drug delivery, leading to advanced treatments in regenerative medicine. One potential future application is in vivo tissue regeneration using bioprinted structures that can enhance the body’s natural healing capabilities. Full article

(This article belongs to the Special Issue Advances in 3D Printing Technologies: Materials, Processes, and Applications)

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56 pages, 25615 KB

Open AccessReview

Recent Progress and Scientific Challenges in Wire-Arc Additive Manufacturing of Metallic Multi-Material Structures

by Sainand Jadhav, Sambhaji Kusekar, Akash Belure, Satyavan Digole, Abhijeet Mali, Muralimohan Cheepu, Manoj Mugale, Suhas Alkunte and Duckbong Kim

J. Manuf. Mater. Process. 2025, 9(8), 284; https://doi.org/10.3390/jmmp9080284 - 21 Aug 2025

Metallic multi-material structures are heterogeneous structures characterized by changing composition, microstructures, and site-specific characteristics, advantageous for numerous applications where multifunctionality is desired. Metallic multi-material structures are known as bimetallic structures (BSs), which are functionally graded materials (FGMs). In recent years, wire-arc additive manufacturing [...] Read more.

Metallic multi-material structures are heterogeneous structures characterized by changing composition, microstructures, and site-specific characteristics, advantageous for numerous applications where multifunctionality is desired. Metallic multi-material structures are known as bimetallic structures (BSs), which are functionally graded materials (FGMs). In recent years, wire-arc additive manufacturing (WAAM) advanced as a promising additive manufacturing process to realize the fabrication of these structures due to its high deposition rate, cost-effectiveness, and material utilization efficiency. This review presents a comprehensive overview of the recent progress, processing strategies, and scientific challenges in WAAM of multi-material structures. The paper begins with an introduction to multi-material structures, followed by a bibliometric analysis of the current research landscape. Conventional and additive manufacturing fabrication approaches are presented. The review highlights key developments in processing strategies and critically evaluates research studies on WAAM of BS and FGMs. Major scientific challenges, including porosity, lack of fusion, residual stresses, cracking, material compatibility, and brittle intermetallic phase formation, are critically analyzed. Additionally, modeling, simulation, and process automation issues are discussed as barriers to industrial-scale implementation. The paper concludes with an outlook on future research directions to address existing challenges and accelerate the adoption of WAAM for complex multi-material components. Full article

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20 pages, 6471 KB

Open AccessArticle

Analysis of the Suitability of Additive Technologies for the Production of Stainless Steel Components

by Michal Sajgalik, Miroslav Matus, Peter Spuro, Richard Joch, Andrej Czan and Libor Beranek

J. Manuf. Mater. Process. 2025, 9(8), 283; https://doi.org/10.3390/jmmp9080283 - 18 Aug 2025

This study presents a comparative analysis of three metal additive manufacturing processes: selective laser melting (SLM), also known as powder bed fusion (PBF); binder jetting (BJ); and atomic diffusion additive manufacturing (ADAM), a form of Material Extrusion (MEX). It focuses on the geometric [...] Read more.

This study presents a comparative analysis of three metal additive manufacturing processes: selective laser melting (SLM), also known as powder bed fusion (PBF); binder jetting (BJ); and atomic diffusion additive manufacturing (ADAM), a form of Material Extrusion (MEX). It focuses on the geometric and dimensional accuracy of ADAM-fabricated 17-4 PH stainless steel components, while AISI 316L stainless steel is the benchmark material for BJ and SLM technologies. In addition to dimension and geometry inspections, this study also measures the distribution of residual stresses and microstructural features of the printed components. Residual stresses were determined quantitatively to identify the internal state of stress developed because of each processing technology. The results reveal significant differences in dimensional accuracy, residual stress profiles, surface roughness, and microstructural characteristics among the three additive manufacturing technologies. The observed trends and correlations provide valuable guidance for selecting the most appropriate additive manufacturing technique based on required accuracy, mechanical properties, and product complexity. Full article

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16 pages, 5567 KB

Open AccessArticle

Long-Term Impact of Sterilization Cycles on the Surface and Mechanical Integrity of Medical-Grade Silicone

by Mohsen Barmouz, Bahman Azarhoushang, Wolfram Kintzel and Volker Bucher

J. Manuf. Mater. Process. 2025, 9(8), 282; https://doi.org/10.3390/jmmp9080282 - 16 Aug 2025

This study investigates the effects of repeated cleaning, disinfection, and sterilization cycles on the surface and mechanical properties of medical-grade silicone, including both pure silicone and silicone–steel composite samples. Given the critical importance of sterilization for infection control, understanding its long-term impact on [...] Read more.

