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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 July 2025 | Viewed by 15514

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Dr. Hansang Kwon

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Department of Material System Engineering, Pukyong National University, Busan 48513, Republic of Korea
Interests: nanomaterials; dissimilar materials; powder metallurgy; composite materials processing; functionally graded materials; surface modification; nanoparticles
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Dear Colleagues,

Since industrial development began, materials processing is central to the field of materials science and engineering, and is a vital step in manufacturing. Materials processing is an important process for realizing the structural features (e.g., crystal structure, microstructure, size, and shape) required for the product to perform well in the intended application by properly utilizing and designing the composition of a given material. It involves a complex series of chemical, thermal, and physical processes that prepare a starting material, create a shape, retain that shape, and refine the structure and shape. The conversion of the starting material to the final product occurs in three steps: preparation of the starting material, processing operation, and post-processing operation(s). Recently, trends in the high-tech industry are pushing toward miniaturization, the creation of products with complex shapes, and multi-functional materials. To keep up with ever-increasing demands, materials processing has been continuously advancing in terms of production, efficiency and performance qualification.

The main aim of the Special Issue is to discuss the topics of processing, manufacturing, structure/property relationship and applications in advanced materials. All of the single phase and alloy, and composite materials in metals, ceramics, and polymers are of interest.

It is our pleasure to invite you to submit a manuscript for this Special Issue.

Dr. Hansang Kwon
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 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. Materials is an international peer-reviewed open access semimonthly 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 2600 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

processing
manufacturing
powder metallurgy
processing of composite materials
surface modification
plasma synthesis
laser processing

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Related Special Issues

Advances in Materials Processing in Materials (24 articles)
Advances in Materials Processing (Second Volume) in Materials (24 articles)

Published Papers (11 papers)

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Research

Jump to: Review

17 pages, 4657 KiB

Open AccessArticle

Experimental Analysis of Magnetic Focusing of the Plasma Arc of a Cutting Torch

by Martin Marek, Dejan Brkić, Pavel Praks, Tomáš Kozubek and Jaroslav Frantík

Materials 2025, 18(8), 1811; https://doi.org/10.3390/ma18081811 - 15 Apr 2025

Viewed by 189

Abstract

This study aimed to verify the possibility of stabilizing and focusing a plasma column generated by a plasma cutter. The simulation performed by the COMSOL Multiphysics software is based on the actual configuration and geometry of the burner. This article presented a universal computational method based on FEM simulations, focusing on the deflection of the current of electrically charged particles in a magnetic field within the context of a plasma cutting torch. The simulations estimate the optimal shape and positioning of a focused electron beam for various magnetic lens positions and plasma stream energies, revealing that higher initial electron energies lead to a more even beam focus. Among the configurations tested, positioning the cathode 3 mm above the ring-shaped permanent magnet proved most effective, maintaining beam linearity and minimizing electron scattering, making it suitable for practical implementations. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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15 pages, 5281 KiB

Open AccessArticle

Fabrication and Compression Properties of Two-Layered Porous Structure of Different Materials by Direct Printing of Resin Porous Structure on Aluminum Foam Using a 3D Printer

