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Advanced Forming of Thin-Walled Materials: Microstructure, Processing and Properties
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Advanced Forming of Thin-Walled Materials: Microstructure, Processing and Properties

A Special Issue of Materials (ISSN 1996-1944) belonging to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 October 2026 | Viewed by 848

Editors

Prof. Dr. Zhubin He

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: constitutive modelling; materials characterization; new forming technology; light-weight manufacturing; hot fluid forming
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Yanli Lin

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: lightweight forming and control of complex thin-walled components; intelligent forming and optimization algorithms; intelligent simulation and program

Special Issue Information

Dear Colleagues,

With the increasing demand for energy efficiency, emission reduction, and structural optimization in transportation systems, lightweight design has become a key development direction in modern engineering. Complex thin-walled structures, including tubular and sheet-based components, are widely utilized due to their high strength-to-weight ratio and functional integration capabilities. However, their manufacturing remains challenging because of material anisotropy, nonlinear deformation behavior, instability, and limited formability under complex loading conditions. These challenges significantly affect forming accuracy, structural integrity, and process reliability, highlighting the urgent need for advanced forming strategies and precise control methodologies.

This Special Issue aims to present and disseminate the most recent advances related to the lightweight forming and control of complex thin-walled structures. We consider contributions addressing innovative forming processes, tooling and equipment design, as well as deformation control strategies for light alloys and advanced materials. Topics of interest include, but are not limited to, constitutive modeling under complex stress states, numerical simulations, deformation mechanisms, forming limits, and advanced experimental characterization techniques. Studies integrating experimental validation with modeling and simulation are particularly encouraged, while purely numerical or theoretical works without sufficient experimental support are outside the scope of this Special Issue.

Prof. Dr. Zhubin He
Prof. Dr. Yanli Lin
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 250 words) can be sent to the Editorial Office for assessment.

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-anonymized 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

  • tubes
  • sheets
  • anisotropic material
  • numerical simulation
  • constitutive behavior
  • processes
  • microstructure

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Published Papers (2 papers)

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Research

17 pages, 3217 KB  
Article
Numerical Simulation of Short-Arc-Plasma Characteristics in DC Electrofusion Magnesium Furnaces
by Qing Wang, Xuezhi Li, Hang Dong, Baozhen Yang, Pengfei Liu, Chuanhui Dai and Xiang Shen
Materials 2026, 19(18), 4025; https://doi.org/10.3390/ma19184025 - 21 Sep 2026
Abstract
To clarify the heat transfer and flow characteristics of arc plasma in a DC magnesium electrofusion furnace under short-arc conditions, a two-dimensional axisymmetric magnetohydrodynamic (MHD) model was developed. Coupled electromagnetic, thermal, and flow fields were solved using COMSOL Multiphysics 6.3, and the model [...] Read more.
To clarify the heat transfer and flow characteristics of arc plasma in a DC magnesium electrofusion furnace under short-arc conditions, a two-dimensional axisymmetric magnetohydrodynamic (MHD) model was developed. Coupled electromagnetic, thermal, and flow fields were solved using COMSOL Multiphysics 6.3, and the model was validated against Bowman’s free-arc experimental data. Results show that the arc is electromagnetically constricted into a contracted column, with high-temperature and high-velocity regions concentrated near the arc center. Unlike conventional long arcs, the short arc reaches the anode before the jet fully diffuses, causing momentum to be concentrated on the anode surface and generating pronounced pressure peaks. Higher current increases the arc temperature and jet velocity, thereby strengthening the pressure and shear stresses exerted on the molten pool. In contrast, increasing the arc length reduces the arc temperature, flow velocity, and surface forces, weakening both momentum transfer and heat transfer to the molten pool. Overall analysis reveals that arc length has a more significant effect on arc–molten pool interactions than current and is the dominant parameter governing short-arc behavior. These findings provide guidance for optimizing operating conditions and improving energy utilization in magnesium electrofusion furnaces. Full article
(This article belongs to the Special Issue Advanced Forming of Thin-Walled Materials: Microstructure, Processing and Properties)
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40 pages, 13315 KB  
Article
Biaxial Cyclic Loading Test for Bauschinger Effect Characterization of Q890 High-Strength Steel
by Lin Zhu, Shuo Wang, Yanli Lin, Yuetong Li, Bingyan Jing, Yibo Su, Leheng Huang, Chunyu Ou, Yingguang Zhao, Xiangyue Sun and Zhubin He
Materials 2026, 19(14), 3025; https://doi.org/10.3390/ma19143025 - 14 Jul 2026
Viewed by 419
Abstract
Large-scale thick curved components made of high-strength steel are critical to deep-sea pressure hulls and large structural components of engineering machinery. During forming, these components experience reverse loading upon unloading, and the pronounced Bauschinger effect of high-strength steel significantly compromises springback prediction accuracy, [...] Read more.
Large-scale thick curved components made of high-strength steel are critical to deep-sea pressure hulls and large structural components of engineering machinery. During forming, these components experience reverse loading upon unloading, and the pronounced Bauschinger effect of high-strength steel significantly compromises springback prediction accuracy, leading to costly die iterations. Existing cyclic tension–compression and shear tests are limited to uniaxial stress states and fail to capture the mechanical behavior under in-plane biaxial cyclic loading. Herein, a cyclic four-point bending method is proposed to characterize the Bauschinger effect of Q890 steel under biaxial cyclic loading. By tailoring the width-to-thickness ratio of the specimens, a series of plane stress states with different initial plastic stress ratios were obtained, covering the dominant stress conditions encountered in forming typical large-scale double-curvature thick plates. Full-field strain evolution during cyclic bending was captured in real time via digital image correlation (DIC), enabling systematic acquisition of equivalent stress–strain curves under various biaxial stress ratios over multiple cycles. As the width-to-thickness ratio increases, both forward and reverse yielding progressively degrade: the equivalent yield strength, forward peak flow stress, and reverse yield strength drop from 1098, 1193, and 742 MPa to 934, 1065, and 685 MPa, respectively. Accordingly, the Bauschinger ratio B, Bauschinger hardening parameter BHP, and Bauschinger energy parameter BEP decrease from 0.479, 0.789, and 4.747 to 0.363, 0.655, and 2.900, respectively, revealing a strong stress-ratio dependence of the Bauschinger effect. Notably, the springback ratio also shows clear dependence on the biaxial stress ratio, loading direction, and cyclic history, indicating that in-plane biaxial stress-state effects should be considered when characterizing the Bauschinger effect and springback behavior of Q890 high-strength steel. Full article
(This article belongs to the Special Issue Advanced Forming of Thin-Walled Materials: Microstructure, Processing and Properties)
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