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Machines
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Novel Manufacturing Processes and Their Innovation for Industries
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Novel Manufacturing Processes and Their Innovation for Industries

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: closed (31 December 2024) | Viewed by 4195

Special Issue Editors

Dr. Xiao Li

E-Mail Website
Guest Editor
Applied Materials and Manufacturing Group, Pacific Northwest National Laboratory, Richland, WA, USA
Interests: advanced manufacturing processes; solid-phase processing; shear-assisted extrusion and processing; friction consolidation and extrusion; friction stir welding
Dr. Hrishikesh Das

E-Mail Website
Guest Editor
Pacific Northwest National Laboratory, PO Box 999, Richland, WA 99352, USA
Interests: friction stir welding; solid phase processing; shape; cold spray
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In a world where new technologies and concepts emerge every day, the manufacturing industry faces endless opportunities as well as unprecedented challenges. Innovative manufacturing processes are key to realizing a paradigm shift in industrial production, ushering in unprecedented levels of efficiency, sustainability, and customization. These innovations encompass a wide array of cutting-edge techniques, from sustainable manufacturing processes and AI and data-driven manufacturing, to novel recycling and upcycling processes.

Sustainable manufacturing processes comprise the creation of products through economically sound processes that minimize negative environmental impacts, e.g., reduce waste and carbon emission, while conserving energy and natural resources. AI and data-driven manufacturing leverage advanced algorithms and data analytics to optimize production processes, enhance decision making, and improve efficiency. By harnessing vast amounts of data generated throughout the manufacturing lifecycle, AI systems can predict equipment failures, optimize workflows, and minimize waste, leading to increased productivity and cost savings. Novel recycling and upcycling processes innovate waste management by transforming discarded materials and by-products into valuable resources. These methods divert waste from landfills, reduce pollution, and promote sustainability by repurposing materials for new applications, contributing to a circular economy and resource conservation efforts.

This Special Issue aims to collect original research and review publications introducing insights gained by conceptual design, experimental development, and numerical simulation of novel manufacturing processes with potential impacts on the industry.

Dr. Xiao Li
Dr. Hrishikesh Das
Guest Editors

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 100 words) can be sent to the Editorial Office for announcement on this website.

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. Machines 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 2400 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

  • advanced manufacturing process
  • artificial intelligence manufacturing
  • data-driven manufacturing
  • recycling and upcycling
  • green manufacturing
  • sustainable manufacturing
  • robot manufacturing
  • additive manufacturing
  • shear-assisted processing and extrusion
  • friction extrusion
  • friction consolidation
  • friction stir welding and processing
  • friction stir additive manufacturing

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

Published Papers (3 papers)