by Yoshihiko Hangai, Reiji Yamazaki and Takaaki Suzuki

Materials 2025, 18(2), 433; https://doi.org/10.3390/ma18020433 - 17 Jan 2025

Viewed by 681

Abstract

The porous structure, in which many pores are intentionally placed inside the material, has excellent impact energy absorption properties. Recent studies have attempted to fabricate multi-layered porous structures with different mechanical properties within a single porous structure sample, and the mechanical properties of these structures are being elucidated. However, these studies mainly attempted to vary the densities, pore structures, and alloy compositions within a single material, such as aluminum, for the entire sample. Since multi-materials are now being promoted to utilize the most suitable material type in the right place, porous structures made of different materials, such as a combination of aluminum and resin, are expected to be required in the future. In this study, we attempted to fabricate two-layered porous structure samples of different materials by printing a resin porous structure using a 3D printer on an aluminum foam fabricated by a precursor foaming process. Static compression tests were performed on the resulting two-layered porous structure samples to investigate their mechanical properties. The resin porous structure printed by the 3D printer and the aluminum foam were both designed to expose the porous structure on the surface of the specimen so that the deformation behavior can be easily observed. The density of the resin porous structure was varied by systematically varying the filling rate of the resin porous structure to be printed, and the effect on the compression properties was investigated. The fabricated two-layered porous structure was effectively bonded between the two layers by the anchor effect, which is a mechanical bonding caused by the resin penetrating into the pores. The layers exhibited robust bonding with no evidence of separation. It was possible to fabricate a two-layered porous structure that exhibited both properties of aluminum foam and those of resin porous structure. It was found that the plateau stress in the resin porous structure layer can be controlled between about 0.5 MPa and 40 MPa, and the deformation behavior and energy absorption properties of the two-layered porous structure can be controlled by varying the resin filling rate of the resin porous structure layer. That is, it was indicated that multi-layered porous structures with various densities and consisting of various types of materials allow for the optimal design of porous structures used in structural materials. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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13 pages, 8877 KiB

Open AccessArticle

The Influence of the Strain Rate on Texture Formation During the Plane Strain Compression of AZ80 Magnesium Alloy

by Yebeen Ji, Jimin Yun, Kibeom Kim, Tae Hee Lee and Kwonhoo Kim

Materials 2024, 17(24), 6292; https://doi.org/10.3390/ma17246292 - 23 Dec 2024

Viewed by 493

Abstract

Controlling microstructure and texture development is a key approach to improving the formability of magnesium alloys. In this study, the effects of the strain rate and initial texture on the texture evolution of magnesium alloys during high-temperature processing are investigated. The plane strain compression of three types of AZ80 magnesium alloys with different initial textures was assessed at 723 K and a train rate of 0.0005 s⁻¹. Work softening was consistently observed in the stress–strain curves of all samples. However, the peak stress varied depending on the initial texture, with lower peak stress observed under conditions favoring prismatic slip. Under these conditions, the activation of non-basal slip suppressed the formation of basal texture. The texture shifted and developed parallel to the transverse direction when prismatic slip was dominant. In contrast, the activation of pyramidal slip led to the formation of a basal texture tilted by 25° from the

(0001)

plane. The effects of recrystallization and grain boundary migration on texture development were minimal. This study contributes to understanding the texture development mechanisms in magnesium alloys and provides insights into improving their workability and ductility through texture modification. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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19 pages, 15518 KiB

Open AccessArticle

Powder Metallurgy Processing to Enhance Superelasticity and Shape Memory in Polycrystalline Cu–Al–Ni Alloys: Reference Material for Additive Manufacturing

by Mikel Pérez-Cerrato, Jose F. Gómez-Cortés, Ernesto Urionabarrenetxea, Isabel Ruiz-Larrea, Fernando Carreño, Ízaro Ayesta, María L. Nó, Nerea Burgos and Jose M. San Juan

Materials 2024, 17(24), 6165; https://doi.org/10.3390/ma17246165 - 17 Dec 2024

Cited by 1 | Viewed by 4661

Abstract

Shape memory alloys (SMAs) are functional materials with a wide range of applications, from the aerospace sector to the biomedical field. Nowadays, there is a worldwide interest in developing SMAs through powder metallurgy like additive manufacturing (AM), which allows innovative building processes. However, producing SMAs using AM techniques is particularly challenging because of the microstructure required to obtain optimal functional properties. This aspect is critical in the case of Cu–Al–based SMAs, due to their high elastic anisotropy, making them brittle in polycrystalline form. In this work, we approached the processing of a Cu–Al–Ni SMA following a specific powder metallurgy route: gas atomization of a pre-alloyed melt; compaction of the atomized powders through hot isostatic pressing; and a final hot rolling plus thermal treatments. Then, the microstructure of the material was characterized by electron microscopy showing a specific [001] texture in the rolling direction that improved the functional behavior. The successive processing steps produce an increase of about 40 °C in the martensitic transformation temperatures, which can be well controlled and reproduced through the developed methodology. The thermomechanical functional properties of superelasticity and shape memory were evaluated on the final SMA. Outstanding, fully recoverable superelastic behavior of 4.5% in tension, as well as a ±5% full shape memory recovery in bending, were reported for many cycles. These experiments demonstrate the enhanced mechanical and functional properties obtained in polycrystalline Cu–Al–Ni SMAs by powder metallurgy. The present results pave the road for producing this kind of SMA with the new AM technologies, which always produce polycrystalline components and can improve their processes taking the powder metallurgy SMA, here produced, as reference material. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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13 pages, 1708 KiB