This study investigates the effects of repeated cleaning, disinfection, and sterilization cycles on the surface and mechanical properties of medical-grade silicone, including both pure silicone and silicone–steel composite samples. Given the critical importance of sterilization for infection control, understanding its long-term impact on material performance is essential. Samples were subjected to up to 1000 cycles, with evaluations at the initial state and after 200, 500, and 1000 cycles. The contact angle initially decreased from 117.1° to 104.0° after 200 cycles, then gradually increased, approaching the original value after 1000 cycles, likely due to the removal of degraded surface layers. Hardness measurements showed a steady increase at each stage, with an approximate 5% rise per cycle group. Notch growth testing revealed a sixfold increase in crack length after 200 cycles and a twofold increase between 500 and 1000 cycles, indicating substantial loss of mechanical integrity. Optical microscopy of the silicone–steel interface revealed progressive deterioration, including crack formation, erosion, and partial debonding, particularly after 1000 cycles. These findings highlight the material and interfacial vulnerabilities of silicone-based medical devices under prolonged sterilization protocols. Full article

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18 pages, 4892 KB

Open AccessArticle

A Real-Time Anomaly Detection Model of Nomex Honeycomb Composites Disc Tool

by Xuanlin Wang, Peihao Tang, Jie Xu, Xueping Liu and Peng Mou

J. Manuf. Mater. Process. 2025, 9(8), 281; https://doi.org/10.3390/jmmp9080281 - 15 Aug 2025

Nomex honeycomb composites (NHCs) are highly sensitive to the abnormal wear state of disc tools during cutting, leading to poor product quality. This paper proposes a real-time anomaly detection method combining a novel CNN–GRU–Attention (CGA) deep learning model with an Exponentially Weighted Moving [...] Read more.

Nomex honeycomb composites (NHCs) are highly sensitive to the abnormal wear state of disc tools during cutting, leading to poor product quality. This paper proposes a real-time anomaly detection method combining a novel CNN–GRU–Attention (CGA) deep learning model with an Exponentially Weighted Moving Average (EWMA) control chart to monitor sensor data from the disc tool. The CGA model integrates an improved CNN layer to extract multidimensional local features, a GRU layer to capture long-term temporal dependencies, and a multi-head attention mechanism to highlight key information and reduce error accumulation. Trained solely on normal operation data to address the scarcity of abnormal samples, the model predicts cutting force time series with an RMSE of 0.5012, MAE of 0.3942, and R² of 0.9128, outperforming mainstream time series data prediction models. The EWMA control chart applied to the prediction residuals detects abnormal tool wear trends promptly and accurately. Experiments on real NHC cutting datasets demonstrate that the proposed method effectively identifies abnormal machining conditions, enabling timely tool replacement and significantly enhancing product quality assurance. Full article

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25 pages, 3250 KB

Open AccessArticle

A Thermoelastic Plate Model for Shot Peen Forming Metal Panels Based on Effective Torque

by Conor Rowan

J. Manuf. Mater. Process. 2025, 9(8), 280; https://doi.org/10.3390/jmmp9080280 - 15 Aug 2025

A common technique used in factories to shape metal panels is shot peen forming, where the panel is sprayed with a high-velocity stream of small steel pellets called “shot.” The impacts between the hard steel shot and the softer metal of the panel [...] Read more.

