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Materials Processing and Emerging Technologies
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Materials Processing and Emerging Technologies

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

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 12990

Special Issue Editors

Dr. Declan Devine

E-Mail Website
Guest Editor
Material Research Institute, Athlone Institute of Technology, Dublin Road, Athlone, Co. Westmeath, Ireland
Interests: polymer; polymer processing; smart manufacturing; tissue engineering; bone regeneration; composites; controlled release; thermoplastic composites; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. John (Sean) Lyons

E-Mail Website
Guest Editor
Faculty of Engineering and Infomatics, Athlone Institute of Technology, Dublin Road, Athlone, Co. Westmeath, Ireland
Interests: polymer; polymer processing; smart manufacturing; robotics; additive manufacturing
Dr. Xavier Velay

E-Mail Website
Guest Editor
Faculty of Engineering & Design, Institute of Technology Sligo, Ash Lane, Sligo, Co. Sligo, Ireland
Interests: Industry 4.0; design thinking; medical products and devices; smart materials; circular economy; engineering management
Dr. Rónán Dunbar

E-Mail Website
Guest Editor
Faculty of Engineering and Informatics, Technological University of the Shannon, Midlands Midwest, Athlone, Co. Westmeath, Ireland
Interests: technology education; innovative teaching and learning; instructional design; learner characteristics; industry-based learning; problem/project-based learning
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Manufacturing processes for materials are experiencing a worldwide transformation from traditional manufacturing to smart and advanced manufacturing techniques, where the integration of digital sciences and material processing has changed the face of the industry. To give rise to knowledge sharing in these times, the guest editing team are bringing together a collection of work related to the processing of materials using these new innovative techniques. The team, in collaboration with the organising committee of the 37th International Manufacturing Conference, seeks publications addressing the following topics:

  • Smart and advanced manufacturing technologies;
  • Medical device and biopharmaceutical manufacturing ;
  • Additive manufacturing (3D printing) ;
  • Polymer engineering technologies;
  • Manufacturing and sustainable development goals ;
  • Innovative manufacturing processes and practices ;
  • Industry 4.0 technologies;
  • Digital twin technologies for material processing ;
  • Immersive technology for materials manufacturing ;
  • Polymer engineering technologies;
  • Machine tool design;
  • Manufacturing and sustainable development goals.

We would like to invite authors to submit manuscripts— experimental and/or theoretical papers, technical notes, review papers, etc.—to this Special Issue of Materials on “Materials processing and emerging technologies”, which fall within its scope.

Thank you very much for your attention. We look forward to receiving your submissions.

Yours Sincerely,

Dr. Declan Devine
Dr. John (Sean) Lyons
Dr. Xavier Velay
Dr. Rónán Dunbar
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

  • smart and advanced manufacturing technologies
  • medical device and biopharmaceutical manufacturing
  • additive manufacturing (3D printing)
  • polymer engineering technologies
  • manufacturing and sustainable development goals

Published Papers (5 papers)

