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Metalworking Processes: Theoretical and Experimental Study

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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: closed (15 December 2024) | Viewed by 19904

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Special Issue Editors

Dr. Konrad Laber

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Department of Metallurgy and Metal Technology, Faculty of Production Engineering and Materials Technology, Czestochowa University of Technology, 19 Armii Krajowej Ave., 42-200 Czestochowa, Poland
Interests: numerical and physical modelling of plastic working processes: rolling, extrusion, materials properties investigation, plasticity and rheological properties investigations—especially in torsion test; thermo-mechanical treatment; microstructure analysis; combined strain—stress state investigations

Dr. Janusz Tomczak

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Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka Str, 20-618 Lublin, Poland
Interests: rolling processes; forging processes; new metalworking techniques; physical and numerical modelling; innovative designs of metal forming machines
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Dr. Beata Leszczyńska-Madej

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Department of Materials Science and Non-Ferrous Metals Engineering, Faculty of Non-Ferrous Metals, AGH University of Krakow, 30-059 Krakow, Poland
Interests: microstructure characterization; materials science; friction stir processes; tribology; metal-matrix composites (MMCs); powder metallurgy; severe plastic deformation (SPD); light metals and alloys; surface engineering; bearing alloys
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Dr. Grażyna Mrówka-Nowotnik

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Department of Material Science, Rzeszów University of Technology, Al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
Interests: microstructure characterization; materials science; aluminum alloys; heat treatment processes; surface modification; plastic deformation processes; intermetallic phases; metallurgy

Dr. Magdalena Barbara Jabłońska

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Centre of Materials Technology, Łukasiewicz Research Network—Institute of Non Ferrous Metals, 40-019 Gliwice, Poland
Interests: materials engineering; manufacturing engineering; mechanical properties; industrial engineering; heat treatment; steels; aluminum alloys; microstructure analysis; mechanical behavior; materials characterization; metal forming; dynamic deformation; severe plastic defeormation; phase transformations; recrystallisation; plasticity; fracture; grain boundaries
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The currently used technologies of plastic working processes and thermomechanical processes of metals and alloys, in addition to shaping the manufactured products and minimizing the energy consumption of the production process, must firstly ensure the required microstructure and related mechanical and technological properties. The modelling of structure changes and mechanical properties in metal thermomechanical treatment processes and technical alloys is one of the most important research areas, and is currently at the center of interest of scientific centers dealing with materials engineering and plastic working processes. Performing direct tests under industrial conditions for the development of such processes is too costly and usually does not allow the optimization of process parameters. Therefore, it is justified to develop methods of optimizing technological processes, ensuring the receipt of a product with the required mechanical properties, based on modern methods of numerical and physical modelling. By using modern computer programs based on the finite element method, it is possible to carry out numerical simulations of technological processes. Computer simulation also enables the design and optimization of industrial processes without long-term and costly experiments in the technological line. Mathematical modelling also enables the determination of the parameters necessary for physical modelling by using metallurgical process simulators. However, numerical modelling alone does not allow for the accurate prediction of the mechanical properties and microstructure of the tested material. The use of the physical simulation methods is a supplement to mathematical modelling, which allows for solving complex problems encountered in the development of new production processes with high efficiency. The physical modelling of industrial processes also enables the determination of material characteristics that are necessary for the numerical modelling of thermomechanical treatment processes. This Special Issue covers new groundbreaking trends in the plastic working and thermomechanical treatment processes of metals and alloys. We cordially invite you to send your manuscripts for publication in this Special Issue. Full articles, communications and literature reviews are welcomed.

Dr. Konrad Laber
Dr. Janusz Tomczak
Dr. Beata Leszczyńska-Madej
Dr. Grażyna Mrówka-Nowotnik
Dr. Magdalena Barbara Jabłońska
Guest Editors

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Keywords

plastic working processes
thermomechanical treatment processes
numerical modelling
physical modelling
microstructure modelling
metallographic tests

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Published Papers (13 papers)

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Research

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20 pages, 16001 KiB

Open AccessArticle

The Influence of Hot Isostatic Pressing on the Mechanical Properties of Ti-6Al-4V Samples Printed Using the LENS Method

by Bożena Gzik-Zroska, Kamil Joszko, Agata Piątek, Wojciech Wolański, Edyta Kawlewska, Arkadiusz Szarek, Wojciech Kajzer and Grzegorz Stradomski

