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Metals
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Manufacturing Processes of Metallic Materials (2nd Edition)
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Manufacturing Processes of Metallic Materials (2nd Edition)

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 30 April 2026 | Viewed by 1452

Special Issue Editors

Dr. Chao Yu

E-Mail Website
Guest Editor
National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, China
Interests: advanced composite material forming technology; electromagnetic induction heating process and technology
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Hong Xiao

E-Mail Website
Guest Editor
National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, China
Interests: metals forming; rolling processes; finite element analysis; joining processes; bonding processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue aims to provide the most recent advances in the manufacturing processes of metallic materials and to identify directions both in experimental and numerical research, including the requirements for sustainable technologies and processes. A key aspect is proper process design in order to guarantee the compliance of the final product with the intended functionality, while at the same time minimizing resource usage.

The Special Issue will cover, but will not be limited to, the following topics:

  • Formability in metal forming processes;
  • Modeling and designing of forming and joining processes;
  • Additive, subtractive, and hybrid manufacturing;
  • Emerging manufacturing processes;
  • Intelligent metal processing technologies;
  • Formaing processes of lightweight metals;
  • Product design and process optimization;
  • Mechanical performance of products;
  • Mechanical joining processes;
  • Bonding and special rolling processes.

Dr. Chao Yu
Prof. Dr. Hong Xiao
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-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly 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

  • metals forming
  • manufacturing processes
  • rolling processes
  • finite element analysis
  • additive manufacturing
  • joining processes
  • bonding processes
  • simulation of manufacturing processes

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

Related Special Issue

Published Papers (3 papers)

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Research

10 pages, 3770 KB  
Communication
Preliminary Investigations into Internally Coated Fittings Made from ZnAl15Cu1Mg (ZEP1510)
by Abdulkerim Karaman, Sasa Ilic, Stefan Schmidt, Marius Ross, Marie Zöller, Michael Marré and Andreas Ujma
Metals 2026, 16(4), 372; https://doi.org/10.3390/met16040372 - 27 Mar 2026
Viewed by 327
Abstract
Stricter drinking water regulations intensify the need to replace leaded brasses in fittings. This work reports preliminary results on internally coated fittings using the wrought zinc alloy ZnAl15Cu1Mg (ZEP1510). A straight-tube Model Geometry 1 was lined internally with HDPE by gas-assisted injection molding, [...] Read more.
Stricter drinking water regulations intensify the need to replace leaded brasses in fittings. This work reports preliminary results on internally coated fittings using the wrought zinc alloy ZnAl15Cu1Mg (ZEP1510). A straight-tube Model Geometry 1 was lined internally with HDPE by gas-assisted injection molding, achieving a continuous barrier of 1.55–1.70 mm without altering the external envelope. A press-type T-fitting (32–32–32) was defined as Model Geometry 2 to benchmark forgeability; process layout (FEM) and warm-forging trials are summarized. Recycling relevance was addressed via a partial-melt (drip-off) route, which removed a substantial polymer fraction but left measurable residues. A production-cycle PCF from material production to finished tee indicates 3.156 kg CO2e for ZEP1510 vs. 5.385 kg CO2e (CuZn40Pb2) and 6.301 kg CO2e (CuZn21Si3), i.e., 41.85% and 50.06% savings. These findings establish manufacturability, indicate recycling feasibility, and quantify a CO2 advantage, outlining the next steps toward lining complex geometries and drinking water compliance. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials (2nd Edition))
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25 pages, 7088 KB  
Article
Selective Laser Melting of Multi-Material Ti15Ta/Ti6Al4V Structures for Biomedical Applications: From Process Parameters to Mechanical Properties and Biological Response
by Igor Polozov, Victoria Nefyodova, Anton Zolotarev, Victoria Sokolova, Sergey Chibrikov and Anatoly Popovich
Metals 2026, 16(3), 301; https://doi.org/10.3390/met16030301 - 8 Mar 2026
Viewed by 361
Abstract
Multi-material structures based on titanium alloys represent a promising approach for the fabrication of functionally graded orthopedic implants capable of combining high mechanical strength with reduced stiffness to minimize the stress-shielding effect. In the present work, multi-material Ti15Ta/Ti6Al4V specimens were fabricated by laser [...] Read more.
Multi-material structures based on titanium alloys represent a promising approach for the fabrication of functionally graded orthopedic implants capable of combining high mechanical strength with reduced stiffness to minimize the stress-shielding effect. In the present work, multi-material Ti15Ta/Ti6Al4V specimens were fabricated by laser powder bed fusion (L-PBF) for the first time, and the processing parameters of the transition zone were systematically optimized. Three regimes were investigated: baseline (93 J/mm3), double scanning (186 J/mm3), and reduced speed (116 J/mm3). The microstructure and elemental distribution were examined by SEM and EDS; mechanical properties were evaluated through tensile testing and microhardness measurements; biocompatibility was assessed using osteoblasts and gingival fibroblasts. The double scanning regime provided the highest density of the transition zone (99.49%). Tensile failure of the specimens occurred in the Ti15Ta region, confirming the quality of the metallurgical bond. The ultimate tensile strength ranged from 534 to 543 MPa with an elongation at break of 15.7–16.4%. Heat treatment at 875 °C led to the formation of an equilibrium lamellar microstructure and smoothing of the interface. Cell viability on both alloys exceeded 88% as confirmed by flow cytometry and remained above the 70% non-cytotoxicity threshold defined by ISO 10993-5. The obtained results demonstrate the technological feasibility of fabricating multi-material Ti15Ta/Ti6Al4V structures and achieving high-quality metallurgical bonding, which constitutes a necessary first step toward the development of functionally graded orthopedic implants. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials (2nd Edition))
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15 pages, 8848 KB  
Article
Optimization of a Center-Punching Mechanical Clinching Process for High-Strength Steel DP980 and Aluminum Alloy AL5052 Sheets
by Ping Qiu, Xiaoxin Lu, Boran Deng, Hong Xiao and Chao Yu
Metals 2025, 15(12), 1388; https://doi.org/10.3390/met15121388 - 18 Dec 2025
Viewed by 442
Abstract
As research on new, lightweight energy vehicles continues to develop, the application of high-strength steel sheets with tensile strength greater than 1 GPa and their mechanical clinching technology, which is associated with aluminum alloys, has emerged as a new research focus. However, due [...] Read more.
As research on new, lightweight energy vehicles continues to develop, the application of high-strength steel sheets with tensile strength greater than 1 GPa and their mechanical clinching technology, which is associated with aluminum alloys, has emerged as a new research focus. However, due to the challenges associated with the cold deformation of high-strength steel, conventional mechanical clinching processes often fail to establish effective joint interlocking, resulting in weak connections. This study proposes a center-punching mechanical clinching process for connecting DP980 high-strength steel to AL5052 aluminum alloy. The mechanical evolution during the forming process was analyzed via finite element simulation. An orthogonal experimental design was employed to optimize key geometric parameters of the punch and die, yielding the optimal configuration for the mold. Mechanical testing of the joint demonstrated average pull-out force and pull-shear forces of 1124 N and 2179 N, respectively, confirming the proposed process’s ability to successfully connect high-strength steel and aluminum alloy. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials (2nd Edition))
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