Journal Description
Journal of Manufacturing and Materials Processing
Journal of Manufacturing and Materials Processing
is an international, peer-reviewed, open access journal on the scientific fundamentals and engineering methodologies of manufacturing and materials processing published bimonthly online by MDPI.
- Open Access— free for readers, with article processing charges (APC) paid by authors or their institutions.
- High Visibility: indexed within Scopus, ESCI (Web of Science), Inspec, CAPlus / SciFinder, and other databases.
- Journal Rank: CiteScore - Q1 (Mechanical Engineering)
- Rapid Publication: manuscripts are peer-reviewed and a first decision is provided to authors approximately 15.6 days after submission; acceptance to publication is undertaken in 3.7 days (median values for papers published in this journal in the first half of 2023).
- Recognition of Reviewers: reviewers who provide timely, thorough peer-review reports receive vouchers entitling them to a discount on the APC of their next publication in any MDPI journal, in appreciation of the work done.
Impact Factor:
3.2 (2022);
5-Year Impact Factor:
3.6 (2022)
Latest Articles
Determination of the Influence of the Tool Side Stress Superposition and Tool Geometry on the Cut Surface Quality during Precision Shear Cutting
J. Manuf. Mater. Process. 2023, 7(4), 145; https://doi.org/10.3390/jmmp7040145 - 08 Aug 2023
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Shearing high-strength steels often leads to a subpar cut quality and excessive stress on the tool components. To enhance the quality of the cut surface, intricate techniques like fine blanking are commonly employed. However, for applications with lower quality requirements, precision shear cutting
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Shearing high-strength steels often leads to a subpar cut quality and excessive stress on the tool components. To enhance the quality of the cut surface, intricate techniques like fine blanking are commonly employed. However, for applications with lower quality requirements, precision shear cutting offers an alternative solution. This research paper introduces a novel approach to directly superimpose radial stress on a workpiece during the precision shear cutting process and showcases for the first time how the application of direct stress superimposition can impact the cut surface by concurrently modifying the shear cutting edge and punch surface. A statistical experimental design is employed to investigate the interrelationships between the parameters and their effects. The results indicate that the overall cut quality, including cylindricity, clean-cut angle, rollover height, and tool stress, defined by punch force and retraction force, is influenced by the superimposed stress. Regarding the clean-cut zone, the statistical significance of direct radially superimposed stress was not observed, except when interacting with sheet thickness and clearance. Additionally, the sheet thickness and cutting gap emerged as significant parameters affecting the overall quality of the cut surface.
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Open AccessArticle
Optimization of Selective Laser Sintering Three-Dimensional Printing of Thermoplastic Polyurethane Elastomer: A Statistical Approach
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, , , , , , and
J. Manuf. Mater. Process. 2023, 7(4), 144; https://doi.org/10.3390/jmmp7040144 - 08 Aug 2023
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This research addresses the challenge of determining the optimal parameters for the selective laser sintering (SLS) process using thermoplastic polyurethane elastomer (TPU) flexa black powder to achieve high-quality SLS parts. This study focuses on two key printing process parameters, namely layer thickness and
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This research addresses the challenge of determining the optimal parameters for the selective laser sintering (SLS) process using thermoplastic polyurethane elastomer (TPU) flexa black powder to achieve high-quality SLS parts. This study focuses on two key printing process parameters, namely layer thickness and the laser power ratio, and evaluates their impact on four output responses: density, hardness, modulus of elasticity, and time required to produce the parts. The primary impacts and correlations of the input factors on the output responses are evaluated using response surface methodology (RSM). A particular response optimizer is used to find the optimal settings of input variables. Additionally, the rationality of the model is verified through an analysis of variance (ANOVA). The research identifies the optimal combination of process parameters as follows: a 0.11 mm layer thickness and a 1.00 laser power ratio. The corresponding predicted values of the four responses are 152.63 min, 96.96 Shore-A, 2.09 MPa, and 1.12 g/cm3 for printing time, hardness, modulus of elasticity, and density, respectively. These responses demonstrate a compatibility of 66.70% with the objective function. An experimental validation of the predicted values was conducted and the actual values obtained for printing time, hardness, modulus of elasticity, and density at the predicted input process parameters are 159.837 min, 100 Shore-A, 2.17 MPa, and 1.153 g/cm3, respectively. The errors between the predicted and experimental values for each response (time, hardness, modulus of elasticity, and density) were found to be 4.51%, 3.04%, 3.69%, and 2.69%, respectively. These errors are all below 5%, indicating the adequacy of the model. This study also comprehensively describes the influence of process parameters on the responses, which can be helpful for researchers and industry practitioners in setting process parameters of similar SLS operations.
