Search for Articles:
Title / Keyword
Author / Affiliation / Email
Journal
Article Type
 
 
Advanced Search
 
Section
Special Issue
Volume
Issue
Number
Page
 
5.2
3.3
Journals
JMMP
Special Issues
Innovative Approaches in Metal Forming and Joining Technologies
share announcement

Innovative Approaches in Metal Forming and Joining Technologies

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

Deadline for manuscript submissions: 31 December 2025 | Viewed by 6544

Special Issue Editor

Dr. Mohammad Mehdi Kasaei

E-Mail Website
Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), 4200-465 Porto, Portugal
Interests: manufacturing; metal forming; joining by plastic deformation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal forming and joining technologies are at the forefront of modern manufacturing, enabling the production of high-performance components for industries such as automotive, aerospace, and energy. With the increasing demand for lightweight, durable, and sustainable structures, innovative approaches are essential to overcoming the challenges associated with processing advanced metals and manufacturing multi-material components.

This Special Issue aims to showcase cutting-edge research on metal forming and joining processes, addressing key challenges such as material formability and joinability, process efficiency, defect mitigation, and performance optimization. We welcome original contributions on experimental and numerical advancements, novel forming and joining techniques, hybrid processes, and the integration of digital and AI-driven approaches. By bringing together insights from academia and industry, this Special Issue seeks to advance our understanding and the application of next-generation manufacturing technologies.

We encourage the submission of innovative approaches in the following research areas:

  • Material characterization;
  • Constitutive modeling;
  • Metal forming;
  • Joining;
  • Hybrid joining;
  • Joint analysis and performance evaluation;
  • Process optimization;
  • Numerical modeling;
  • Tool design;
  • Artificial intelligence for forming and joining;
  • Sustainability and recyclability in forming and joining.

Dr. Mohammad Mehdi Kasaei
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

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

  • material characterization
  • metal forming
  • joining
  • hybrid joining
  • joint design
  • optimization
  • machine learning
  • sustainability

Benefits of Publishing in a Special Issue

  • Ease of navigation: Grouping papers by topic helps scholars navigate broad scope journals more efficiently.
  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
  • Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
  • External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
  • Reprint: MDPI Books provides the opportunity to republish successful Special Issues in book format, both online and in print.

Further information on MDPI's Special Issue policies can be found here.

Published Papers (6 papers)

Download All Papers
Order results
Result details
Show export options expand_more Show export options expand_less
Select all
Export citation of selected articles as:

Research

26 pages, 9708 KB  
Article
Heat Treatment and Fracture Behavior of Aluminum/Steel FSW Joints: A Comprehensive Analysis of a Curved Interface
by Tiago Oliveira Gonçalves Teixeira, Reza Beygi, Masih Bolhasani Hesari, Ricardo João Camilo Carbas, Eduardo Andre Sousa Marques, Mohammad Mehdi Kasaei and Lucas Filipe Martins da Silva
J. Manuf. Mater. Process. 2025, 9(11), 381; https://doi.org/10.3390/jmmp9110381 - 20 Nov 2025
Viewed by 419
Abstract
Joining dissimilar metals, such as aluminum and steel, presents an attractive option for creating lightweight yet durable structures. However, challenges arise from the formation of brittle intermetallic compounds (IMCs) at the interface of dissimilar joints, which significantly impact joint strength under load and [...] Read more.
Joining dissimilar metals, such as aluminum and steel, presents an attractive option for creating lightweight yet durable structures. However, challenges arise from the formation of brittle intermetallic compounds (IMCs) at the interface of dissimilar joints, which significantly impact joint strength under load and often lead to brittle failure. This research elaborates on how an S-shaped Al/Steel interface made by a modified friction stir welding (FSW) process mitigates the detrimental effect of IMC thickening on joint strength. This study aims to explore the effects of various post-weld heat treatments on steel and aluminum joints produced through FSW (100–400 °C for 30–90 min). Al/steel FSW joints were characterized by SEM/EDS for interface microstructure and composition, microhardness mapping, tensile testing, and fractography. Any post-weld heat treatment above the temperature of 100 °C caused a drop in joint strength from 2400 N to 1800 N due to the elimination of protrusions in the IMC layer. Further post-weld heat treatment had a negligible effect on the joint strength due to an S-shaped interface. A finite element simulation using a cohesive model for the joint interface is used to study the fracture mechanism of the joint. Both experimental observations and simulation results suggest that the portion of the S-shaped interface perpendicular to the loading direction acts as an initiation site of fracture and fails in a brittle manner. The top and bottom of the interface, which are inclined to the loading direction, fail in a ductile manner with noticeable plastic deformation in the steel adjacent to the interface. The proposed method for FSW of aluminum to steel significantly improves joint durability at elevated temperatures, particularly up to 400 °C. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

