Journal of Manufacturing and Materials Processing

31 pages, 5560 KiB

Open AccessArticle

Design of Reconfigurable Handling Systems for Visual Inspection

by Alessio Pacini, Francesco Lupi and Michele Lanzetta

J. Manuf. Mater. Process. 2025, 9(8), 257; https://doi.org/10.3390/jmmp9080257 (registering DOI) - 31 Jul 2025

Industrial Vision Inspection Systems (VISs) often struggle to adapt to increasing variability of modern manufacturing due to the inherent rigidity of their hardware architectures. Although the Reconfigurable Manufacturing System (RMS) paradigm was introduced in the early 2000s to overcome these limitations, designing such [...] Read more.

Industrial Vision Inspection Systems (VISs) often struggle to adapt to increasing variability of modern manufacturing due to the inherent rigidity of their hardware architectures. Although the Reconfigurable Manufacturing System (RMS) paradigm was introduced in the early 2000s to overcome these limitations, designing such reconfigurable machines remains a complex, expert-dependent, and time-consuming task. This is primarily due to the lack of structured methodologies and the reliance on trial-and-error processes. In this context, this study proposes a novel theoretical framework to facilitate the design of fully reconfigurable handling systems for VISs, with a particular focus on fixture design. The framework is grounded in Model-Based Definition (MBD), embedding semantic information directly into the 3D CAD models of the inspected product. As an additional contribution, a general hardware architecture for the inspection of axisymmetric components is presented. This architecture integrates an anthropomorphic robotic arm, Numerically Controlled (NC) modules, and adaptable software and hardware components to enable automated, software-driven reconfiguration. The proposed framework and architecture were applied in an industrial case study conducted in collaboration with a leading automotive half-shaft manufacturer. The resulting system, implemented across seven automated cells, successfully inspected over 200 part types from 12 part families and detected more than 60 defect types, with a cycle below 30 s per part. Full article

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14 pages, 1885 KiB

Open AccessArticle

Advancements in Hole Quality for AISI 1045 Steel Using Helical Milling

by Pedro Mendes Silva, António José da Fonseca Festas, Robson Bruno Dutra Pereira and João Paulo Davim

J. Manuf. Mater. Process. 2025, 9(8), 256; https://doi.org/10.3390/jmmp9080256 (registering DOI) - 31 Jul 2025

Abstract

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, [...] Read more.

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, remains underexplored in the literature. This study addresses this gap by systematically evaluating the influence of key process parameters—cutting speed (V_c), axial depth of cut (a_p), and tool diameter (D_t)—on hole quality attributes, including surface roughness, burr formation, and nominal diameter accuracy. A full factorial experimental design (2³) was employed, coupled with analysis of variance (ANOVA), to quantify the effects and interactions of these parameters. The results reveal that, with a higher V_c, it is possible to reduce surface roughness (R_a) by 30% to 40%, while an increased a_p leads to a 50% increase in R_a. Additionally, D_t emerged as the most critical factor for nominal diameter accuracy, reducing geometrical errors by 1% with a larger D_t. Burr formation was predominantly observed at the lower end of the hole, highlighting challenges specific to this technique. These findings provide valuable insights into optimizing helical milling for low-carbon steels, offering a foundation for broader industrial adoption and further research. Full article

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16 pages, 3072 KiB

Open AccessArticle

Process Development to Repair Aluminum Components, Using EHLA and Laser-Powder DED Techniques

by Adrienn Matis, Min-Uh Ko, Richard Kraft and Nicolae Balc

J. Manuf. Mater. Process. 2025, 9(8), 255; https://doi.org/10.3390/jmmp9080255 (registering DOI) - 31 Jul 2025

Abstract

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. [...] Read more.