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Research

14 pages, 6790 KiB  
Article
Lightweight Design of a Connecting Rod Using Lattice-Structure Parameter Optimisation: A Test Case for L-PBF
by Michele Amicarelli, Michele Trovato and Paolo Cicconi
Machines 2025, 13(3), 171; https://doi.org/10.3390/machines13030171 - 21 Feb 2025
Viewed by 485
Abstract
Lightweight design is a common way of reducing mass while enhancing the performance of mechanical components. The paper proposes a method to analyse the substitution of bulk volume with optimised lattice structures. The approach considers an early DoE analysis to explore the design [...] Read more.
Lightweight design is a common way of reducing mass while enhancing the performance of mechanical components. The paper proposes a method to analyse the substitution of bulk volume with optimised lattice structures. The approach considers an early DoE analysis to explore the design space, Finite Element Analysis to evaluate the feasibility of possible design solutions, and Artificial Intelligence tools to look for optimal design solutions, including Genetic Algorithms and Response Surface Methods. To validate the methodological approach, this work proposes the design optimisation of a lightweight diesel engine connecting rod, redesigned using Triply Periodic Minimal Surface (TPMS) lattice structures where they are functionally convenient. The TPMS cells analysed are gyroid, diamond, and SplitP. Laser-Powder Bed Fusion (L-PBF) is the Additive Manufacturing process considered during the redesign phase. The resulting connecting rod achieves a mass of roughly 614 g, obtaining a lightweight of more than 50% of the initial weight, using gyroid lattice structures and titanium alloy powders such as Ti6Al4V. Full article
(This article belongs to the Special Issue Novel Manufacturing Processes and Their Innovation for Industries)
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16 pages, 3625 KiB  
Article
Influence of Plastic Deformation on the Precipitation Evolution in the Aluminum Alloys in Friction Stir Welding
by Iuliia Morozova, Anton Naumov, Nikolay Doynov and Vesselin Michailov
Machines 2025, 13(1), 45; https://doi.org/10.3390/machines13010045 - 10 Jan 2025
Viewed by 523
Abstract
The influence of temperature on the precipitation evolution in different zones of friction stir welded (FSW) heat-treatable aluminum alloys has been well investigated. However, the role of plastic deformation in affecting precipitation transformations remains less explored. To isolate the contribution of these factors [...] Read more.
The influence of temperature on the precipitation evolution in different zones of friction stir welded (FSW) heat-treatable aluminum alloys has been well investigated. However, the role of plastic deformation in affecting precipitation transformations remains less explored. To isolate the contribution of these factors and specifically assess the role of plastic deformation, an approach combining numerical and physical modeling techniques was used. Welding temperature cycles in the FSW weld zones calculated by means of a 3D finite element model were accurately reproduced using a Gleeble instrument. This approach was implemented under two scenarios such as the reproduction of the influence of temperature alone, and the combined effects of temperature and thermally induced plastic strain. The precipitation states and hardness obtained from these controlled experiments were compared to those observed in actual friction stir welds, providing a deeper understanding of the influence mechanisms at play. The results revealed that deformation significantly influences precipitation formation in the stir zone of both 2024 and 6082 alloys, with this effect extending to the heat-affected zone in the case of the 2024 alloy. Full article
(This article belongs to the Special Issue Novel Manufacturing Processes and Their Innovation for Industries)
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18 pages, 2030 KiB  
Article
Innovative Electrostatic Precipitator Solutions for Efficient Removal of Fine Particulate Matter: Enhancing Performance and Energy Efficiency
by Edgar Sokolovskij, Artūras Kilikevičius, Aleksandras Chlebnikovas, Jonas Matijošius and Darius Vainorius
Machines 2024, 12(11), 761; https://doi.org/10.3390/machines12110761 - 30 Oct 2024
Viewed by 2530
Abstract
The removal of particulate matter (PM) from air streams is essential for advancing environmental technologies and safeguarding public health. This study explores the performance of an electrostatic precipitator (ESP) in eliminating fine and ultra-fine PM under varied experimental conditions. It uniquely examines the [...] Read more.
The removal of particulate matter (PM) from air streams is essential for advancing environmental technologies and safeguarding public health. This study explores the performance of an electrostatic precipitator (ESP) in eliminating fine and ultra-fine PM under varied experimental conditions. It uniquely examines the influence of PM size and feed rate on ESP removal efficiency. The system’s use of low voltages enhances energy sustainability, while its innovative design improves corona discharge, leading to significant reductions in fine and ultra-fine PM emissions. Plants using electrical devices are increasingly being incorporated into material processing lines to reduce pollution in the surrounding work area, as well as to collect particle emissions in the atmosphere. It is also possible to recycle some raw materials in this way with low energy consumption. This cleaning technology increases the added value of industrial equipment, which affects its competitiveness and its impact on sustainable manufacturing. The experimental results indicate a steady electrostatic field voltage of 15.1 kilovolts, with an airflow maintained at 0.8 m/s through a doser at 2.5 bar, eliminating the need for a fan. The PM feed rate varied between 2 and 20 mm/h, with six trials conducted to ensure the data were consistent. Preliminary studies devoid of ESP intervention demonstrated little PM removal, since buildup on the chamber walls distorted the results. The installation of the ESF markedly enhanced the removal efficiency, achieving up to 95.5%. Further analysis revealed that ESP performance depended on PM concentration in the agglomeration chamber, achieving a clearance rate exceeding 98% under optimal conditions. Fine PM (0.35 to 8.7 µm) was more efficiently removed than ultra-fine PM (0.2 to 0.35 µm). The highest removal efficiency was observed at a feed rate of 0.962 mg/s, while the lowest occurred at 0.385 mg/s. A strong positive correlation between particle concentration and removal efficiency (Pearson value up to 0.829) was observed, particularly at feed rates of 0.128, 0.641, and 1.283 mg/s. The study’s findings confirm that the ESP is highly effective in removing particulate matter, particularly fine and ultra-fine particles, with an optimal feed rate, significantly enhancing the system’s performance. Full article
(This article belongs to the Special Issue Novel Manufacturing Processes and Their Innovation for Industries)
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