Open AccessArticle

Development of a Mathematical Model of the Self-Shielded Flux-Cored Arc Surfacing Process for the Determination of Deposition Rate

by Michał Szymura, Artur Czupryński and Vladislav Ochodek

Materials 2024, 17(22), 5616; https://doi.org/10.3390/ma17225616 - 17 Nov 2024

Viewed by 716

Abstract

The article presents a method of developing a mathematical model of the arc surfacing process performed using the self-shielded flux-cored filler metal wire with the chromium cast iron (Fe15) weld deposit. A three-level design (static, determined, and complete) was used to determine the function of the test object, thus enabling the simulation of deposition rate in relation to wire feed speed and electrode extension. The deposition rate for the specified set of surfacing parameters amounted to between 4.31 kg/h and 11.25 kg/h. The study was also concerned with identifying the effect of the significance level of test factors and interactions between them on the resultant factor, as well as an assessment of the adequacy of the test object function. In relation to significance level α = 0.01, regression coefficients b₀, b₁, b₂, and b₁₁ significantly affected the deposition rate of the surfacing process. Coefficient b₂₂ was significant at a level of 0.40, whereas coefficient b₁₂ was significant at a level of 0.15. The mathematical model presenting the effect of wire feed speed and electrode extension, as well as interactions between them on the deposition rate of the surfacing process, was adequate for the adopted level of significance α = 0.05. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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10 pages, 2387 KiB

Open AccessArticle

Controlled Formation of Porous Cross-Bar Arrays Using Nano-Transfer Printing

by Yu Na Kim, Eun Bin Kang, Tae Wan Park and Woon Ik Park

Materials 2024, 17(22), 5609; https://doi.org/10.3390/ma17225609 - 16 Nov 2024

Viewed by 913

Abstract

Nano-transfer printing (nTP) has emerged as an effective method for fabricating three-dimensional (3D) nanopatterns on both flat and non-planar substrates. However, most transfer-printed 3D patterns tend to exhibit non-discrete and/or non-porous structures, limiting their application in high-precision nanofabrication. In this study, we introduce a simple and versatile approach to produce highly ordered, porous 3D cross-bar arrays through precise control of the nTP process parameters. By selectively adjusting the polymer solution concentration and spin-coating conditions, we successfully generated discrete, periodic line patterns, which were then stacked at a 90-degree angle to form a porous 3D cross-bar structure. This technique enabled the direct transfer printing of PMMA line patterns with well-defined, square-arrayed holes, without requiring additional deposition of functional materials. This method was applied across diverse substrates, including planar Si wafers, flexible PET, metallic copper foil, and transparent glass, demonstrating its adaptability. These well-defined 3D cross-bar patterns enhance the versatility of nTP and are anticipated to find broad applicability in various nano-to-microscale electronic devices, offering high surface area and structural precision to support enhanced functionality and performance. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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22 pages, 7689 KiB

Open AccessArticle

Influence of SS316L Nanoparticles on the Sintered Properties of Two-Component Micro-Powder Injection Moulded Bimodal SS316L/Zirconia Bi-Materials

by Al Basir, Abu Bakar Sulong, Norhamidi Muhamad, Afifah Z. Juri, Nashrah Hani Jamadon, Farhana Mohd Foudzi, Nabilah Afiqah Mohd Radzuan and Kambiz Rashidi