Materials 2025, 18(3), 612; https://doi.org/10.3390/ma18030612 - 29 Jan 2025

Viewed by 669

Abstract

The aim of this work was to assess the influence of the parameters of the hot isostatic pressing (HIP) process and the direction of printing of Ti-6Al-4V samples made using the laser-engineered net shaping (LENS) method on strength properties. The tests were carried out using a static testing machine and a digital image correlation system. Samples before and after the HIP process were tested. The HIP process was carried out at a temperature of 1150 °C, a heating time of 240 min and various pressure values of 500, 1000 and 1500 bar. Based on the comparative analysis of the test results, it has been shown that the ability to adjust the parameters of the HIP process has a significant impact on the final mechanical properties of the samples. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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21 pages, 13606 KiB

Open AccessArticle

Flow Behavior Analysis of the Cold Rolling Deformation of an M50 Bearing Ring Based on the Multiscale Finite Element Model

by Wenting Wei, Zheng Liu, Qinglong Liu, Guanghua Zhou, Guocheng Liu, Yanxiong Liu and Lin Hua

Materials 2025, 18(1), 77; https://doi.org/10.3390/ma18010077 - 27 Dec 2024

Viewed by 482

Abstract

Through the ferrite single-phase parameters of M50 bearing steel obtained based on nanoindentation experiments and the representative volume element (RVE) model established based on the real microstructure of M50, this paper established a multiscale finite element model for the cold ring rolling of M50 and verified its accuracy. The macroscale and mesoscale flow behaviors of the ring during the cold rolling deformation process were examined and explained. The macroscopic flow behavior demonstrated that the stress distribution was uniform following rolling. The equivalent plastic strain (PEEQ) grew stepwise over time, with the raceway showing the highest PEEQ. The mesoscopic simulation revealed that the stress was concentrated in the cementite, and the maximum occurred at the junction of the ferrite and cementite. The largest PEEQ was found in the ferrite matrix positioned between the two adjacent cementites. The cementite flew with the deformation of the ferrite. The radial displacement of the cementite decreased from the edge of the raceway to both ends and decreased from the inner to the outer surface. Its axial displacement was basically the same on the inner surface and decreased from the inner to the outer surface. Its circumferential displacement decreased from the inner and outer surfaces to the intermediate thickness region. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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23 pages, 28085 KiB

Open AccessArticle

The Influence of Temperature in the Wire Drawing Process on the Wear of Drawing Dies

by Maciej Suliga, Piotr Szota, Monika Gwoździk, Joanna Kulasa and Anna Brudny

Materials 2024, 17(20), 4949; https://doi.org/10.3390/ma17204949 - 10 Oct 2024

Cited by 1 | Viewed by 1536

Abstract

This paper presents a wear analysis of tungsten carbide drawing dies in the process of steel wire drawing. The finite element method (FEM) analysis showed a significant correlation between drawing die geometry, single reduction size and drawing speed on the rate of drawing die wear. It has been shown that in steel wire drawing at higher drawing speeds, intense heating of the drawing die occurs due to friction at the wire/drawing die interface, leading to premature wear. Tribological tests on the material for the drawing die cores (94%WC+6%Co) confirmed the gradual abrasion of the steel and carbide sample surfaces with the “products” of abrasion sticking to their surfaces. The increase in temperature increases the coefficient of friction, translating into accelerated wear of the drawing dies. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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24 pages, 33071 KiB

Open AccessArticle

Structure and Mechanical Properties of AlMgSi(Cu) Extrudates Straightened with Dynamic Deformation