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. To optimize the process parameters, single-track depositions were analyzed for both laser-powder DED (feed rate of 2 m/min) and EHLA (feed rate 20 m/min) for AlSi10Mg and Al6061 powders. The cross-sections of single tracks revealed the bonding characteristics and provided laser-powder DED, a suitable parameter selection for the repair. Three damage types were identified on the Al component to define the specification of the repair process and to highlight the capabilities of laser-powder DED and EHLA in repairing intricate surface scratches and dents. Our research is based on variation of the powder mass flow and beam power, studying the influence of these parameters on the weld bead geometry and bonding quality. The evaluation criteria include bonding defects, crack formation, porosity, and dilution zone depth. The bidirectional path planning strategy was applied with a fly-in and fly-out path for the hatching adjustment and acceleration distance. Samples were etched for a qualitative microstructure analysis, and the HV hardness was tested. The novelty of the paper is the new process parameters for laser-powder DED and EHLA deposition strategies to repair large Al components (6061 T6), using AlSi10Mg and Al6061 powder. Our experimental research tested the defect-free deposition and the compatibility of AlSi10Mg on the Al6061 substrate. The readers could replicate the method presented in this article to repair by laser-powder DED/EHLA large Al parts and avoid the replacement of Al components with new ones. Full article

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21 pages, 4865 KiB

Open AccessArticle

Impact of Laser Power and Scanning Speed on Single-Walled Support Structures in Powder Bed Fusion of AISI 316L

by Dan Alexander Gallego, Henrique Rodrigues Oliveira, Tiago Cunha, Jeferson Trevizan Pacheco, Oksana Kovalenko and Neri Volpato

J. Manuf. Mater. Process. 2025, 9(8), 254; https://doi.org/10.3390/jmmp9080254 - 30 Jul 2025

Abstract

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing [...] Read more.

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing processes, L-PBF stands out, paving the way for the execution of part designs with geometries previously considered unfeasible. Despite offering several advantages, parts with overhang features require the use of support structures to provide dimensional stability of the part. Support structures achieve this by resisting residual stresses generated during processing and assisting heat dissipation. Although the scientific community acknowledges the role of support structures in the success of L-PBF manufacturing, they have remained relatively underexplored in the literature. In this context, the present work investigated the impact of laser power and scanning speed on the dimensioning, integrity and tensile strength of single-walled block type support structures manufactured in AISI 316L stainless steel. The method proposed in this work is divided in two stages: processing parameter exploration, and mechanical characterization. The results indicated that support structures become more robust and resistant as laser power increases, and the opposite effect is observed with an increment in scanning speed. In addition, defects were detected at the interfaces between the bulk and support regions, which were crucial for the failure of the tensile test specimens. For a layer thickness corresponding to 0.060 mm, it was verified that the combination of laser power and scanning speed of 150 W and 500 mm/s resulted in the highest tensile resistance while respecting the dimensional deviation requirement. Full article

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

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22 pages, 3504 KiB

Open AccessArticle

Improving Geometric Formability in 3D Paper Forming Through Ultrasound-Assisted Moistening and Radiative Preheating for Sustainable Packaging

by Heike Stotz, Matthias Klauser, Johannes Rauschnabel and Marek Hauptmann

J. Manuf. Mater. Process. 2025, 9(8), 253; https://doi.org/10.3390/jmmp9080253 - 26 Jul 2025

Abstract

In response to increasing sustainability demands, the packaging industry is shifting toward paper-based alternatives to replace polymer packaging. However, achieving complex, three-dimensional geometries comparable to plastics remains challenging due to the limited stretchability of paper. This study investigates advanced preconditioning techniques to enhance [...] Read more.

In response to increasing sustainability demands, the packaging industry is shifting toward paper-based alternatives to replace polymer packaging. However, achieving complex, three-dimensional geometries comparable to plastics remains challenging due to the limited stretchability of paper. This study investigates advanced preconditioning techniques to enhance the formability of paper materials for deep-draw packaging applications. A custom-built test rig was developed at Syntegon Technology GmbH to systematically evaluate the effects of ultrasound-assisted moistening and segmented radiative heating. Under optimized conditions, 2.67 s moistening, 70.00 °C punch temperature, and 2999 W radiation power, maximum stretchability increased from 13.00% to 26.93%. The results confirm the effectiveness of ultrasound in accelerating moisture uptake and radiation heating in achieving uniform thermal distribution across the paper substrate. Although prototype constraints, such as the absence of inline conditioning and real-time measurement, limit process stability and scalability, the findings provide a strong foundation for developing industrial 3D paper forming processes that support sustainable packaging innovation. Full article

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21 pages, 4393 KiB

Open AccessArticle

Lightweight and Sustainable Steering Knuckle via Topology Optimization and Rapid Investment Casting

by Daniele Almonti, Daniel Salvi, Emanuele Mingione and Silvia Vesco

J. Manuf. Mater. Process. 2025, 9(8), 252; https://doi.org/10.3390/jmmp9080252 - 24 Jul 2025

Abstract

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing [...] Read more.

