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Advanced Materials, Machinability and Intelligent Manufacturing Systems
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Advanced Materials, Machinability and Intelligent Manufacturing Systems

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

Deadline for manuscript submissions: 20 November 2025 | Viewed by 3055

Special Issue Editors

Prof. Dr. Anna Burduk

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Guest Editor
Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, ul. Łukasiewicza 5, 50-371 Wrocław, Poland
Interests: machine learning; intelligent manufacturing systems; optimization of production systems; modeling and simulation of manufacturing processes; risk assessment in manufacturing systems
Special Issues, Collections and Topics in MDPI journals
Dr. Andre Batako

E-Mail Website
Guest Editor
General Engineering Research Institute, Faculty of Engineering and Technology, Liverpool John Moores University, Liverpool L3 3AF, UK
Interests: manufacturing; machining; grinding; dynamics; vibration; impact; cutting
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Anthony M. Xavior

E-Mail Website
Guest Editor
School of Mechanical Engineering, Vellore Institute of Technology, Vellore 632014, India
Interests: materials; manufacturing; metal matrix composites; selective laser melting (additive manufacturing); machinability; high entropy alloys; hydrogen embrittlement
Dr. Suthep Butdee

E-Mail Website
Guest Editor
Research and Development Institute, Rajamangala University of Technology Krungthep, Bangkok, Thailand
Interests: expert system and artificial intelligent; lightweight material; smart manufacturing; intelligent cyber physical system; advanced machining and cutting tool design; cold and hot forging; predictive maintenance
Dr. Jose Machado

E-Mail Website
Guest Editor
Mechanical Engineering Department, MEtRICs Research Center, University of Minho, 4800-058 Guimarães, Portugal
Interests: cyber-physical systems; dependable controllers for dependable mechatronic systems; mechatronic systems design for medical/biomedical applications, wellbeing and/or rehabilitation
Special Issues, Collections and Topics in MDPI journals
Dr. Kamil Krot

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, Wrocław University of Science and Technology, ul. Łukasiewicza 5, 50-371 Wrocław, Poland
Interests: automation; advanced robotics; data processing; IIoT; autonomus mobile robots

Special Issue Information

Dear Colleagues,

The modern global economy faces several important challenges that require the creation of new technological solutions. The issues related to advanced materials, machinability and intelligent manufacturing systems hold a pivotal role in the advancement of modern engineering and technology. The significance of these fields stems from their potential to revolutionize various industries, driving innovation and sustainability in the global economy.

With the development of new materials, it has become necessary to develop new technological solutions enabling the production of products with new, previously unknown functional characteristics and functions. Challenges in the field of manufacturing technology require in-depth research not only in the field of technology but also new tools and the environment for performing manufacturing processes. Changes in the global economy also include the widespread use of artificial intelligence technologies. In addition to self-adaptive production systems, intelligent materials that change their properties as a result of external factors such as radiation intensity or temperature changes are also important.

The Special Issue awaits the results of the latest work in the above-mentioned areas, which may contribute to the development of advanced materials and machinability technologies, as well as broadly understood intelligent manufacturing systems. We, therefore, welcome contributions on the following topics, though this list is not exhaustive:

  • Materials and applications of additive manufacturing;
  • Design, synthesis and applications of polymeric materials;
  • The use of intelligent methods in the design and production of new materials;
  • Machining/Forming of advanced materials;
  • New techniques for processing difficult-to-machine materials;
  • Advanced aerospace material and composites;
  • Processes and applications of producing biological materials;
  • Production of metal matrix composites (MMC) and ceramic matrix composites (CMC);
  • Characteristics and machinability of MMC and CMC composites;
  • Modeling of materials and production processes;
  • Modeling of the machinability of composite materials.