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

Materials 2024, 17(16), 3983; https://doi.org/10.3390/ma17163983 - 10 Aug 2024

Cited by 2 | Viewed by 1181

Abstract

Before artificial ageing, extruded aluminium profiles are subjected to stretching with a small cold deformation in the range of 0.5–2%. This deformation improves the geometrical stability of the extruded product and causes changes in the microstructure of the profile, which leads to the strain hardening of the material after artificial ageing. The work has resulted in the creation of the prototype of an original device, which is unique in the world, for the dynamic stretching of the extruded profiles after quenching. The semi-industrial unit is equipped with a hydraulic system for stretching and a pneumatic system for cold dynamic deformation. The aim of this research paper is to produce advantageous microstructural changes and increase the strength properties of the extruded material. The solution of the dynamic stretching of the profiles after extrusion is a great challenge and an innovation not yet practised. The paper presents the results of microstructural and mechanical investigations carried out on extruded AlMgSi(Cu) alloys quenched on the run-out table of the press, dynamically stretched under different conditions, and artificially aged for T5 temper. Different stretching conditions were applied: a static deformation of 0.5% at a speed of 0.02 m/s, and dynamic deformation of 0.25%, 0.5%, 1%, and 1.5% at speeds of 0.05 and 2 m/s. After the thermomechanical treatment of the profiles, microstructural observations were carried out using an optical microscope (OM) and a scanning electron microscope (SEM). A tensile test was also carried out on the specimens stretched under different conditions. In all the cases, the dynamically stretched profiles showed higher strength properties, especially those deformed at a higher speed of 2 m/s, where the increase in UTS was observed in the range of 7–18% compared to the classical (static) stretching. The microstructure of the dynamically stretched profiles is more homogeneous with a high proportion of fine dispersoids. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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16 pages, 14580 KiB

Open AccessArticle

Ultra-Fine Bainite in Medium-Carbon High-Silicon Bainitic Steel

by Xinpan Yu, Yong Wang, Huibin Wu and Na Gong

Materials 2024, 17(10), 2225; https://doi.org/10.3390/ma17102225 - 9 May 2024

Viewed by 1583

Abstract

The effects of austenitizing and austempering temperatures on the bainite transformation kinetics and the microstructural and mechanical properties of a medium-carbon high-silicon ultra-fine bainitic steel were investigated via dilatometric measurements, microstructural characterization and mechanical tests. It is demonstrated that the optimum austenitizing temperature exists for 0.3 wt.%C ultra-fine bainitic steel. Although the finer austenite grain at 950 °C provides more bainite nuclei site and form finer bainitic ferrite plates, the lower dislocation density in plates and the higher volume fraction of the retained austenite reduces the strength and impact toughness of ultra-fine steel. When the austenitizing temperature exceeds 1000 °C, the true thickness of bainitic ferrite plates and the volume fraction of blocky retained austenite in the bainite microstructure increase significantly with the increases in austenitizing temperature, which do harm to the plasticity and impact toughness. The effect of austempering temperature on the transformation behavior and microstructural morphology of ultra-fine bainite is greater than that of austenitizing temperature. The prior martensite, formed when the austempering temperature below Ms, can refine the bainitic ferrite plates and improve the strength and impact toughness. However, the presence of prior martensite divides the untransformed austenite and inhibits the growth of bainite sheaves, thus prolonging the finishing time of bainite transformation. In addition, prior martensite also strengthens the stability of untransformed austenite though carbon partition and enhances the volume fraction of blocky retained austenite, which reduces the plasticity of ultra-fine bainitic steel. According to the experimental results, the optimum austempering process for 0.3 wt. %C ultra-fine bainitic steel is through austenitization at 1000 °C and austempering at 340 °C. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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25 pages, 16651 KiB

Open AccessArticle

Analysis of the Uniformity of Mechanical Properties along the Length of Wire Rod Designed for Further Cold Plastic Working Processes for Selected Parameters of Thermoplastic Processing