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing and manufacturing a MacPherson steering knuckle using topology optimization (TO), additive manufacturing, and rapid investment casting (RIC). Static structural simulations confirmed the mechanical integrity of the optimized design, with stress and strain values remaining within the elastic limits of the SG A536 iron alloy. The TO process achieved a 30% reduction in mass, resulting in lower material use and production costs. Additive manufacturing of optimized geometry reduced resin consumption by 27% and printing time by 9%. RIC simulations validated efficient mold filling and solidification, with porosity confined to removable riser regions. Life cycle assessment (LCA) demonstrated a 27% reduction in manufacturing environmental impact and a 31% decrease throughout the component life cycle, largely due to vehicle lightweighting. The findings highlight the potential of integrated TO and advanced manufacturing techniques to produce structurally efficient and environmentally sustainable automotive components. This workflow offers promising implications for broader industrial applications that aim to balance mechanical performance with ecological responsibility. Full article

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22 pages, 11182 KiB

Open AccessArticle

Application of Laser Thermal Deformation Sintering in the Manufacture of Drum-Type Diamond Tools

by Oleksii Kaglyak, Leonid Golovko, Oleksii Goncharuk, Svitlana Voloshko, Oleksandr Kapustynskyi and Nikolaj Višniakov

J. Manuf. Mater. Process. 2025, 9(8), 251; https://doi.org/10.3390/jmmp9080251 - 24 Jul 2025

Abstract

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological [...] Read more.

An analysis of the existing methods of sintering diamond-containing composites is presented. On the basis of mathematical modeling and experimental studies, the conditions of the laser liquid-phase sintering of diamond-containing composites under which they retain their strength are determined. The energy and technological parameters of the laser irradiation process are characterized, which determine the range of laser processing modes within which no oxidation and crack formation occur, and a high-quality composite with specified geometrical parameters is formed. It has been proven that composites consisting of synthetic diamond grains and a metal bond do not lose strength under the condition that the temperature during laser heating does not exceed 1600 °C and the exposure time is 0.3 s. Electron microscopy and X-ray diffractometry were used for experimental studies of the microstructure and phase composition of the sintered layers. A new design and manufacturing method for a drum-type abrasive tool with replaceable diamond inserts for grinding large-sized aircraft and shipbuilding products are proposed. Components of a laser technological complex for the implementation of the process of sintering the diamond-containing layer of the abrasive inserts of the drum have been developed. Full article

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19 pages, 2311 KiB

Open AccessArticle

Stochastic Optimization of Quality Assurance Systems in Manufacturing: Integrating Robust and Probabilistic Models for Enhanced Process Performance and Product Reliability

by Kehinde Afolabi, Busola Akintayo, Olubayo Babatunde, Uthman Abiola Kareem, John Ogbemhe, Desmond Ighravwe and Olanrewaju Oludolapo

J. Manuf. Mater. Process. 2025, 9(8), 250; https://doi.org/10.3390/jmmp9080250 - 23 Jul 2025

Abstract

This research integrates stochastic optimization techniques with robust modeling and probabilistic modeling approaches to enhance photovoltaic cell manufacturing processes and product reliability. The study employed an adapted genetic algorithm to tackle uncertainties in the manufacturing process, resulting in improved operational efficiency. It consistently [...] Read more.