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Open AccessArticle
Experimental Analysis and Spatial Component Impact of the Inert Cross Flow in Open-Architecture Laser Powder Bed Fusion
J. Manuf. Mater. Process. 2023, 7(4), 143; https://doi.org/10.3390/jmmp7040143 - 07 Aug 2023
Abstract
Laser-based powder bed fusion is an additive manufacturing process in which a high-power laser melts a thin layer of metal powder layer by layer to yield a three-dimensional object. An inert gas must remove process byproducts formed during laser processing to ensure a
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Laser-based powder bed fusion is an additive manufacturing process in which a high-power laser melts a thin layer of metal powder layer by layer to yield a three-dimensional object. An inert gas must remove process byproducts formed during laser processing to ensure a stable and consistent process. The process byproducts include a plasma plume and spatter particles. An NC sensor gantry is installed inside a bespoke open-architecture laser-based powder bed fusion system to experimentally characterize the gas velocity throughout the processing area. The flow maps are compared to manufactured samples, where the relative density and melt pools are analyzed, seeking a potential correlation between local gas flow conditions and the components. The results show a correlation between low gas flow velocities and increased porosity, leading to lower part quality. Local flow conditions across the build plate also directly impact components, highlighting the importance of optimizing the gas flow subsystem. The experimental flow analysis method enables optimization of the gas flow inlet geometry, and the data may be used to calibrate the computational modeling of the process.
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(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing)
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Open AccessCommunication
Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage
J. Manuf. Mater. Process. 2023, 7(4), 142; https://doi.org/10.3390/jmmp7040142 - 07 Aug 2023
Abstract
The detection of ductile damage by image-based methods is time-consuming and typically probes only small areas. It is therefore of great interest for various cold forming processes, such as sheet-bulk metal forming, to develop new methods that can be used during the forming
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The detection of ductile damage by image-based methods is time-consuming and typically probes only small areas. It is therefore of great interest for various cold forming processes, such as sheet-bulk metal forming, to develop new methods that can be used during the forming process and that enable an efficient detection of ductile damage. In the present study, ductile damage in DC04 was examined using ultrasonic testing. First, different grain sizes were set by heat treatment. Subsequently, the sheet metal was formed by cold rolling. A clear correlation between the average void diameter and the measured ultrasonic velocity could be shown. The ultrasonic velocity showed a clear decrease when the average void size increased because of the increasing forming degree. The ultrasonic measurements were finally employed to calculate a damage parameter D to determine the amount of ductile damage in the microstructure for different grain sizes after cold rolling.