by Konrad Błażej Laber

Materials 2024, 17(4), 905; https://doi.org/10.3390/ma17040905 - 15 Feb 2024

Cited by 1 | Viewed by 1602

Abstract

This study presents the results of research, the aim of which was to analyze the uniformity of the distribution of selected mechanical properties along the length of a 5.5 mm diameter wire rod of 20MnB4 steel for specific thermoplastic processing parameters. The scope of the study included, inter alia, metallographic analyses, microhardness tests, thermovision investigations, and tests of the wire rod mechanical properties (yield strength, ultimate tensile strength, elongation, relative reduction in area at fracture), along with their statistical analysis, for three technological variants of the rolling process differing by rolling temperature in the final stage of the rolling process (Reducing Sizing Mill rolling block [RSM]) and by cooling rate using STELMOR^® cooling process. The obtained results led to the conclusion that the analyzed rolling process is characterized by a certain disparity of the analyzed mechanical properties along the length of the wire rod, which, however, retains a certain stability. This disparateness is caused by a number of factors. One of them, which ultimately determines the properties of the finished wire rod, is the process of controlled cooling in the STELMOR^® line. Despite technological advances concerning technical solutions (among them, increasing the roller track speed in particular sections), it is currently not possible to completely eliminate the temperature difference along the length of the wire rod caused by the contact of individual coils with each other. From this point of view, for the analyzed thermoplastic processing parameters, there is no significant impact by the production process parameters on the quality of the finished steel product. Whereas, while comparing the mechanical properties and microstructure of the wire rod produced in the different technological combinations, it was found that the wire rod rolled in an RSM block at 850 °C and cooled after the rolling process on a roller conveyor at 10 °C/s had the best set of mechanical properties and the smallest microstructure variations. The wire rod produced in this way had the required level of plasticity reserve, which enables further deformation of the given type of steel in compression tests with a relative plastic strain of 75%. The uniformity of mechanical properties along the length of wire rods designed for further cold plastic working processes is an important problem. This is an important issue, given that wire rods made from 20MnB4 steel are an input material for further cold plastic working processes, e.g., for the drawing processes or the production of nails. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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16 pages, 12182 KiB

Open AccessArticle

Effects of Zn, Mg, and Cu Content on the Properties and Microstructure of Extrusion-Welded Al–Zn–Mg–Cu Alloys

by Krzysztof Remsak, Sonia Boczkal, Kamila Limanówka, Bartłomiej Płonka, Konrad Żyłka, Mateusz Węgrzyn and Dariusz Leśniak

Materials 2023, 16(19), 6429; https://doi.org/10.3390/ma16196429 - 27 Sep 2023

Cited by 6 | Viewed by 1349

Abstract

The study presents the results of research on the influence of different contents of main alloying additions, such as Mg (2 ÷ 2.5 wt.%), Cu (1.2 ÷ 1.9 wt.%), and Zn (5.5 ÷ 8 wt.%), on the strength properties and plasticity of selected Al–Zn–Mg–Cu alloys extruded on a bridge die. The test material variants were based on the EN AW-7075 alloy. The research specimens, in the form of 100 mm extrusion billets obtained with the DC casting method, were homogenized and extrusion welded during direct extrusion on a 5 MN horizontal press. A 60 × 6 mm die cross-section was used, with one bridge arranged in a way to extrude a flat bar with a weld along its entire length. The obtained materials in the F and T6 tempers were characterized in terms of their strength properties, hardness, and microstructure, using EBSD and SEM. The extrusion welding process did not significantly affect the properties of the tested materials; the measured differences in the yield strength and tensile strength between the materials, with and without the welding seam, were up to ±5%, regardless of chemical composition. A decrease in plasticity was observed with an increase in the content of the alloying elements. The highest strength properties in the T6 temper were achieved for the alloy with the highest content of alloying elements (10.47 wt.%), both welded and solid. Significant differences in the microstructure between the welded and solid material in the T6 temper were observed. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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18 pages, 7107 KiB

Open AccessArticle

Experimental Investigation on Microstructure Alteration and Surface Morphology While Grinding 20Cr2Ni4A Gears with Different Grinding Allowance Allocation

by Rong Wang, Size Peng, Bowen Zhou, Xiaoyang Jiang, Maojun Li and Pan Gong

Materials 2023, 16(18), 6111; https://doi.org/10.3390/ma16186111 - 7 Sep 2023

Cited by 2 | Viewed by 1476

Abstract

Transmission gear is a key component of vehicles and its surface integrity affects the safety of the transmission system as well as the entire mechanical system. The design and optimization of allowances in form grinding are important for improving dimensional accuracy and machining efficiency during the manufacturing of heavy-duty gears. This work aims to investigate the effects of grinding allowance allocation on surface morphology, grinding temperature, microstructure, surface roughness, and microhardness fluctuation during the form grinding of 20Cr2Ni4A gears. Results indicated that grinding temperature was primarily influenced by rough grinding involving significant grinding depths exceeding 0.02 mm. The ground surface exhibited slight work hardening, while thermal softening led to a reduction in microhardness of around 40 HV. Ground surface roughness Ra varied from 0.930 μm to 1.636 μm, with an allowance allocation of the last two passes exerting the most significant influence. Analysis of surface and subsurface microstructures indicated that a removal thickness of 0.02 mm during fine grinding was insufficient to eliminate the roughness obtained from rough grinding. Evident ridges, gullies, and surface defects such as material extraction, adhesion, and plastic deformation were also observed. The proposed grinding strategy was validated in practical manufacturing with good surface quality and geometrical accuracy. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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29 pages, 13633 KiB