This research integrates stochastic optimization techniques with robust modeling and probabilistic modeling approaches to enhance photovoltaic cell manufacturing processes and product reliability. The study employed an adapted genetic algorithm to tackle uncertainties in the manufacturing process, resulting in improved operational efficiency. It consistently achieved optimal fitness, with values remaining at 1.0 over 100 generations. The model displayed a dynamic convergence rate, demonstrating its ability to adjust performance in response to process fluctuations. The system preserved resource efficiency by utilizing approximately 2600 units per generation, while minimizing machine downtime to 0.03%. Product reliability reached an average level of 0.98, with a maximum value of 1.02, indicating enhanced consistency. The manufacturing process achieved better optimization through a significant reduction in defect rates, which fell to 0.04. The objective function value fluctuated between 0.86 and 0.96, illustrating how the model effectively managed conflicting variables. Sensitivity analysis revealed that changes in sigma material and lambda failure had a minimal effect on average reliability, which stayed above 0.99, while average defect rates remained below 0.05. This research exemplifies how stochastic, robust, and probabilistic optimization methods can collaborate to enhance manufacturing system quality assurance and product reliability under uncertain conditions. Full article

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55 pages, 8888 KiB

Open AccessArticle

Single, Multi-, and Many-Objective Optimization of Manufacturing Processes Using Two Novel and Efficient Algorithms with Integrated Decision-Making

by Ravipudi Venkata Rao and Joao Paulo Davim

J. Manuf. Mater. Process. 2025, 9(8), 249; https://doi.org/10.3390/jmmp9080249 - 22 Jul 2025

Abstract

Manufacturing processes are inherently complex, multi-objective in nature, and highly sensitive to process parameter settings. This paper presents two simple and efficient optimization algorithms—Best–Worst–Random (BWR) and Best–Mean–Random (BMR)—developed to solve both constrained and unconstrained optimization problems of manufacturing processes involving single, multi-, and [...] Read more.

Manufacturing processes are inherently complex, multi-objective in nature, and highly sensitive to process parameter settings. This paper presents two simple and efficient optimization algorithms—Best–Worst–Random (BWR) and Best–Mean–Random (BMR)—developed to solve both constrained and unconstrained optimization problems of manufacturing processes involving single, multi-, and many-objectives. These algorithms are free from metaphorical inspirations and require no algorithm-specific control parameters, which often complicate other metaheuristics. Extensive testing reveals that BWR and BMR consistently deliver competitive, and often superior, performance compared to established methods. Their multi- and many-objective extensions, named MO-BWR and MO-BMR, respectively, have been successfully applied to tackle 2-, 3-, and 9-objective optimization problems in advanced manufacturing processes such as friction stir processing (FSP), ultra-precision turning (UPT), laser powder bed fusion (LPBF), and wire arc additive manufacturing (WAAM). To aid in decision-making, the proposed BHARAT can be integrated with MO-BWR and MO-BMR to identify the most suitable compromise solution from among a set of Pareto-optimal alternatives. The results demonstrate the strong potential of the proposed algorithms as practical tools for intelligent decision-making in real-world manufacturing applications. Full article

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37 pages, 21436 KiB

Open AccessReview

An Overview of the Working Conditions of Laser–Arc Hybrid Processes and Their Effects on Steel Plate Welding

by Girolamo Costanza, Fabio Giudice, Severino Missori, Cristina Scolaro, Andrea Sili and Maria Elisa Tata

J. Manuf. Mater. Process. 2025, 9(8), 248; https://doi.org/10.3390/jmmp9080248 - 22 Jul 2025

Abstract

Over the past 20 years, laser beam–electric arc hybrid welding has gained popularity, enabling high quality and efficiency standards needed for steel welds in structures subjected to severe working conditions. This process enables single-pass welding of thick components, overcoming issues concerning the individual [...] Read more.

Over the past 20 years, laser beam–electric arc hybrid welding has gained popularity, enabling high quality and efficiency standards needed for steel welds in structures subjected to severe working conditions. This process enables single-pass welding of thick components, overcoming issues concerning the individual use of traditional processes based on an electric arc or laser beam. Therefore, thorough knowledge of both processes is necessary to combine them optimally in terms of efficiency, reduced presence of defects, corrosion resistance, and mechanical and metallurgical features of the welds. This article aims to review the technical and metallurgical aspects of hybrid welding reported in the scientific literature mainly of the last decade, outlining possible choices for system configuration, the inter-distance between the two heat sources, as well as the key process parameters, considering their effects on the weld characteristics and also taking into account the consequences for solidification modes and weld composition. Finally, a specific section has been reserved for hybrid welding of clad steel plates. Full article

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21 pages, 13574 KiB

Open AccessArticle

Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components

by Viththagan Vivekanandam, Shubham Sanjay Joshi, Jaime Lazaro-Nebreda and Zhongyun Fan

J. Manuf. Mater. Process. 2025, 9(7), 247; https://doi.org/10.3390/jmmp9070247 - 21 Jul 2025

Abstract

Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a [...] Read more.

Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a series of fatigue tests conducted at varying stress levels. The material showed significant variability under identical fatigue conditions, suggesting the presence of microstructural defects. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and scanning transmission electron microscopy (S/TEM) were used to identify the nature and location of the defects and evaluate the underlying mechanisms influencing the fatigue performance. Computer tomography (CT) also confirmed the presence of oxide inclusions on the fracture surface and near the edges of the samples. These oxide inclusions are distributed throughout the material heterogeneously and in the form of broken oxide films, suggesting that they might have originated during the material’s early processing stages. These oxides acted as stress concentrators, initiating microcracks that led to catastrophic and unpredictable early failure, ultimately reducing the fatigue life of micro-oxide-containing samples. These results highlight the need for better casting control and improved post-processing techniques to minimise the effect of oxide presence in the final components, thus enhancing their fatigue life. Full article

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29 pages, 4788 KiB

Open AccessArticle

Statistical and Machine Learning Classification Approaches to Predicting and Controlling Peak Temperatures During Friction Stir Welding (FSW) of Al-6061-T6 Alloys

by Assad Anis, Muhammad Shakaib and Muhammad Sohail Hanif

J. Manuf. Mater. Process. 2025, 9(7), 246; https://doi.org/10.3390/jmmp9070246 - 21 Jul 2025

Abstract

This paper presents optimization of peak temperatures achieved during friction stir welding (FSW) of Al-6061-T6 alloys. This research work employed a novel approach by investigating the effect of FSW welding process parameters on peak temperatures through the implementation of finite element analysis (FEA), [...] Read more.

This paper presents optimization of peak temperatures achieved during friction stir welding (FSW) of Al-6061-T6 alloys. This research work employed a novel approach by investigating the effect of FSW welding process parameters on peak temperatures through the implementation of finite element analysis (FEA), the Taguchi method, analysis of variance (ANOVA), and machine learning (ML) algorithms. COMSOL 6.0 Multiphysics was used to perform FEA to predict peak temperatures, incorporating seven distinctive welding parameters: tool material, pin diameter, shoulder diameter, tool rotational speed, welding speed, axial force, and coefficient of friction. The influence of these parameters was investigated using an L32 Taguchi array and analysis of variance (ANOVA), revealing that axial force and tool rotational speed were the most significant parameters affecting peak temperatures. Some simulations showed temperatures exceeding the material’s melting point, indicating the need for improved thermal control. This was achieved by using three machine learning (ML) algorithms, i.e., Logistic Regression, k-Nearest Neighbors (k-NN), and Naive Bayes. A dataset of 324 data points was prepared using a factorial design to implement these algorithms. These algorithms predicted the welding conditions where the temperature exceeded the melting temperature of Al-6061-T6. It was found that the Logistic Regression classifier demonstrated the highest performance, achieving an accuracy of 98.14% as compared to Naive Bayes and k-NN classifiers. These findings contribute to sustainable welding practices by minimizing excessive heat generation, preserving material properties, and enhancing weld quality. Full article

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14 pages, 3997 KiB

Open AccessArticle

Investigation of Die Design Influence on Required Forces in Near-Solidus Forging of Complex Components

by John Damilola Sunday, Alberto Murillo-Marrodán, Eduardo García and Carl Slater

J. Manuf. Mater. Process. 2025, 9(7), 245; https://doi.org/10.3390/jmmp9070245 - 21 Jul 2025

Abstract

This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design (conical, cylindrical, curvilinear), and [...] Read more.