A common technique used in factories to shape metal panels is shot peen forming, where the panel is sprayed with a high-velocity stream of small steel pellets called “shot.” The impacts between the hard steel shot and the softer metal of the panel cause localized plastic deformation, which is used to improve the fatigue properties of the material’s surface. The residual stress distribution imparted by impacts also results in bending, which suggests that a torque is associated with it. In this paper, we model shot peen forming as the application of spatially varying torques to a Kirchhoff plate, opting to use the language of thermoelasticity in order to introduce these torque distributions. First, we derive the governing equations for the thermoelastic thin plate model and show that only a torque-type resultant of the temperature distribution shows up in the bending equation. Next, to calibrate from the shot peen operation, an empirical “effective torque” parameter used in the thermoelastic model, a simple and non-invasive test is devised. This test relies only on measuring the maximum displacement of a uniformly shot peened plate as opposed to characterizing the residual stress distribution. After discussing how to handle the unconventional fully free boundary conditions germane to shot peened plates, we introduce an approach to solving the inverse problem whereby the peening distribution required to obtain a specified plate contour can be obtained. Given that the relation between shot peen distributions and bending displacements at a finite set of points is non-unique, we explore a regularization of the inverse problem which gives rise to shot peen distributions that match the capabilities of equipment in the factory. In order to validate our proposed model, an experiment with quantified uncertainty is designed and carried out which investigates the agreement between the predictions of the calibrated model and real shot peen-forming operations. Full article

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20 pages, 10593 KB

Open AccessArticle

Optimising WC-25Co Feedstock and Parameters for Laser-Directed Energy Deposition

by Helder Nunes, José Nhanga, Luís Regueiras, Ana Reis, Manuel F. Vieira, Bruno Guimarães, Daniel Figueiredo, Cristina Fernandes and Omid Emadinia

J. Manuf. Mater. Process. 2025, 9(8), 279; https://doi.org/10.3390/jmmp9080279 - 14 Aug 2025

Laser-Directed Energy Deposition (L-DED) is an additive manufacturing technique used for producing and repairing components, mainly for coating applications, depositing metal matrix composites such as cemented carbides, composed of hard metal carbides and a metallic binder. In this sense, this study evaluated the [...] Read more.

Laser-Directed Energy Deposition (L-DED) is an additive manufacturing technique used for producing and repairing components, mainly for coating applications, depositing metal matrix composites such as cemented carbides, composed of hard metal carbides and a metallic binder. In this sense, this study evaluated the preparation of a ready-to-press WC-25Co powder as a reliable feedstock for L-DED process. This powder required pre-heat treatment studies to prevent fragmentation during powder feeding, due to the absence of metallurgical bonding between WC and Co particles. In the current study, the Taguchi methodology was used, varying laser power, powder feed rate, and scanning speed to reach an optimised deposition window. The best bead morphology resulted from 2400 W laser power, 11 mm/s scanning speed, and 9 g/min feed rate. Moreover, defects such as porosity and cracking were mitigated by applying a remelting strategy of 2400 W and 9 mm/s. Therefore, a perfect deposition is obtained using the optimised processing parameters. Microstructural analysis of the optimised deposited line revealed a fine structure, comprising columnar and equiaxed dendrites of complex carbides. The average hardness of the deposited WC-25Co powder on a AISI 1045 steel was 854 ± 37 HV0.2. These results demonstrate the potential of L-DED for processing high-performance cemented carbide coatings. Full article

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20 pages, 7113 KB

Open AccessArticle

Extrusion 3D-Printed Kaolinite Ceramic Filters for Water Applications

by Rawan Elsersawy, Romina Donyadari and Mohammad Abu Hasan Khondoker

J. Manuf. Mater. Process. 2025, 9(8), 278; https://doi.org/10.3390/jmmp9080278 - 14 Aug 2025

Ceramic materials have been utilized for centuries across a range of industries due to their chemical stability and porous microstructure. One prominent application is water filtration, where ceramics offer an effective medium for removing contaminants. Ceramic filters can operate under either pressure-driven or [...] Read more.