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Research

24 pages, 8606 KiB  
Article
Indirect Induction Sintering of Metal Parts Produced through Material Extrusion Additive Manufacturing
by Manuel Ortega Varela de Seijas, Andreas Bardenhagen, Thomas Rohr and Enrico Stoll
Materials 2023, 16(2), 885; https://doi.org/10.3390/ma16020885 - 16 Jan 2023
Cited by 9 | Viewed by 4058
Abstract
Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being [...] Read more.
Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being increasingly used, resulting in almost fully dense parts, whereby geometries are shaped, debinded and sintered sequentially until the completion of the part. Traditionally, “brown” debinded geometries are transported to conventional furnaces to densify the powder compacts, requiring careful tailoring of the heating profiles and sintering environment. This approach is decoupled and often involves time-consuming post-processing, whereby after the completion of the shaping and debinding steps, the parts need to be transported to a sintering furnace. Here, it is shown that sintering via indirect induction heating of a highly filled commercially available filament embedded with stainless steel 316L powder can be an effective route to densify Fused Filament Fabricated (FFF) parts. The results show that densities of 99.8% can be reached with very short soaking times, representing a significant improvement compared to prior methods. A hybrid machine is proposed, whereby a custom-built machine is integrated with an induction heater to combine FFF with local indirect induction sintering. Sintering in situ, without the need for part transportation, simplifies the processing of metal parts produced through material extrusion additive manufacturing. Full article
(This article belongs to the Special Issue Materials Processing and Emerging Technologies)
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16 pages, 5000 KiB  
Article
Comparison of Conventional and Robotic Fused Filament Fabrication on Silicone Build Plates
by Thomas Herzog, Georg Schnell, Carsten Tille and Hermann Seitz
Materials 2022, 15(18), 6352; https://doi.org/10.3390/ma15186352 - 13 Sep 2022
Cited by 2 | Viewed by 1098
Abstract
The objective of this study is the investigation of the transferability of the material extrusion process from conventional to robotic fabrication on silicone build plates for use in Enhanced Multipoint Moulding with Additive Attachments. Therefore, the study is based on two series of [...] Read more.
The objective of this study is the investigation of the transferability of the material extrusion process from conventional to robotic fabrication on silicone build plates for use in Enhanced Multipoint Moulding with Additive Attachments. Therefore, the study is based on two series of experiments. The first series of tests used a conventional plant extended by a silicone construction platform. In comparison, a six-axis industrial robot was chosen to produce the test specimens in the second series of tests. The comparisons of adhesion strengths and relative shape deviations are used to validate the transferability. The results of the tests show a very good transferability of the process from conventional to robotic production. Whilst angular specimen geometries can be transferred directly, for round specimen geometries, the results show a need for further adaptation to the robot kinematics. The round specimen geometries showed deviations in the surface quality caused by an over-extrusion in the robotic manufacturing. This over-extrusion results from the slicing process in combination with the robot control and may be avoided through further optimisation of the process parameters. Overall, to the best of our knowledge, this study is the first that successfully demonstrates the transfer of Fused Filament Fabrication (FFF) from a conventional system to manufacturing using robots on silicone build plates for the use in Enhanced Multipoint Moulding with Additive Attachments. Full article
(This article belongs to the Special Issue Materials Processing and Emerging Technologies)
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15 pages, 5057 KiB  
Article
Development and Validation of Empirical Models to Predict Metal Additively Manufactured Part Density and Surface Roughness from Powder Characteristics
by Paul Quinn, Sinéad M. Uí Mhurchadha, Jim Lawlor and Ramesh Raghavendra
Materials 2022, 15(13), 4707; https://doi.org/10.3390/ma15134707 - 5 Jul 2022
Cited by 5 | Viewed by 1562
Abstract
Metal additive manufacturing (AM) processes, viz laser powder bed fusion (L-PBF), are becoming an increasingly popular manufacturing tool for a range of industries. The powder material used in L-PBF is costly, and it is rare for a single batch of powder to be [...] Read more.
Metal additive manufacturing (AM) processes, viz laser powder bed fusion (L-PBF), are becoming an increasingly popular manufacturing tool for a range of industries. The powder material used in L-PBF is costly, and it is rare for a single batch of powder to be used in a single L-PBF build. The un-melted powder material can be sieved and recycled for further builds, significantly increasing its utilisation. Previous studies conducted by the authors have tracked the effect of both powder recycling and powder rejuvenation processes on the powder characteristics and L-PBF part properties. This paper investigates the use of multiple linear regression to build empirical models to predict the part density and surface roughness of 316L stainless steel parts manufactured using recycled and rejuvenated powder based on the powder characteristics. The developed models built on the understanding of the effect of powder characteristics on the part properties. The developed models were found to be capable of predicting the part density and surface roughness to within ±0.02% and ±0.5 Ra, respectively. The models developed enable L-PBF operators to input powder characteristics and predict the expected part density and surface roughness. Full article
(This article belongs to the Special Issue Materials Processing and Emerging Technologies)
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10 pages, 3046 KiB  
Article
Investigation of the Mechanical Properties of Friction Drilling with 6082-T6 Aluminium Alloy
by Hao Wu, Mark Porter, Richard Ward, Justin Quinn, Cormac McGarrigle and Shaun McFadden
Materials 2022, 15(7), 2469; https://doi.org/10.3390/ma15072469 - 27 Mar 2022
Cited by 1 | Viewed by 2294
Abstract
Friction drilling is a non-conventional hole-making process suitable for thin-section, ductile metals. During friction drilling, heat is generated due to tool rotation and the resulting flow of metal creates a bushing on the exit side of the hole. The bushing offers a longer [...] Read more.
Friction drilling is a non-conventional hole-making process suitable for thin-section, ductile metals. During friction drilling, heat is generated due to tool rotation and the resulting flow of metal creates a bushing on the exit side of the hole. The bushing offers a longer engagement length for any subsequent thread making process. The threaded holes in this study were created by friction drilling and thread forming in 6082-T6 aluminium alloy. Four scenarios of the threaded holes were created with four levels of rotation rates of friction drilling processes (2000 rpm to 4000 rpm) and the mechanical properties of the threaded holes were compared. It was shown that 3000–3500 rpm is the optimum range of the rotation rate that achieved the higher load-bearing capacities (i.e., resistance to thread stripping) of 5.0–5.5 kN. In addition, the regions close to the thread surfaces in all scenarios were found to have experienced localised hardening to a hardness from 113 HV to around 125 HV. Full article
(This article belongs to the Special Issue Materials Processing and Emerging Technologies)
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19 pages, 5880 KiB  
Article
Comprehensive Knowledge-Driven AI System for Air Classification Process
by Henryk Otwinowski, Jaroslaw Krzywanski, Dariusz Urbaniak, Tomasz Wylecial and Marcin Sosnowski
Materials 2022, 15(1), 45; https://doi.org/10.3390/ma15010045 - 22 Dec 2021
Cited by 8 | Viewed by 2533
Abstract
Air classifier devices have a distinct advantage over other systems used to separate materials. They maximize the mill’s capacity and therefore constitute efficient methods of reducing the energy consumption of crushing and grinding operations. Since improvement in their performance is challenging, the development [...] Read more.
Air classifier devices have a distinct advantage over other systems used to separate materials. They maximize the mill’s capacity and therefore constitute efficient methods of reducing the energy consumption of crushing and grinding operations. Since improvement in their performance is challenging, the development of an efficient modeling system is of great practical significance. The paper introduces a novel, knowledge-based classification (FLClass) system of bulk materials. A wide range of operating parameters are considered in the study: the mean mass and the Sauter mean diameter of the fed material, classifier rotor speed, working air pressure, and test conducting time. The output variables are the Sauter mean diameter and the cut size of the classification product, as well as the performance of the process. The model was successfully validated against experimental data. The maximum relative error between the measured and predicted data is lower than 9%. The presented fuzzy-logic-based approach allows an optimization study of the process to be conducted. For the considered range of input parameters, the highest performance of the classification process is equal to almost 362 g/min. To the best of our knowledge, this paper is the first one available in open literature dealing with the fuzzy logic approach in modeling the air classification process of bulk materials. Full article
(This article belongs to the Special Issue Materials Processing and Emerging Technologies)
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