This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design (conical, cylindrical, curvilinear), and draft angles (20° and 30°), with 42CrMo4E steel modeled at 1360 °C. Key responses including punch and lateral forces, temperature distribution, strain localization, and die stress were evaluated to assess design effects. Results showed that the gating system geometry critically controls material flow and load requirements. The conical gating design with a 30° draft angle yielded the lowest punch (141.54 t) and lateral (149.44 t) forces, alongside uniform temperature and strain distributions, which improve product quality by minimizing defects and incomplete filling. Lower lateral forces also reduce die opening risk, enhancing die life. In contrast, the base case with a 20° draft angle exhibited higher forces and uneven strain, increasing die stress and compromising part quality. These findings highlight the importance of selecting appropriate gating systems and draft angles to reduce forming loads, increase die life, and improve uniform material flow, contributing to better understanding of die design in NSF of complex steel components. Full article

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14 pages, 3471 KiB

Open AccessArticle

Dispersant-Induced Enhancement of Rheological Properties in Metal–Photopolymer Mixtures for 3D Printing

by Zhiyuan Qu, Guangchao Song, Josue Olortegui-Revoredo, Patrick Kwon and Haseung Chung

J. Manuf. Mater. Process. 2025, 9(7), 244; https://doi.org/10.3390/jmmp9070244 - 20 Jul 2025

Abstract

The Scalable and Expeditious Additive Manufacturing (SEAM) process is an advanced additive manufacturing (AM) technique that relies on the optimization of metal powder suspensions to achieve high-quality 3D-printed components. This study explores the critical role of dispersants in enhancing the performance of stainless [...] Read more.

The Scalable and Expeditious Additive Manufacturing (SEAM) process is an advanced additive manufacturing (AM) technique that relies on the optimization of metal powder suspensions to achieve high-quality 3D-printed components. This study explores the critical role of dispersants in enhancing the performance of stainless steel (SS) 420 metal powder suspensions for the SEAM process by improving powder loading, recyclability, flowability, and consequent final part density. The addition of dispersant allows for increased powder contents while preserving stable rheological properties, thereby enabling higher powder loading without compromising the rheological characteristics required in the SEAM process. Previously, our team implemented a two-step printing strategy to address the segregation issues during printing. Nonetheless, the semi-cured layer was not recyclable after printing, resulting in a significant amount of waste in the SEAM process. This, in turn, leads to a considerable increase in material costs. On the other hand, the addition of a dispersant has been shown to enhance suspension stability, enabling multiple cycles of reuse. This novel approach has been demonstrated to reduce material waste and lower production costs. The enhanced flowability guarantees uniform suspension spreading, resulting in defect-free layer deposition and superior process control. Moreover, the dispersant’s ability to impede particle agglomeration and promote powder loading contributes to the attainment of a 99.33% relative density in the final sintered SS420 parts, thereby markedly enhancing their mechanical integrity. These findings demonstrate the pivotal role of dispersants in refining the SEAM process, enabling the production of high-density, cost-effective metal components with superior material utilization and process efficiency. Full article

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22 pages, 4496 KiB

Open AccessArticle

Non-Isothermal Process of Liquid Transfer Molding: Transient 3D Simulations of Fluid Flow Through a Porous Preform Including a Sink Term

by João V. N. Sousa, João M. P. Q. Delgado, Ricardo S. Gomez, Hortência L. F. Magalhães, Felipe S. Lima, Glauco R. F. Brito, Railson M. N. Alves, Fernando F. Vieira, Márcia R. Luiz, Ivonete B. Santos, Stephane K. B. M. Silva and Antonio G. B. Lima

J. Manuf. Mater. Process. 2025, 9(7), 243; https://doi.org/10.3390/jmmp9070243 - 18 Jul 2025

Abstract

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent [...] Read more.

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent properties and quality. A true physical phenomenon occurring in the RTM process, especially when using vegetable fibers, is related to the absorption of resin by the fiber during the infiltration process. The real effect is related to the slowdown in the advance of the fluid flow front, increasing the mold filling time. This phenomenon is little explored in the literature, especially for non-isothermal conditions. In this sense, this paper does a numerical study of the liquid injection process in a closed and heated mold. The proposed mathematical modeling considers the radial, three-dimensional, and transient flow, variable injection pressure, and fluid viscosity, including the effect of liquid fluid absorption by the reinforcement (fiber). Simulations were carried out using Computational Fluid Dynamic tools. The numerical results of the filling time were compared with experimental results, and a good approximation was obtained. Further, the pressure, temperature, velocity, and volumetric fraction fields, as well as the transient history of the fluid front position and injection fluid volumetric flow rate, are presented and analyzed. Full article