Materials 2024, 17(22), 5536; https://doi.org/10.3390/ma17225536 - 13 Nov 2024

Viewed by 887

Abstract

Two-component micro-powder injection moulding (2C-μPIM) is a prospective approach for fabricating bi-material micro-components of stainless steel 316L (SS316L) and 3 mol% yttria-stabilised zirconia (3YSZ) at an appealing cost. However, the fundamental challenge lies in preventing the formation of large-scale cracks at the interface of two different materials during sintering. This study investigated how SS316L nanoparticles in bimodally configured SS316L powder that incorporated both nanoparticles and microparticles influenced the sintering of 2C-μPIM-processed miniature bi-materials made of bimodal SS316L and 3YSZ. In this study, feedstocks were developed by integrating monomodal (micro-sized) SS316L powder, three types of nano/micro-bimodal SS316L powders, and 3YSZ powder individually with palm stearin and low-density polyethylene binders. The results indicated that increasing the SS316L nanoparticle content to 45 vol.% caused a 19.5% increase in the critical powder loading in the bimodal SS316L powder as compared to that in the monomodal SS316L powder. The addition of SS316L nanoparticles increased the relative density and hardness of the sintered bi-materials, with the maximum values obtained being 96.8% and 1156.8 HV, respectively. Field emission scanning electron microscopy investigations revealed that adding 15 vol.% and 30 vol.% SS316L nanoparticle contents reduced interface cracks in bi-materials significantly, while 45 vol.% resulted in a crack-free interface. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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24 pages, 21789 KiB

Open AccessArticle

Estimation of Quality of Seam Welds in AlMgSi(Cu) Extrusion by Using an Original Device for Weldability Testing

by Marek Bogusz, Dariusz Leśniak, Józef Zasadziński, Wojciech Libura, Beata Leszczyńska-Madej, Jacek Madura, Tomasz Latos, Kamila Limanówka and Bartłomiej Płonka

Materials 2024, 17(22), 5448; https://doi.org/10.3390/ma17225448 - 7 Nov 2024

Viewed by 1960

Abstract

Extrusion welding of AlMgSi(Cu) alloys is carried out by using porthole dies, as a result of which hollow shapes are formed with longitudinal seam welds. In the case of the inappropriate selection of the chemical composition of the aluminium alloy or improper metal welding conditions, the weld may have reduced strength in relation to that of the base material, thus weakening the strength of structures based on aluminium extrudates. The prediction of metal welding conditions, depending on the chemical composition of the alloy, the temperature and the unit welding pressures, effectively supports the design of porthole dies, thus significantly reducing the number of necessary extrusion tests and die geometry corrections needed during its implementation in industrial practice, and consequently significantly reducing production costs. In this work, an original laboratory test device simulating the behaviour of metal in a welding chamber of a porthole die was applied to examine the ability of AlMgSi(Cu) alloys to produce high-quality joints. Two different chemical compositions of AlMgSi(Cu) aluminium alloys differing in Mg, Si and Cu contents were used: alloy no. 1A (0.68% wt. Mg, 1.04% wt. Si, 0.61% wt. Cu) and alloy no. 3A (0.8% wt. Mg, 1.21% wt. Si, 1.22% wt. Cu). The weldability tests were carried out under various welding temperatures of 450, 500 and 550 °C and under various welding pressures of 150 MPa, 250 MPa and 350 MPa. The microstructural changes in the produced welds were evaluated with the use of OM and SEM/EDS with chemical analysis in micro-areas, whereas the mechanical effects were evaluated by using a static tensile test. Samples after static tensile testing were subjected to fractographic tests to determine the nature of the fractures. The highest values of relative weld strength were obtained under the highest welding temperature of 550 °C and the highest unit welding pressure of 350 MPa: 87% for alloy number 1/1A (high-strength weld), and 62% for alloy number 6/3A (medium-strength weld). Finally, the extrusion tests were performed in industrial conditions with an examination of the EBSD structure and strength of the longitudinal welds. High values of relative weld strength for extrudates from alloy no. 1/1A and alloy no. 3A, 96% and 89%, respectively, were found, which confirmed the previous weldability testing results. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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13 pages, 2233 KiB