Open AccessArticle

Modeling of Closure of Metallurgical Discontinuities in the Process of Forging Zirconium Alloy

by Grzegorz Banaszek, Kirill Ozhmegov, Anna Kawałek, Sylwester Sawicki, Alexandr Arbuz and Abdrakhman Naizabekov

Materials 2023, 16(15), 5431; https://doi.org/10.3390/ma16155431 - 2 Aug 2023

Cited by 4 | Viewed by 1236

Abstract

This article presents the results of testing the conditions of closing foundry voids during the hot forging operation of an ingot made of zirconium with 1% Nb alloy and use of physical and numerical modeling, continuing research presented in a previous thematically related article published in the journal Materials. The study of the impact of forging operation parameters on the rheology of zirconium with 1% Nb alloy was carried out on a Gleeble 3800 device. Using the commercial FORGE^®NxT 2.1 program, a numerical analysis was performed of the influence of thermo-mechanical parameters of the hot elongation operation in trapezoidal flat and rhombic trapezoidal anvils on the closure of foundry voids. The analysis of the obtained test results was used to formulate recommendations on the technology of hot forging and the anvilgeometry, ensuring closure of foundry voids. Based on their research, the authors conclude that the shape of the deformation basin and the value and hydrostatic pressure have the greatest influences on the closure of foundry voids. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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14 pages, 10686 KiB

Open AccessArticle

The Optimized Homogenization Process of Cast 7Mo Super Austenitic Stainless Steel

by Runze Zhang, Jinshan He, Shiguang Xu, Fucheng Zhang and Xitao Wang

Materials 2023, 16(9), 3438; https://doi.org/10.3390/ma16093438 - 28 Apr 2023

Cited by 3 | Viewed by 1798

Abstract

Super austenitic stainless steels are expected to replace expensive alloys in harsh environments due to their superior corrosion resistance and mechanical properties. However, the ultra-high alloy contents drive serious segregation in cast steels, where the σ phase is difficult to eliminate. In this study, the microstructural evolution of 7Mo super austenitic stainless steels under different homogenization methods was investigated. The results showed that after isothermal treatment for 30 h at 1250 °C, the σ phase in steels dissolved, while the remelting morphologies appeared at the phase boundaries. Therefore, the stepped solution heat treatment was further conducted to optimize the homogenized microstructure. The samples were heated up to 1220 °C, 1235 °C and 1250 °C with a slow heating rate, and held at these temperatures for 2 h, respectively. The elemental segregation was greatly reduced without incipient remelting and the σ phase was eventually reduced to less than 0.6%. A prolonged incubation below the dissolution temperature will lead to a spontaneous compositional adjustment of the eutectic σ phase, resulting in uphill diffusion of Cr and Mn, and reducing the homogenization efficiency of ISHT, which is avoided by SSHT. The hardness reduced from 228~236 Hv to 220~232 Hv by adopting the cooling process of “furnace cooling + water quench”. In addition, the study noticed that increasing the Ce content or decreasing the Mn content can both refine the homogenized grain size and accelerate diffusion processes. This study provides a theoretical and experimental basis for the process and composition optimization of super austenitic stainless steels. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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24 pages, 8643 KiB

Open AccessArticle

Innovative Methodology for Physical Modelling of Multi-Pass Wire Rod Rolling with the Use of a Variable Strain Scheme