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

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16 pages, 4905 KiB

Open AccessArticle

Characteristics of Laser-Remelted Al–Ca–Cu–Mn (Zr) Alloys as a New Material for Additive Manufacturing

by Nikolay V. Letyagin, Torgom K. Akopyan, Pavel A. Palkin, Stanislav O. Cherkasov, Anastasiya S. Fortuna, Alexandr B. Lyukhter and Ruslan Yu. Barkov

J. Manuf. Mater. Process. 2025, 9(7), 242; https://doi.org/10.3390/jmmp9070242 - 17 Jul 2025

Abstract

In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al₂₇Ca₃Cu₇ primary crystals [...] Read more.

In this study, prospects of designing new Al–Ca–Cu–Mn (Zr) alloys for additive manufacturing (AM) were evaluated for the example of laser remelting of thin-sheet rolled products. The new as-cast alloys have a hypereutectic structure containing Al₂₇Ca₃Cu₇ primary crystals and ultrafine eutectic particles of (Al,Cu)₄Ca and Al₂₇Ca₃Cu₇ phases in equilibrium with the aluminum solid solution. The solid solutions are additionally strengthened by alloying with Mn and micro additions of Zr, which contribute to the formation of coarsening-resistant phases without compromising the manufacturability of the alloys. Laser remelting, which simulates AM-typical solidification conditions, promotes the formation of a pseudoeutectic cellular structure without the occurrence of undesirable primary Al₂₇Ca₃Cu₇. The size of the dendritic cells and eutectic particles is 10 times smaller (for solidification rates of ~200 K/s) than that of the as-cast state. This structure provides for a higher hardness of the laser-remelted alloy (96 HV) as compared to the as-cast alloy (85 HV). Data for the alloy after 350–400 °C long-term annealing for up to 100 h show that the hardness of the Al–Ca–Cu–Mn–Zr alloys declines relatively slowly by ~7.5% as compared to the Zr-free alloy, whose hardness decreases by ~22%. Thus, one can consider these alloys as a promising candidate for AM processes that require high thermal stability. Full article

(This article belongs to the Special Issue Laser Surface Modification: Advances and Applications)

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18 pages, 11712 KiB

Open AccessArticle

Measuring Transient Friction Coefficient Affected by Plastic Heat Generation Using a Warm Ring Compression Test with an In Situ Measurement System Measuring Ring Expansion Velocity

by Alireza Soleymanipoor, Tomoyoshi Maeno, Kosuke Tosaka, Masato Kakudo, Kazuhito Takahashi, Motoki Yanagisawa and Osami Tsukamoto

J. Manuf. Mater. Process. 2025, 9(7), 241; https://doi.org/10.3390/jmmp9070241 - 16 Jul 2025

Abstract

Frictional conditions at the workpiece–die interface are critical in metal forming, as significant plastic deformation generates heat that affects lubricant performance. Understanding lubricant behavior, especially its influence on friction under elevated temperatures, is essential for optimizing forming processes and meeting ecological demands. While [...] Read more.

Frictional conditions at the workpiece–die interface are critical in metal forming, as significant plastic deformation generates heat that affects lubricant performance. Understanding lubricant behavior, especially its influence on friction under elevated temperatures, is essential for optimizing forming processes and meeting ecological demands. While the conventional ring compression test evaluates friction through inner diameter changes, it becomes unreliable when friction is transient. In this study, a warm ring compression test incorporating an in situ measurement system is proposed to evaluate the transient frictional behavior of lubricants under temperature rise due to plastic deformation. Results show that at T = 50 °C and 150 °C, the friction coefficient increases notably with the compression ratio, whereas at T = 100 °C, it remains relatively stable. This stability is likely due to the optimal performance of the chlorinated base lubricant at 100 °C, where boundary lubrication is most effective. At T = 50 °C, the additive activation is insufficient, and at T = 150 °C, thermal degradation may reduce its effectiveness. Finite element simulations using the transient friction coefficient reproduce the deformed ring cross-section with high accuracy, while those using constant friction values show less agreement. Full article