Ceramic materials have been utilized for centuries across a range of industries due to their chemical stability and porous microstructure. One prominent application is water filtration, where ceramics offer an effective medium for removing contaminants. Ceramic filters can operate under either pressure-driven or gravity-driven mechanisms. While traditional fabrication techniques, such as pottery, have been historically employed to produce ceramic filters, these methods are limited by user skills, lack of reproducibility, and geometric constraints. In contrast, modern additive manufacturing techniques provide enhanced precision, repeatability, and customization. This study employs extrusion-based 3D printing to fabricate gravity-driven ceramic filters with tailored geometries to meet specific performance requirements. The use of 3D printing allows for efficient production of uniform filters with optimized internal structures. The selected ceramic material, derived from natural sources, offers environmental compatibility, as it is both sustainable and biodegradable. The fabricated filters were evaluated for their effectiveness in treating water. The filtration tests showed significant improvements in water quality, including reduced turbidity, color, iron, manganese, and total and calcium hardness. pH increased from 6.23 to 7.26, and conductivity dropped from 7.43 mS to 4.5 mS, indicating effective ion removal. These findings highlight the potential of 3D-printed ceramic filters as an environmentally friendly and effective solution for decentralized water purification applications. Full article

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34 pages, 11215 KB

Open AccessArticle

New Approach to High-Speed Multi-Coordinate Milling Based on Kinematic Cutting Parameters and Acoustic Signals

by Petr M. Pivkin, Mikhail P. Kozochkin, Artem A. Ershov, Ludmila A. Uvarova, Alexey B. Nadykto and Sergey N. Grigoriev

J. Manuf. Mater. Process. 2025, 9(8), 277; https://doi.org/10.3390/jmmp9080277 - 13 Aug 2025

In this work, a new approach to high-speed multi-coordinate milling was developed. The new approach is based on a new model of trochoidal machining; this is, in turn, based on the theoretical thickness of a chip and its ratio to the cutting edge’s [...] Read more.

In this work, a new approach to high-speed multi-coordinate milling was developed. The new approach is based on a new model of trochoidal machining; this is, in turn, based on the theoretical thickness of a chip and its ratio to the cutting edge’s radius, allowing us to establish the vibroacoustic indicators of cutting efficiency. The new model can be used for the real-time assessment of prevailing cutting mechanisms and chip formation. A set of new indicators and parameters for trochoidal high-speed milling (HSM), which can be used to calculate tool paths during technological preparation of slotting, was determined and verified. The size effect in the multi-coordinate HSM of slots on cast iron was identified based on the dependency of vibroacoustic signals on the cutting tooth’s geometry, HSM’a operational machining modes, theoretical chip thicknesses, the sizes of the cut chips, and the quality/roughness of the surface being machined. Based on the analysis of vibroacoustic signals, a set of the most important indicators for monitoring HSM and determining cutting and crack-formation mechanisms during chip deformation was derived. Based on the new model, recommendations for monitoring HSM and for assigning the tool path relative to the workpiece during production preparation were developed and validated. Full article

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20 pages, 4555 KB

Open AccessArticle

An Experimental Study on Ultrasonic-Assisted Drilling of CFRP Composites with Minimum Quantity Lubrication

by Ramazan Hakkı Namlu, Mustafa Burak Sağener, Zekai Murat Kılıç, Oguz Colak and Sadık Engin Kılıç

J. Manuf. Mater. Process. 2025, 9(8), 276; https://doi.org/10.3390/jmmp9080276 - 12 Aug 2025

The increasing use of carbon fiber reinforced polymer (CFRP) composites in industries such as aerospace, due to its high strength-to-weight ratio, durability, and resistance to corrosion has led to a growing demand for more efficient machining processes. However, the multilayered structure of CFRP [...] Read more.

The increasing use of carbon fiber reinforced polymer (CFRP) composites in industries such as aerospace, due to its high strength-to-weight ratio, durability, and resistance to corrosion has led to a growing demand for more efficient machining processes. However, the multilayered structure of CFRP composites, composed of densely packed fibers, presents significant challenges during machining. Additionally, when cutting fluids are used to improve effective cooling and lubrication, the material tends to absorb the fluid, causing damage and leading to problem of weaking of composite structure. To address these issues, this study compares ultrasonic-assisted drilling (UAD) and minimum quantity lubrication (MQL) techniques with conventional drilling (CD) and dry cutting to improve the performance of CFRP composite drilling. The results show that using UAD and MQL together reduced thrust force by up to 27%, improved surface roughness inside the holes by up to 31%, reduced improved hole diameter, cylindricity, roundness, and delamination. Full article

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16 pages, 9287 KB

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

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

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19 pages, 4219 KB

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 - 11 Aug 2025

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 KB

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

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 KB

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

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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