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Recent Developments in Materials Processing for Modern Applications: Advancements and...
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Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 December 2026 | Viewed by 11966

Special Issue Editors

Dr. Liviu Andrușcă

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Gheorghe Asachi Technical University of Iasi, 700050 Iași, Romania
Interests: materials testing; dynamic loading; materials processing; mechanical properties; 3D printing; processes modeling; finite elements analysis simulations
Dr. Nicanor Cimpoesu

E-Mail Website
Guest Editor
Faculty of Materials Science and Engineering, Gheorghe Asachi Technical University of Iasi, 700050 Iași, Romania
Interests: microstructure; ceramic materials; scanning electron microscopy in materials science; energy dispersive spectroscopy in materials science; biocompatible and biodegradable materials; corrosion resistance; ferrous alloys; shape memory alloys; metallic and non-metallic layers
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

From the perspectives of engineers, physicists, researchers, and scientists, we intend to analyze and discuss different modern topics of materials processing. The high potential of the enhancement of a material through processing (thermal or mechanical, forming; machining; joining; welding; laser processing; plasma processing; micro- and nano- processing) makes standard materials suitable for more applications. Actual activity in the domain presents a few problems connected to obtaining and processing metallic alloys, the modification of the surface state, and the characterization, modeling, and simulation of prototyping technologies. Based on the multiple possibilities of applying alloys with well-established production technologies by modifying their properties through various processing methods, this Special Issue is dedicated to showcasing the results obtained through various thermo-mechanical processes, specialized treatments, the sintering of materials obtained through 3D printing, or other processing processes implemented at the laboratory or industrial level.

This Special Issue of the Journal of Manufacturing and Materials Processing intends to focus on the most recent advances in obtaining and processing materials used in the industrial, automotive, chemical, or medical fields with improved performances.

Dr. Liviu Andrușcă
Dr. Nicanor Cimpoesu
Guest Editors

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

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • microstructure
  • processing
  • thermo-mechanical processing
  • dual-phase materials

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Published Papers (7 papers)