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15 pages, 2354 KiB

Open AccessArticle

Comprehensive Experimental Analysis of Electrochemical Jet Machining (ECJM) for Advanced Material Processing

by Shailesh Shirguppikar, Aleksandar Ašonja, Eleonora Desnica, Vaibhav Ganachari, Pankaj B. Gavali, Lakshmanan Selvarajan and Blaža Stojanović

J. Manuf. Mater. Process. 2025, 9(7), 240; https://doi.org/10.3390/jmmp9070240 - 16 Jul 2025

Abstract

This study examines the capabilities and optimisation of electrochemical jet machining (ECJM), a component of the electrochemical machining (ECM) production chain. A localised electrolyte jet helps remove material from selective areas; it is a suitable process for contoured parts and hard-to-machine material without [...] Read more.

This study examines the capabilities and optimisation of electrochemical jet machining (ECJM), a component of the electrochemical machining (ECM) production chain. A localised electrolyte jet helps remove material from selective areas; it is a suitable process for contoured parts and hard-to-machine material without inflicting thermal or mechanical stresses. In this regard, the study incorporates details of an experimental layout and variation in parameters in terms of voltage, electrolyte concentration, and jet velocity. The most striking findings indicate that the material removal rate and surface quality are susceptible to parameters such as applied voltage and stand-off distance, and electrolyte concentration and jet velocity (via electrolyte supply rate) fixed. Higher voltages and fixed electrolyte concentrations give higher removal rates, though this might impair the surface finish, thereby requiring a trade-off at best. These results provide insights into optimising process parameters for enhanced precision and efficiency in ECJM. Future research could focus on advanced electrolytes and improving scalability for industrial applications. Full article

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18 pages, 2473 KiB

Open AccessArticle

Experimental Investigations on Microstructure and Mechanical Properties of L-Shaped Structure Fabricated by WAAM Process of NiTi SMA

by Vatsal Vaghasia, Rakesh Chaudhari, Sakshum Khanna, Jash Modi and Jay Vora

J. Manuf. Mater. Process. 2025, 9(7), 239; https://doi.org/10.3390/jmmp9070239 - 11 Jul 2025

Abstract

In the present study, an L-shaped multi-walled structure of NiTi shape memory alloy (SMA) was fabricated by using the wire arc additive manufacturing (WAAM) method on a titanium substrate. The present study aims to investigate the fabricated structure for microstructure, macrostructure, and mechanical [...] Read more.

In the present study, an L-shaped multi-walled structure of NiTi shape memory alloy (SMA) was fabricated by using the wire arc additive manufacturing (WAAM) method on a titanium substrate. The present study aims to investigate the fabricated structure for microstructure, macrostructure, and mechanical properties. The 40 layers of L-shaped structure were successfully fabricated at optimized parameters of wire feed speed at 6 m/min, travel speed at 12 mm/s, and voltage at 20 V. The macrographs demonstrated the continuous bonding among the layers with complete fusion. The microstructure in the area between the two middle layers has exhibited a mixture of columnar grains (both coarse and fine), interspersed with dendritic colonies. The microstructure in the topmost layers has exhibited finer colonial structures in relatively greater numbers. The microhardness (MH) test has shown the average values of 283.2 ± 3.67 HV and 371.1 ± 5.81 HV at the bottom and topmost layers, respectively. A tensile test was conducted for specimens extracted from deposition and build directions, which showed consistent mechanical behavior. For the deposition direction, the average ultimate tensile strength (UTS) and elongation (EL) were obtained as 831 ± 22.91 MPa and 14.32 ± 0.55%, respectively, while the build direction has shown average UTS and EL values of 774 ± 6.56 MPa and 14.16 ± 0.21%, respectively. The elongation exceeding 10% in all samples suggests that the fabricated structure demonstrates properties comparable to those of wrought metal. Fractography of all tensile specimens has shown good ductility and toughness. Lastly, a differential scanning calorimetry test was carried out to assess the retention of shape memory effect for the fabricated structure. The authors believe that the findings of this work will be valuable for various industrial applications. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)

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