22 pages, 9513 KB  
Article
Hindering Effect of Solid-Solutioning on Intermetallic Growth in Aluminum–Matrix Composite Reinforced with Mechanically Alloyed Ni-Cu Particles
by Masih Bolhasani Hesari, Reza Beygi, Ali Bayrami, Mohammad Mehdi Kasaei, Majid Zarezade Mehrizi, Eduardo A. S. Marques and Lucas F. M. da Silva
J. Manuf. Mater. Process. 2025, 9(11), 364; https://doi.org/10.3390/jmmp9110364 - 4 Nov 2025
Viewed by 459
Abstract
In the present study, aluminum matrix composites (AMCs) were fabricated by friction stir processing (FSP) using Ni-Cu particles. Ni-Cu particles were added to the Al matrix in two ways. First, without any treatment and in the form of a mixture of as-received powders. [...] Read more.
In the present study, aluminum matrix composites (AMCs) were fabricated by friction stir processing (FSP) using Ni-Cu particles. Ni-Cu particles were added to the Al matrix in two ways. First, without any treatment and in the form of a mixture of as-received powders. Second, treated through mechanical alloying to form Monel solid-solution particles. The particles were added to a groove to be processed by the FSP tool to produce a local AMC. To investigate the kinetics of intermetallic compounds (IMCs) growth in reinforcement particles, the produced AMCs were annealed at 500 °C for 2 h. To characterize the reinforcing particles, several analyses were performed on the samples. Field-emission scanning electron microscopy (FE-SEM) was used to study the size, morphology, and IMC thickness. TEM was performed to characterize the IMCs through high-resolution chemical analyses. Tensile testing was used to understand the mechanical properties and fracture behavior of AMCs. Tensile testing revealed a noticeable improvement in strength for the as-mixed sample, with a UTS of 90.3 MPa, approximately 22% higher than that of the base aluminum. In contrast, the mechanical alloying sample with annealing heat treatment exhibited a severe drop in ductility, with elongation decreasing from 17.98% in the as-mixed sample to 1.52%. The results showed that heat treatment thickened the IMC layer around the reinforcing particles formed during the FSP process with as-mixed particles. In the AMC reinforced with mechanically alloyed Ni-Cu powders, IMC formation during FSP was significantly suppressed compared to that of as-mixed particles, despite the finer size resulting from milling. Additionally, the heat treatment resulted in only a slight increase in IMC thickness. The IMC layer thickness after heat treatment in both the mechanically alloyed sample and the as-mixed sample was approximately 2 µm and 20–40 µm, respectively. The reason behind this difference and its effect on the fracture behavior of the composite were elaborated in this study, giving insights into metal-matrix production with controlled reaction. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

11 pages, 10135 KB  
Article
Optimization of Direct Bonding Process for Lotus-Type Porous Copper to Alumina Substrates
by Sang-Gyu Choi, Sangwook Kim, Jinkwan Lee, Keun-Soo Kim and Soongkeun Hyun
J. Manuf. Mater. Process. 2025, 9(11), 352; https://doi.org/10.3390/jmmp9110352 - 27 Oct 2025
Viewed by 434
Abstract
The effects of processing conditions and holding time on the direct bonding (DBC) of lotus-type porous copper to alumina substrates were systematically investigated. The evolution of copper morphology and the resulting shear strength were evaluated under varying pressures (0.3–0.6 Torr) and bonding durations [...] Read more.
The effects of processing conditions and holding time on the direct bonding (DBC) of lotus-type porous copper to alumina substrates were systematically investigated. The evolution of copper morphology and the resulting shear strength were evaluated under varying pressures (0.3–0.6 Torr) and bonding durations (5–160 min) at a fixed bonding temperature. It was found that pressure within the tested range exerted a negligible influence on joint quality, as direct bonding occurred consistently. In contrast, holding time was found to be a critical factor: a duration of 10 min yielded optimal bonding with high shear strength while preserving the porous structure, whereas shorter times led to incomplete bonding, and longer times caused structural collapse due to liquid-phase flow. The oxidation behavior, governed by parabolic growth kinetics, was identified as the primary mechanism controlling morphological evolution. These findings provide practical guidance for optimizing DBC bonding of porous copper in power semiconductor applications, balancing joint strength and structural integrity. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

17 pages, 9040 KB  
Article
Adaptive Torque Control for Process Optimization in Friction Stir Welding of Aluminum 6061-T6 Using a Horizontal 5-Axis CNC Machine
by Austin Clark and Ihab Ragai
J. Manuf. Mater. Process. 2025, 9(7), 232; https://doi.org/10.3390/jmmp9070232 - 7 Jul 2025
Viewed by 1574
Abstract
The research presented herein investigates the impact of axial force and feed rate in the Friction Stir Welding (FSW) of aluminum alloy 6061-T6 in a GROB G552 horizontal 5-axis CNC machine with adaptive torque control enabled. The purpose of this study is to [...] Read more.
The research presented herein investigates the impact of axial force and feed rate in the Friction Stir Welding (FSW) of aluminum alloy 6061-T6 in a GROB G552 horizontal 5-axis CNC machine with adaptive torque control enabled. The purpose of this study is to further advance the performance and characteristics of FSW aluminum alloys in 5-axis CNCs, particularly in conjunction with adaptive torque control. The Taguchi and ANOVA methods were utilized to define parameter tables and analyze the resulting data. Optical microscopy and tensile tests were performed on the welded samples to evaluate weld quality. The results from this study provide clear evidence that axial force has a significant effect on tensile strength in FSW AA6061-T6. The maximum UTS found in this study, welded with an axial force of 9.4 kN, retained 69% tensile strength of the base material. Conversely, a decrease in strength and an increase in void formation was found at higher feed rates with this force. Ideal welds, with minimal defects across all feed rates, were performed with an axial force of 8.3 kN. A feed rate of 300 mm/min at this force resulted in a 67% base metal strength. These findings contribute to improving joint strength and application efficiency in FSW AA6061-T6 performed in a horizontal 5-axis CNC machine where adaptive torque control is enabled. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