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(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)
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Open AccessArticle
The Influence of Injection Temperature and Pressure on Pattern Wax Fluidity
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, , , , , and
J. Manuf. Mater. Process. 2023, 7(4), 141; https://doi.org/10.3390/jmmp7040141 - 04 Aug 2023
Abstract
In the investment casting process, the pattern made of wax is obtained in a die for further formation of a shell mold. The problem of die-filling by pattern wax is significant because it influences the quality of the final casting. This work investigates
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In the investment casting process, the pattern made of wax is obtained in a die for further formation of a shell mold. The problem of die-filling by pattern wax is significant because it influences the quality of the final casting. This work investigates three commercial pattern waxes’ fluidity with a newly developed injection fluidity test. It was shown that the fluidity of waxes increased with increasing injection temperature and pressure, and the simultaneous increase in temperature and pressure gives a much more significant enhancement of fluidity than an increase in temperature or pressure separately. The rheological behavior of the waxes was also investigated at different temperatures using a rotational viscosimeter, and temperature dependences of waxes’ dynamic viscosity were determined. It was shown that wax viscosity is increased more than ten times with decreasing temperature from 90 to 60 °C. A good correlation between wax fluidity and its viscosity is observed, which is different from metallic alloys, where the solidification behavior is more critical. The difference in wax flow behavior in comparison with metallic melts is associated with the difference in dynamic viscosity, which for investigated waxes and metallic melts is 3000–27,000 mPa·s and 0.5–6.5 mPa·s, respectively. The difference in investigated filled waxes’ fluidity is observed, which can be associated with the type and amount of filler. The twice-increasing fraction of cross-linked polystyrene decreases fluidity twice. At the same time, terephthalic acid has a minor influence on wax fluidity.
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(This article belongs to the Topic Advanced Processes in Metallurgical Technologies)
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Open AccessArticle
Grain Refinement of Pure Magnesium for Microforming Application
J. Manuf. Mater. Process. 2023, 7(4), 140; https://doi.org/10.3390/jmmp7040140 - 04 Aug 2023
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Magnesium is a suitable candidate material for temporary implant applications, such as a miniplate, due to its biocompatibility, density, and elastic modulus comparable to that of human bone. The biodegradability property of magnesium can minimize the need for a second surgery after the
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Magnesium is a suitable candidate material for temporary implant applications, such as a miniplate, due to its biocompatibility, density, and elastic modulus comparable to that of human bone. The biodegradability property of magnesium can minimize the need for a second surgery after the healing process, thereby reducing costs and pain for patients. On the other hand, microforming is a promising technology for manufacturing miniplates with high production rates and good mechanical properties. However, the application of magnesium in microforming is limited and remains a challenge in resolving issues related to the size effect in microforming and the low formability of magnesium, especially at room temperature. Grain refinement and homogenization are alternative approaches to controlling the size effect in magnesium microforming and improving formability. As the grain refinement process influences the mechanical and corrosion behavior of magnesium, this research shows that the grain refinement process for pure magnesium improves the overall performance of the microforming process for implant applications.
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Open AccessArticle
Analysis of Tempering Effects on LDS-MID and PCB Substrates for HF Applications
J. Manuf. Mater. Process. 2023, 7(4), 139; https://doi.org/10.3390/jmmp7040139 - 03 Aug 2023
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Mechatronic Integrated Devices or Molded Interconnect Devices (MID) are three-dimensional (3D) circuit carriers. They are mainly fabricated by laser direct structuring (LDS) and subsequent electroless copper plating of an injection molded 3D substrate. Such LDS-MID are used in many applications today, especially antennas.
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Mechatronic Integrated Devices or Molded Interconnect Devices (MID) are three-dimensional (3D) circuit carriers. They are mainly fabricated by laser direct structuring (LDS) and subsequent electroless copper plating of an injection molded 3D substrate. Such LDS-MID are used in many applications today, especially antennas. However, in high frequency (HF) systems in 5G and radar applications, the demand on 3D circuit carriers and antennas increases. Electroless copper, widely used in MID, has significantly lower electrical conductivity compared to pure copper. Its lower conductivity increases electrical loss, especially at higher frequencies, where signal budget is critical. Heat treatment of electroless copper deposits can improve their conductivity and adhesion to the 3D substrates. This paper investigates the effects induced by tempering processes on the metallization of LDS-MID substrates. As a reference, HF Printed Circuit Boards (PCB) substrates are also considered. Adhesion strength and conductivity measurements, as well as permittivity and loss angle measurements up to 1 GHz, were carried out before and after tempering processes. The main influencing factors on the tempering results were found to be tempering temperature, atmosphere, and time. Process parameters like the heating rate or applied surface finishes had only a minor impact on the results. It was found that tempering LDS-MID substrates can improve the copper adhesion and lower their electrical resistance significantly, especially for plastics with a high melting temperature. Both improvements could improve the reliability of LDS-MID, especially in high frequency applications. Firstly, because increased copper adhesion can prevent delamination and, secondly, because the lowered electrical resistance indicates, in accordance with the available literature, a more ductile copper metallization and thus a lower risk of microcracks.