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Research

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16 pages, 5186 KB  
Article
A FEM-ML Hybrid Framework for Optimizing the Cooling Schedules of Roll-Bonded Clad Plates
by Alexey G. Zinyagin, Alexander V. Muntin, Nikita R. Borisenko, Andrey P. Stepanov and Maria O. Kryuchkova
J. Manuf. Mater. Process. 2026, 10(2), 49; https://doi.org/10.3390/jmmp10020049 - 30 Jan 2026
Viewed by 550
Abstract
In the production of clad rolled plates from asymmetric sandwich-type slab for pipeline applications, achieving both target mechanical properties and high geometric flatness remains a critical challenge due to differential thermal stresses between the dissimilar steel layers during accelerated cooling. This study aims [...] Read more.
In the production of clad rolled plates from asymmetric sandwich-type slab for pipeline applications, achieving both target mechanical properties and high geometric flatness remains a critical challenge due to differential thermal stresses between the dissimilar steel layers during accelerated cooling. This study aims to develop an optimal cooling schedule for a 25 mm thick clad plate, comprising a X70-grade steel base layer and an AISI 316L cladding, to ensure required strength and minimal bending. A comprehensive approach was employed, integrating a 3D finite element model (Ansys) for simulating thermoelastic stresses with a CatBoost machine learning model trained on industrial data to predict heat transfer coefficients accurately. A parametric analysis of cooling strategies was conducted. Results showed that a standard cooling strategy caused unacceptable bending of plate after cooling exceeding 130 mm. An optimized strategy featuring delayed activation of the lower cooling headers (on the cladding side) created a compensating thermoelastic moment, successfully reducing bending to approximately 20 mm while maintaining the base layer’s requisite mechanical properties. The findings validate the efficacy of the combined FEM-machine learning methodology and propose a viable, industrially implementable cooling strategy for high-quality clad plate production. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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14 pages, 4953 KB  
Article
Micro- and Nano-Integration in the Production of GaAs and Ga2O3 Nanowire Arrays by Top-Down Design
by Elena I. Monaico, Eduard V. Monaico, Veaceslav V. Ursaki and Ion M. Tiginyanu
J. Manuf. Mater. Process. 2025, 9(11), 376; https://doi.org/10.3390/jmmp9110376 - 16 Nov 2025
Cited by 1 | Viewed by 1073
Abstract
In this paper, a strategy is proposed based on the microstructuring of GaAs substrates by photolithography combined with nanostructuring by electrochemical etching for the purposes of obtaining GaAs nanowire domains in selected regions of the substrate. The micropatterning is based on previously obtained [...] Read more.
In this paper, a strategy is proposed based on the microstructuring of GaAs substrates by photolithography combined with nanostructuring by electrochemical etching for the purposes of obtaining GaAs nanowire domains in selected regions of the substrate. The micropatterning is based on previously obtained knowledge about the mechanisms of pore growth in GaAs substrates during anodization. According to previous findings, crystallographically oriented pores, or “crysto pores,” grow along specific crystallographic directions within the GaAs substrates, with preferential propagation along the <111>B direction. Taking advantage of this feature, it is proposed to pattern the (111)B surface by photolithography and to, subsequently, apply anodization in an HNO3 electrolyte. It is shown that the areas of the GaAs substrate under the photoresist mask are protected against porosification due to the growth of pores perpendicular to the surface of the substrates in such a configuration. Pores overlapping under adjusted electrochemical etching conditions results in the formation of GaAs nanowire arrays in the substrate regions not covered by photoresist. Thermal annealing conditions in an argon atmosphere with a low oxygen concentration were developed for the selective oxidation of GaAs nanowires, thus producing a wide-bandgap Ga2O3 nanowire pattern on the GaAs substrate. It is shown that the morphology of nanowires can be controlled by adjusting the electrochemical parameters. Smooth-walled nanowire arrays were obtained under specific conditions, while perforated and wall-modulated nanowires were formed when crystallographic pores intersected at a higher applied anodizing potential. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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17 pages, 4080 KB  
Article
Green Mechanochemical Synthesis of Binary and Ternary Cadmium Chalcogenides with Tunable Band Gaps
by Matjaž Kristl, Neža Zanjkovič, Jona Kunej, Sašo Gyergyek and Janja Stergar
J. Manuf. Mater. Process. 2025, 9(11), 375; https://doi.org/10.3390/jmmp9110375 - 15 Nov 2025
Viewed by 888
Abstract
In this work, we report on the mechanochemical preparation and characterization of binary (CdS, CdSe, and CdTe) and ternary (CdS0.5Se0.5, CdS0.5Te0.5, and CdSe0.5Te0.5) cadmium chalcogenides. The compounds were synthesized in a [...] Read more.
In this work, we report on the mechanochemical preparation and characterization of binary (CdS, CdSe, and CdTe) and ternary (CdS0.5Se0.5, CdS0.5Te0.5, and CdSe0.5Te0.5) cadmium chalcogenides. The compounds were synthesized in a planetary micro mill using a zirconia grinding bowl and zirconia grinding balls. The products were examined by powder X-ray diffraction (pXRD), transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy (EDX), dynamic light scattering (DLS), UV–Vis spectroscopy, and differential scanning calorimetry (DSC). Interestingly, CdO formed as a by-product only during milling of Cd+S and Cd+Se in air, while it was absent in the Cd+Te and all ternary systems. The materials were obtained in the form of irregularly shaped aggregates measuring up to several hundred nanometers, composed of nearly spherical primary nanoparticles with diameters in the 10–20 nm range. The band gap energies calculated using Tauc plots for CdS0.5Se0.5, CdS0.5Te0.5, and CdSe0.5Te0.5 were 2.01 eV, 1.72 eV, and 1.53 eV, respectively. These results demonstrate the expected tunability of band gaps in ternary cadmium chalcogenides and attest to the potential of such materials for semiconducting applications, particularly in solar cells. The mechanochemical approach is once again shown to be a simple and effective method for the preparation of both binary and ternary chalcogenides, avoiding the use of solvents, toxic precursors, and energy-consuming reaction conditions. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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17 pages, 2287 KB  
Article
Compressive Strength Impact on Cut Depth of Granite During Abrasive Water Jet Machining
by Isam Qasem, La’aly A. Al-Samrraie and Khalideh Al Bkoor Alrawashdeh
J. Manuf. Mater. Process. 2025, 9(8), 262; https://doi.org/10.3390/jmmp9080262 - 5 Aug 2025
Cited by 1 | Viewed by 2150
Abstract
Background: Compared to the conventional method of machining granite, abrasive water jet machining (AWJM) offers several benefits, including flexible cutting mechanisms and machine efficiency, among other possible advantages. The high-speed particles carried by water remove the materials, preventing heat damage and maintaining the [...] Read more.
Background: Compared to the conventional method of machining granite, abrasive water jet machining (AWJM) offers several benefits, including flexible cutting mechanisms and machine efficiency, among other possible advantages. The high-speed particles carried by water remove the materials, preventing heat damage and maintaining the granite’s structure. Methods: Three types of granite with different compressive strengths are investigated in terms of the effects of pump pressure (P), traverse speed (T), and abrasive mass flow (A) on the cutting depth. Results: The results of the study demonstrated that the coarse-grained granite negatively affected the penetration depth, while the fine-grained granite produced a higher cutting depth. The value of an optimal depth of penetration was also generated; for example, the optimum depth obtained for Black Galaxy Granite, M1 (32.27 mm), was achieved at P = 300 MPa, T = 100 mm/min, and A = 180.59 g/min. Conclusions: In terms of processing parameters, the maximum penetration depth can be achieved in granite with a higher compressive strength. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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Review