25 pages, 6526 KB  
Article
Engineering Perfection in GTAW Welding: Taguchi-Optimized Root Height Reduction for SS316L Pipe Joints
by Mohammad Sohel, Vishal S. Sharma and Aravinthan Arumugam
J. Manuf. Mater. Process. 2025, 9(6), 188; https://doi.org/10.3390/jmmp9060188 - 6 Jun 2025
Viewed by 2214
Abstract
This study presents a systematic optimization of GTAW welding parameters to achieve a pipe-to-pipe butt weld with a root height consistently below 2 mm when joining stainless-steel 316L material, employing the Taguchi design of experiments. To the authors’ knowledge, no similar studies have [...] Read more.
This study presents a systematic optimization of GTAW welding parameters to achieve a pipe-to-pipe butt weld with a root height consistently below 2 mm when joining stainless-steel 316L material, employing the Taguchi design of experiments. To the authors’ knowledge, no similar studies have been conducted to explore the optimization of welding parameters specifically aimed at minimizing weld root height under 2 mm in stainless-steel EO pipeline welding applications. This gap in the existing literature highlights the innovative aspect of the current study, which seeks to address these challenges and improve welding precision and joint reliability. Root height, also referred to as weld root reinforcement, is defined as the excess weld metal protruding beyond the inner surface root side of a butt-welded joint. The input parameters considered are the welding current, voltage, speed, and root gap configurations of 1, 1.5, and 2 mm. Welding was performed according to the Taguchi L-09 experimental design. Nine weld samples were evaluated using liquid penetrant testing to detect surface-breaking defects, such as porosity, laps, and cracks; X-ray radiography to identify internal defects; and profile radiography to assess erosion, corrosion, and root height. Among the nine welded plate samples, the optimal root height (less than 2 mm) was selected and further validated through the welding of a one-pipe sample. An additional macro examination was conducted to confirm the root height and assess the overall root weld integrity and quality. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

12 pages, 7004 KB  
Article
Bonding Characteristics in Air of a Decomposable Composite Sheet Containing Sn-3.0Ag-0.5Cu Particles for Formation of a Robust Metallic Solder Joint in Die Attachment
by Hye-Min Lee and Jong-Hyun Lee
J. Manuf. Mater. Process. 2025, 9(5), 161; https://doi.org/10.3390/jmmp9050161 - 15 May 2025
Viewed by 848
Abstract
To address solder paste drawbacks, such as die contamination and flux residue, a polymer-based sheet containing Sn-3.0 (wt%) Ag-0.5Cu solder particles as fillers was fabricated, and its bonding characteristics were analyzed. The reductant in the manufactured sheet evaporated while removing the oxide layers [...] Read more.
To address solder paste drawbacks, such as die contamination and flux residue, a polymer-based sheet containing Sn-3.0 (wt%) Ag-0.5Cu solder particles as fillers was fabricated, and its bonding characteristics were analyzed. The reductant in the manufactured sheet evaporated while removing the oxide layers on the solder and copper finish surfaces during heating. Subsequently, the resin component (polymethyl methacrylate) began to decompose thermally and gradually dissipated. Ultimately, the resulting joint formed a solder interconnection with a small amount of residual resin. This joint is expected to exhibit superior thermal conductivity compared with composite joints with a polymer matrix structure. Die-attach tests were conducted in air using the fabricated sheet between Cu finishes. Results showed that joints formed at 300 °C for 30 s and 350 °C for 10 s provided excellent shear strength values of 48.0 and 44.3 MPa, respectively, along with appropriately developed intermetallic compound (IMC) layers at the bonding interface. In contrast, bonding at 350 °C for 60 s resulted in excessive growth of IMC layers at the interface. When comparing size effects of solder particles, type 6 particles exhibited superior shear strength along with a relatively thinner total IMC layer thickness compared to when type 7 particles were used. Full article
(This article belongs to the Special Issue Innovative Approaches in Metal Forming and Joining Technologies)
►▼ Show Figures

Figure 1

Show export options expand_more Show export options expand_less
Select all
Export citation of selected articles as:
 
Displaying articles 1-6
Back to TopTop