Prof. Dr. Anna Burduk
Dr. Andre Batako
Prof. Dr. Anthony M. Xavior
Dr. Suthep Butdee
Dr. Jose Machado
Dr. Kamil Krot
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. 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

  • composites
  • aerospace materials
  • high-entropy alloys
  • hydrogen storage
  • cutting tools
  • machinability
  • production management
  • intelligent manufacturing

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

Published Papers (4 papers)

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Research

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17 pages, 2867 KiB  
Article
Constitutive Analysis of the Deformation Behavior of Al-Mg-Si Alloy Under Various Forming Conditions Using Several Modeling Approaches
by Bandar Alzahrani, Ali Abd El-Aty, Yong Xu, Yong Hou, Shi-Hong Zhang, Alamry Ali, Mohamed M. Z. Ahmed and Abdallah Shokry
Materials 2025, 18(5), 1121; https://doi.org/10.3390/ma18051121 - 1 Mar 2025
Viewed by 347
Abstract
The hot-flow behaviors of Al-Mg-Si alloy are complex because they depend on ε, ε˙, and T. Hence, it is vital to understand and determine the Al-Mg-Si alloy’s flow behaviors under several deformation conditions. Therefore, in this study, Crystal Plasticity [...] Read more.
The hot-flow behaviors of Al-Mg-Si alloy are complex because they depend on ε, ε˙, and T. Hence, it is vital to understand and determine the Al-Mg-Si alloy’s flow behaviors under several deformation conditions. Therefore, in this study, Crystal Plasticity (CP) modeling, modified Zerilli–Armstrong (MZA), and two JC models were developed to precisely determine the hot deformation behaviors of this alloy. The reliability and predictability of these models were evaluated via comparisons of the determined and experimental results acquired in the ε˙ range of 10−3 to 1 s−1 and T range of 400–550 °C. Additionally, statistical parameters including the RMSE, AARE, and R were utilized to assess these models’ reliability for determining this alloy’s flow behaviors under several forming conditions. By analyzing these statistical parameters and comparing the predicted and experimental stresses, it can be concluded that the flow stresses predicted by the CP modeling and S2-MJC model exhibit a strong alignment with the experimental flow stresses. This contrasts with the results from the MZA and S1-MJC models. These results are attributed to the ability of CP modeling to couple the microstructure state of this alloy and the interactions between ε and ε˙ on the one hand and between T, ε˙, and ε on the other hand, facilitated by a comprehensive set of parameters that link the dynamic recovery and softening mechanisms components in the S2‐MJC model. Full article
(This article belongs to the Special Issue Advanced Materials, Machinability and Intelligent Manufacturing Systems)
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16 pages, 1167 KiB  
Article
Application of Fuzzy Logic-Based Expert Advisory Systems in Optimizing the Decision-Making Process for Material Selection in Additive Manufacturing
by Kinga Skrzek, Emilia Mazgajczyk and Bogdan Dybała
Materials 2025, 18(2), 324; https://doi.org/10.3390/ma18020324 - 13 Jan 2025
Viewed by 578
Abstract
In the era of Industry 4.0, additive manufacturing (AM) technology plays a crucial role in optimizing production processes, especially for small- and medium-sized enterprises (SMEs) striving to enhance competitiveness. Selecting the appropriate material for AM is a complex process that requires considering numerous [...] Read more.
In the era of Industry 4.0, additive manufacturing (AM) technology plays a crucial role in optimizing production processes, especially for small- and medium-sized enterprises (SMEs) striving to enhance competitiveness. Selecting the appropriate material for AM is a complex process that requires considering numerous technical, economic, and environmental criteria. Fuzzy logic-based advisory systems can effectively support decision-making in conditions of uncertainty and subjective user preferences. This study presents a developed advisory system model that uses the Analytic Hierarchy Process (AHP) method and triangular and trapezoidal membership functions, enabling dynamic adjustment of criterion weights. The results demonstrated that the system achieved 85% alignment with user preferences, confirming its effectiveness. Future research may focus on integrating fuzzy logic with machine learning algorithms to further enhance the system’s precision and flexibility. Full article
(This article belongs to the Special Issue Advanced Materials, Machinability and Intelligent Manufacturing Systems)
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20 pages, 11517 KiB  
Article
Study on Springback Behavior in Hydroforming of Micro Channels for a Metal Bipolar Plate
by Zonghui Su, Wenlong Xie, Yong Xu, Changsheng Li, Liangliang Xia, Baocheng Yang, Mingyu Gao, Hongwu Song and Shihong Zhang
Materials 2024, 17(21), 5386; https://doi.org/10.3390/ma17215386 - 4 Nov 2024
Viewed by 883
Abstract
Bipolar plates are one of the most important components of proton exchange membrane fuel cells. With the miniaturization of bipolar plate flow channel sizes and the increasing demand for precision, springback has become a key focus of research in the bipolar plate forming [...] Read more.
Bipolar plates are one of the most important components of proton exchange membrane fuel cells. With the miniaturization of bipolar plate flow channel sizes and the increasing demand for precision, springback has become a key focus of research in the bipolar plate forming process. In this paper, the hydroforming process for 316L stainless steel bipolar plates was studied, and an FEM model was built to examine the stress and strain at various locations on the longitudinal section of the plate. Modeling accuracy was validated by the comparison of experimental profile and thickness distribution. The effects of forming pressure and grain size on springback behavior are discussed. The results show that with increasing forming pressure, the springback value decreases initially, followed by an increase, but then again decreases. When the forming pressure is 80 MPa–100 MPa, the deformation of the lower element of the upper rounded corner is not uniform with more elastic regions, and the springback is positively correlated with forming pressure. The springback distribution pattern on the cross-section of the bipolar plate changes from a normal distribution to a distribution of “M” shape with increased pressure. The larger the grain size, the lower the yield strength elastic proportion, resulting in a decrease in springback of the sheet. The maximum amount of springback of the bipolar plate is 3.1 μm when the grain size is 60.7 μm. The research results provide a reference for improving the forming quality of metal bipolar plates with different flow channel shapes. Full article
(This article belongs to the Special Issue Advanced Materials, Machinability and Intelligent Manufacturing Systems)
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Review