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42 pages, 2357 KB  
Review
Advances in Materials and Manufacturing for Scalable and Decentralized Green Hydrogen Production Systems
by Gabriella Stefánia Szabó, Florina-Ambrozia Coteț, Sára Ferenci and Loránd Szabó
J. Manuf. Mater. Process. 2026, 10(1), 28; https://doi.org/10.3390/jmmp10010028 - 9 Jan 2026
Cited by 7 | Viewed by 2054
Abstract
The expansion of green hydrogen requires technologies that are both manufacturable at a GW-to-TW power scale and adaptable for decentralized, renewable-driven energy systems. Recent advances in proton exchange membrane, alkaline, and solid oxide electrolysis reveal persistent bottlenecks in catalysts, membranes, porous transport layers, [...] Read more.
The expansion of green hydrogen requires technologies that are both manufacturable at a GW-to-TW power scale and adaptable for decentralized, renewable-driven energy systems. Recent advances in proton exchange membrane, alkaline, and solid oxide electrolysis reveal persistent bottlenecks in catalysts, membranes, porous transport layers, bipolar plates, sealing, and high-temperature ceramics. Emerging fabrication strategies, including roll-to-roll coating, spatial atomic layer deposition, digital-twin-based quality assurance, automated stack assembly, and circular material recovery, enable high-yield, low-variance production compatible with multi-GW power plants. At the same time, these developments support decentralized hydrogen systems that demand compact, dynamically operated, and material-efficient electrolyzers integrated with local renewable generation. The analysis underscores the need to jointly optimize material durability, manufacturing precision, and system-level controllability to ensure reliable and cost-effective hydrogen supply. This paper outlines a convergent approach that connects critical-material reduction, high-throughput manufacturing, a digitalized balance of plant, and circularity with distributed energy architectures and large-scale industrial deployment. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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27 pages, 4899 KB  
Review
Advances in Texturing of Polycrystalline Diamond Tools in Cutting Hard-to-Cut Materials
by Sergey N. Grigoriev, Anna A. Okunkova, Marina A. Volosova, Khaled Hamdy and Alexander S. Metel
J. Manuf. Mater. Process. 2026, 10(1), 27; https://doi.org/10.3390/jmmp10010027 - 9 Jan 2026
Viewed by 1223
Abstract
The operational ability of a unit or mechanism depends mainly on the quality of the mechanically produced working surfaces. Many materials can be assigned to a group of hard-to-cut materials that includes titanium- and aluminum-based alloys, a new class of heat-resistant alloys, SiCp/Al [...] Read more.
The operational ability of a unit or mechanism depends mainly on the quality of the mechanically produced working surfaces. Many materials can be assigned to a group of hard-to-cut materials that includes titanium- and aluminum-based alloys, a new class of heat-resistant alloys, SiCp/Al composites, hard alloys, and other alloys. The difficulties in their machining are related not only to the high temperatures achieved on the contact pads under mechanical load and the extreme cutting conditions but also to the properties of those materials, which affect the adhesion of the chip to the tool faces, hindering chip flow. One of the possible solutions to reduce those effects and improve the operational life of the tool, and as a consequence, the final quality of the working surface of the unit, is texturing the rake face of the tool with microgrooves or nanogrooves, microholes or nanoholes (pits, dimples), micronodes, cross-chevron textures, and other microtextures, the depth of which is in the range of 3.0–200.0 µm. This review is addressed at systematizing the data obtained on micro- and nanotexturing of PCD tools for cutting hard-to-cut materials by different techniques (fiber laser graving, femto- and nanosecond laser, electrical discharge machining, fused ion beam), additionally subjected to fluorination and dip- and drop-based coatings, and the effect created by the use of the textured PCD tool on the machined surface. Full article
(This article belongs to the Special Issue Recent Developments in Materials Processing for Modern Applications: Advancements and Challenges)
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46 pages, 5042 KB  
Review
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
Cited by 3 | Viewed by 3193
Abstract
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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