by Konrad Błażej Laber

Materials 2023, 16(2), 578; https://doi.org/10.3390/ma16020578 - 6 Jan 2023

Cited by 1 | Viewed by 1880

Abstract

This paper presents the results of physical modelling of the process of multi-pass rolling of a wire rod with controlled, multi-stage cooling. The main goal of this study was to verify the possibility of using a torsion plastometer, which allows conducting tests on multi-sequence torsion, tensile, compression and in the so-called complex strain state to physically replicate the actual technological process. The advantage of the research methodology proposed in this paper in relation to work published so far, is its ability to replicate the entire deformation cycle while precisely preserving the temperature of the deformed material during individual stages of the reproduced technological process and its ability to quickly and accurately determine selected mechanical properties during a static tensile test. Changes in the most important parameters of the process (strain, strain rate, temperature, and yield stress) were analyzed for each variant. After physical modelling, the material was subjected to metallographic and hardness tests. Then, on the basis of mathematical models and using measurements of the average grain size, chemical composition, and hardness, the yield strength, ultimate tensile strength, and plasticity reserve were determined. The scope of the tests also included determining selected mechanical properties during a static tensile test. The obtained results were verified by comparing to results obtained under industrial conditions. The best variant was a variant consisting of physically replicating the rolling process in a bar rolling mill as multi-sequence non-free torsion; the rolling process in an NTM block (no twist mill) as non-free continuous torsion, with the total strain equal to the actual strain occurring at this stage of the technological process; and the rolling process in an RSM block (reducing and sizing mill) as tension, while maintaining the total strain value in this block. The differences between the most important mechanical parameters determined during a static tensile test of a wire rod under industrial conditions and the material after physical modelling were 1.5% for yield strength, approximately 6.1% for ultimate tensile strength, and approximately 4.1% for the relative reduction of the area in the fracture and plasticity reserve. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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24 pages, 17321 KiB

Open AccessArticle

FEM Numerical and Experimental Study on Dimensional Accuracy of Tubes Extruded from 6082 and 7021 Aluminium Alloys

by Dariusz Leśniak, Józef Zasadziński, Wojciech Libura, Krzysztof Żaba, Sandra Puchlerska, Jacek Madura, Maciej Balcerzak, Bartłomiej Płonka and Henryk Jurczak

Materials 2023, 16(2), 556; https://doi.org/10.3390/ma16020556 - 6 Jan 2023

Cited by 6 | Viewed by 2251

Abstract

The extrusion of hollow profiles from hard-deformable AlZnMg alloys by using porthole dies encounters great technological difficulties in practice. High extrusion force accompanies the technological process, which is caused by high deformation resistance and high friction resistance in extrusion conditions. As a result of high thermo-mechanical loads affecting the die, a significant loss of dimensional accuracy of extruded profiles can be observed. The different projects of porthole dies for the extrusion of Ø50 × 2 mm tubes from the 7021 alloy were numerically calculated and then tested in industrial conditions by using a press of 25 MN capacity equipped with a container with a diameter of 7 inches (for 7021 alloy and 6082 alloy for comparison). New extrusion die 3 with modified bridge and mandrel geometry and a special radial–convex entry to the die opening was proposed. FEM was applied to analyse the metal flow during extrusion, geometrical stability of extruded tubes and the die deflection. The photogrammetric measuring method was used to evaluate dimensional accuracy of tubes extruded in different conditions and geometrical deviations in porthole dies elements, especially the bridges and the mandrels. Research revealed a high dimensional accuracy of tubes extruded from the 6082 alloy and from the 7021 alloy by using original extrusion die 3, while much higher dimensional deviations were noted for tubes extruded from the 7021 alloy by using extrusion dies 1 and 2, particularly in relation to the circularity, centricity and wall thickness. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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24 pages, 7466 KiB

Open AccessReview

Advanced Bending and Forming Technologies for Bimetallic Composite Pipes

by Hui Li, Yingxia Zhu, Wei Chen, Chen Yuan and Lei Wang

Materials 2025, 18(1), 111; https://doi.org/10.3390/ma18010111 - 30 Dec 2024

Cited by 1 | Viewed by 1217

Abstract

Bimetallic composite pipes, as critical components, effectively integrate the superior properties of diverse materials to meet the growing demand for lightweight, high-strength, and corrosion-resistant solutions. These pipes find extensive applications in petrochemical, power generation, marine engineering, refrigeration equipment, and automotive manufacturing industries. This paper comprehensively reviews advanced bending and forming technologies, with a focus on challenges such as wrinkling, excessive wall thinning, springback, cross-sectional distortion, and interlayer separation. The review combines theoretical analysis, experimental findings, and numerical simulations to provide insights into defect prevention strategies and process optimization. It also evaluates emerging technologies such as artificial neural networks and intelligent control systems, which demonstrate significant potential in enhancing bending accuracy, reducing defects, and improving manufacturing efficiency. Additionally, this work outlines future research directions, emphasizing innovations required to meet the stringent performance standards of bimetallic composite pipe components in high-end applications. Full article

(This article belongs to the Special Issue Metalworking Processes: Theoretical and Experimental Study)

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