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Advanced Machining and Technologies in Materials Science
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Advanced Machining and Technologies in Materials Science

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

Deadline for manuscript submissions: 28 February 2026 | Viewed by 2500

Special Issue Editor

Dr. Janusz Kluczyński

E-Mail Website
Guest Editor
Institute of Robots and Machine Design, Faculty of Mechanical Engineering, Military University of Technology, 2 Gen. S. Kaliskiego St., 00-908 Warsaw, Poland
Interests: additive manufacturing; mechanical properties of polymers and metals; fatigue and fracture of polymers and metals
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue aims to present groundbreaking developments in advanced manufacturing processes, precision manufacturing, and innovative material applications. The scope of this Special Issue includes high-performance machining techniques, additive and hybrid manufacturing, advanced coatings and tool materials, smart manufacturing, automation, and sustainable machining processes. We welcome experimental, theoretical, and computational studies that push the boundaries of modern machining and material sciences. A key aspect of these advancements is the development and application of innovative materials with superior properties. Therefore, this Special Issue aims to promote knowledge regarding the enhancement of machining efficiency via the achievement of exceptional hardness and wear resistance, improving the longevity of tools by reducing friction and thermal effects, and developing materials that offer high strength, corrosion resistance, and thermal stability.  This Special Issue explores the interplay between material properties and manufacturing techniques, driving innovation toward more efficient, precise, and sustainable production.

Dr. Janusz Kluczyński
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

  • advanced manufacturing
  • additive manufacturing
  • hybrid technologies
  • high-speed machining
  • production technologies, precision manufacturing

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Published Papers (4 papers)

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Research

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13 pages, 2753 KB  
Article
Effect of CMT and MIG Welding on Microstructure and Mechanical Properties of Al-Zn-Mg-Cu-Er-Zr Alloy
by Wu Wei, Yijie Sun, Chao Zhang, Limin Zhai, Peng Wang, Li Cui, Shengping Wen, Wei Shi and Xiaorong Zhou
Materials 2025, 18(20), 4688; https://doi.org/10.3390/ma18204688 - 13 Oct 2025
Viewed by 275
Abstract
Cold metal transfer (CMT) welding and metal inert gas (MIG) arc welding of a novel Al-Zn-Mg-Cu-Er-Zr alloy are systematically analyzed. The effect of the two welding processes on the morphology, microstructure, and mechanical properties of welded joints was investigated. The evolution of the [...] Read more.
Cold metal transfer (CMT) welding and metal inert gas (MIG) arc welding of a novel Al-Zn-Mg-Cu-Er-Zr alloy are systematically analyzed. The effect of the two welding processes on the morphology, microstructure, and mechanical properties of welded joints was investigated. The evolution of the microstructures and grain structures in the welded joints is studied using an optical microscope (OM), X-ray diffraction (XRD), and scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS). The results show that both welding methods obtain well-formed full-penetration welds, and the width of the heat-affected zone (HAZ) of CMT welding is smaller than that of MIG welding. The two welded joints reveal coarse cellular grain structures with precipitates of η (MgZn2), Al3Er, and S (Al6CuMg4) secondary phases. The average grain size of the weld metal in the cold metal transfer welding (12.96 μm) joint is much finer than that of the metal inert gas arc welding joint (22.63 μm), with a higher proportion of high-angle grain boundaries (HAGBs). The hardness of cold metal transfer welding and metal inert gas arc welding weld zones is 103.9 HV and 92.6 HV, respectively, and the tensile strength of the joint is 334.0 MPa and 270.3 MPa, respectively. Full article
(This article belongs to the Special Issue Advanced Machining and Technologies in Materials Science)
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22 pages, 17666 KB  
Article
Modeling and Experimental Investigation of Ultrasonic Vibration-Assisted Drilling Force for Titanium Alloy
by Chuanmiao Zhai, Xubo Li, Cunqiang Zang, Shihao Zhang, Bian Guo, Canjun Wang, Xiaolong Gao, Yuewen Su and Mengmeng Liu
Materials 2025, 18(19), 4460; https://doi.org/10.3390/ma18194460 - 24 Sep 2025
Viewed by 414
Abstract
To overcome the issues of excessive cutting force, poor chip segmentation, and premature tool wear during the drilling of Ti-6Al-4V titanium alloy. This study established the cutting edge motion trajectory function and instantaneous dynamic cutting thickness equation for ultrasonic vibration-assisted drilling through kinematic [...] Read more.
To overcome the issues of excessive cutting force, poor chip segmentation, and premature tool wear during the drilling of Ti-6Al-4V titanium alloy. This study established the cutting edge motion trajectory function and instantaneous dynamic cutting thickness equation for ultrasonic vibration-assisted drilling through kinematic analysis. Based on this, an analytical model of drilling force was formulated, integrating tool geometry, cutting radius scale effects, dynamic chip thickness, and drilling depth. In parallel, a finite element model was constructed to achieve visual simulation analysis of chip deformation and cutting force. Finally, the accuracy of the model was verified through experiments, with a comprehensive analysis performed on how cutting parameters affect thrust force. The findings indicate that the average absolute prediction errors of thrust force and torque between the analytical model and finite element simulations were 7.87% and 6.26%, respectively, confirming the model’s capability to accurately capture instantaneous force and torque variations. Compared to traditional drilling methods, the application of ultrasonic vibration assistance resulted in reductions of 40.8% in thrust force and 41.7% in torque. The drilling force exhibited nonlinear growth as the spindle speed and feed rate were elevated, while it declined with greater vibration frequency and amplitude as drilling depth increased. Furthermore, the combined effect of optimized vibration parameters enhanced chip fragmentation, producing short discontinuous chips and effectively preventing entanglement. Overall, this research provides a theoretical and practical foundation for optimizing ultrasonic vibration-assisted drilling and improving precision hole making in titanium alloys. Full article
(This article belongs to the Special Issue Advanced Machining and Technologies in Materials Science)
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11 pages, 1946 KB  
Article
Influence of Surface Treatments on the Pull-Off Performance of Adhesively Bonded Polylactic Acid (PLA) Specimens Manufactured by Fused Deposition Modeling (FDM)
by Gianluca Parodo, Giuseppe Moffa, Alessandro Silvestri, Luca Sorrentino, Gabriel Testa and Sandro Turchetta
Materials 2025, 18(17), 3965; https://doi.org/10.3390/ma18173965 - 24 Aug 2025
Cited by 1 | Viewed by 838
Abstract
This study investigates the influence of different surface treatments (namely, mechanical abrasion and solvent cleaning with isopropyl alcohol and acetone) on the adhesive bonding performance of polylactic acid (PLA) substrates produced by Fused Deposition Modeling (FDM). Pull-off tests revealed that the isopropanol-cleaned specimens [...] Read more.
This study investigates the influence of different surface treatments (namely, mechanical abrasion and solvent cleaning with isopropyl alcohol and acetone) on the adhesive bonding performance of polylactic acid (PLA) substrates produced by Fused Deposition Modeling (FDM). Pull-off tests revealed that the isopropanol-cleaned specimens achieved the highest bond strength, with an average pull-off value exceeding 8.5 MPa, compared to approximately 5.6 MPa for untreated PLA. Conversely, acetone cleaning resulted in the lowest performance (about 3.5 MPa), while mechanical abrasion yielded intermediate values of about 6 MPa. FTIR analysis confirmed that no chemical reactions occurred, although acetone and abrasion induced significant physical surface changes, unlike isopropanol, which acted as an effective cleaning agent. These findings demonstrate that surface cleanliness plays a dominant role over morphological alterations in enhancing the adhesion of PLA-based 3D-printed joints. Full article
(This article belongs to the Special Issue Advanced Machining and Technologies in Materials Science)
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Review