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29 pages, 13056 KiB  
Review
Ultrasonic Melt Processing: Progress, Applications, and Future Directions
by Shuang Yang, Yu Weng, Qin Zhao, Gang Wu, Zhian Deng and Ling Qin
Materials 2025, 18(3), 522; https://doi.org/10.3390/ma18030522 - 23 Jan 2025
Viewed by 617
Abstract
Ultrasonic melt processing (UMP) has garnered significant attention from both academic and industrial communities as a promising solution to critical challenges in the metal casting industry. This technique offers a clean, environmentally friendly, and energy-efficient approach to improving melt quality and achieving structural [...] Read more.
Ultrasonic melt processing (UMP) has garnered significant attention from both academic and industrial communities as a promising solution to critical challenges in the metal casting industry. This technique offers a clean, environmentally friendly, and energy-efficient approach to improving melt quality and achieving structural refinement. However, due to the opaque nature of metals, understanding the fundamental mechanisms governing the interactions among ultrasonic bubbles, acoustic streaming, and the melt remains still challenging. This review traces the evolution of UMP research, from its inception in the mid-20th century to recent advancements, with particular emphasis on the application of state-of-the-art synchrotron X-ray imaging and computational modeling. These approaches have been instrumental in unraveling the complex, multiscale dynamics occurring across both temporal and spatial scales. Key findings in various metallic alloy systems are critically reviewed, focusing on new insights into cavitation bubbles, acoustic streaming, and the interactions of growing solid phases in different alloys. Additionally, the review discusses the resulting phenomena, including grain refinement, fragmentation, and the mitigation of solidification defects, in detail. The review concludes by identifying critical research gaps and emerging trends, underscoring the indispensable role of in situ studies and robust theoretical frameworks in advancing UMP. These developments are poised to reshape the future of innovation in materials science and engineering. Full article
(This article belongs to the Special Issue Advanced Materials, Machinability and Intelligent Manufacturing Systems)
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