Open AccessArticle

Optimization of Ceramic Paste Composition for 3D Printing via Robocasting

by Szymon Przybyła, Maciej Kwiatkowski, Michał Kwiatkowski and Marek Hebda

Materials 2024, 17(18), 4560; https://doi.org/10.3390/ma17184560 - 17 Sep 2024

Cited by 2 | Viewed by 1600

Abstract

This article presents a procedure for selecting optimal ceramic paste formulations dedicated to the 3D printing process using robocasting technology. This study investigated pastes with varying ceramic powder particle sizes and different proportions of additives, such as ceramic microspheres and nutshells. This selection process allowed for the classification of ceramic mixtures into those suitable and unsuitable for this additive manufacturing technique. Subsequently, the viscosity of the pastes was measured, and extrudability tests were performed to determine the force required for extrusion and evaluate the quality of the extruded material. In the final stage, the setting time of the ceramic pastes was assessed to establish the drying time of the printed elements. It was found that the length of the extruded band of ceramic paste was inversely proportional to the Al₂O₃ content. Moreover, the extrusion force for samples with varying ceramic powder particle sizes (MG1–MG5) ranged from 133 to 166 N, compared to 77 N for the base sample (BM1). The obtained results enable further development in robocasting additive technology, including the development of a rapid and effective method for validating ceramic pastes used in this process. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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16 pages, 8371 KiB

Open AccessArticle

Influence of Severe Plastic Deformation and Aging on Low Cycle Fatigue Behavior of Al-Mg-Si Alloys

by Wonhoe Kim, Kibeom Kim and Kwonhoo Kim

Materials 2024, 17(9), 2148; https://doi.org/10.3390/ma17092148 - 3 May 2024

Cited by 1 | Viewed by 1472

Abstract

Strain-controlled low cycle fatigue (LCF) tests were conducted on conventionally grained (CG) and ultrafine-grained (UFG) Al-Mg-Si alloys treated under various aging conditions. In the cyclic stress response (CSR) curves, CG peak-aged (PA) alloys showed initial cyclic hardening and subsequent saturation, whereas CG over-aged (OA) alloys displayed cyclic softening behavior close to saturation. The UFG materials exhibited continuous cyclic softening except for UFG 3; it originates from the microstructural stability of the UFG materials processed by severe plastic deformation (SPD). Using a strain-based criterion, the LCF behavior and life of the CG and UFG materials were analyzed and evaluated; the results are discussed in terms of strengthening mechanisms and microstructural evolution. In the CG materials, the LCF life changed markedly owing to differences in deformation inhomogeneity depending on the precipitate state. However, the UFG materials displayed a decreasing LCF life as cyclic softening induced by dynamic recovery became more severe; additionally, a relationship between the microstructural stability of the UFG materials and the cyclic strain hardening exponent n′ was suggested. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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Review

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20 pages, 4572 KiB

Open AccessReview

Device Applications Enabled by Bandgap Engineering Through Quantum Dot Tuning: A Review

by Ho Kyung Lee, Taehyun Park and Hocheon Yoo

Materials 2024, 17(21), 5335; https://doi.org/10.3390/ma17215335 - 31 Oct 2024

Viewed by 1083

Abstract

Quantum dots (QDs) are becoming essential materials for future scientific and real-world applications, owing to their interesting and distinct optical and electrical properties compared to their bulk-state counterparts. The ability to tune the bandgap of QDs based on size and composition—a key characteristic—opens up new possibilities for enhancing the performance of various optoelectronic devices. These advances could extend to cutting-edge applications such as ultrawide-band or dual-band photodetectors (PDs), optoelectronic logic gates, neuromorphic devices, and security functions. This paper revisits the recent progress in QD-embedded optoelectronic applications, focusing on bandgap tunability. The current limitations and challenges in advancing and realizing QD-based optoelectronic devices are also discussed. Full article

(This article belongs to the Special Issue Advances in Materials Processing (3rd Edition))

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