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20 pages, 1890 KB  
Review
Laser Surface Hardening of Carburized Steels: A Review of Process Parameters and Application in Gear Manufacturing
by Janusz Kluczyński, Katarzyna Jasik, Jakub Łuszczek and Jakub Pokropek
Materials 2025, 18(15), 3623; https://doi.org/10.3390/ma18153623 - 1 Aug 2025
Viewed by 706
Abstract
This article provides a comprehensive overview of recent studies concerning laser heat treatment (LHT) of structural and tool steels, with particular attention to the 21NiCrMo2 steel used for carburized gear wheels. Analysis includes the influence of critical laser processing conditions—including power output, motion [...] Read more.
This article provides a comprehensive overview of recent studies concerning laser heat treatment (LHT) of structural and tool steels, with particular attention to the 21NiCrMo2 steel used for carburized gear wheels. Analysis includes the influence of critical laser processing conditions—including power output, motion speed, spot size, and focusing distance—on surface microhardness, hardening depth, and microstructure development. The findings indicate that the energy density is the dominant factor that affects the outcomes of LHT. Optimal results, in the form of a high surface microhardness and a sufficient depth of hardening, were achieved within the energy density range of 80–130 J/mm2, allowing for martensitic transformation while avoiding defects such as melting or cracking. At densities below 50 J/mm2, incomplete hardening occurred with minimal microhardness improvement. On the contrary, densities exceeding 150–180 J/mm2 caused surface overheating and degradation. For carburized 21NiCrMo2 steel, the most effective parameters included 450–1050 W laser power, 1.7–2.5 mm/s scanning speed, and 2.0–2.3 mm beam diameter. The review confirms that process control through energy-based parameters allows for reliable prediction and optimization of LHT for industrial applications, particularly in components exposed to cyclic loads. Full article
(This article belongs to the Special Issue Advanced Machining and Technologies in Materials Science)
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