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Open AccessArticle
Fabrication of Bimetallic High-Strength Low-Alloy Steel/Si-Bronze Functionally Graded Materials Using Wire Arc Additive Manufacturing
J. Manuf. Mater. Process. 2023, 7(4), 138; https://doi.org/10.3390/jmmp7040138 - 31 Jul 2023
Abstract
In this paper, bimetallic functionally graded structures were fabricated using wire and arc additive manufacturing (WAAM). The bimetallic walls were built by depositing Si-Bronze and high-strength low-alloy (HSLA) steel, successively. The microstructural evolution of the built structures, especially within the fusion zone between
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In this paper, bimetallic functionally graded structures were fabricated using wire and arc additive manufacturing (WAAM). The bimetallic walls were built by depositing Si-Bronze and high-strength low-alloy (HSLA) steel, successively. The microstructural evolution of the built structures, especially within the fusion zone between the dissimilar alloys, was investigated in relation to their mechanical properties. The built bimetallic walls showed a high level of integrity. An overall interface length of 9 mm was investigated for microstructural evolution, elemental mapping and microhardness measurements along the building direction. Microhardness profiles showed a gradual transition in hardness passing through the diffusion zone with no evidence for intermetallic compounds. Failure of the tensile specimens occurred at the Si-Bronze region, as expected. Bending tests confirmed good ductility of the joint between the dissimilar alloys. Direct shear test results proved a shear strength comparable to that of HSLA steel. The obtained results confirm that it is appropriate to fabricate HSLA steel/Si-Bronze FGMs using WAAM technology.
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(This article belongs to the Special Issue Advances in Metal Additive Manufacturing/3D Printing)
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Open AccessArticle
Manufacturing of High Conductivity, High Strength Pure Copper with Ultrafine Grain Structure
J. Manuf. Mater. Process. 2023, 7(4), 137; https://doi.org/10.3390/jmmp7040137 - 30 Jul 2023
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Applications of Copper (Cu) range from small scale applications such as microelectronics interconnects to very large high-powered applications such as railguns. In all these applications, Cu conductivity and ampacity play vital roles. In some applications such as railguns, where Cu also plays a
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Applications of Copper (Cu) range from small scale applications such as microelectronics interconnects to very large high-powered applications such as railguns. In all these applications, Cu conductivity and ampacity play vital roles. In some applications such as railguns, where Cu also plays a structural role, not only is high conductivity needed, but high strength, high ductility, and high wear resistance are also critical. Current technologies have achieved their full potential for producing better materials. New approaches and technologies are needed to develop superior properties. This research examines a new fabrication approach that is expected to produce Cu with superior mechanical strength, enhanced wear resistance, and increased electrical conductivity. Materials with refined grain structures were obtained by breaking down the coarse-grained Cu particles via cryogenic ball milling, followed by the consolidation of powders using cold isostatic pressing (CIP) and subsequent Continuous Equal Channel Angular Pressing (C-ECAP). The mixture of fine and ultrafine grains, with sizes between 200 nm to 2.5 µm and an average of 500 nm, was formed after ball milling at cryogenic temperatures. Further processing via C-ECAP produced nanostructured Cu with average grain sizes below 50 nm and excellent homogenous equiaxed grain shapes and random orientations. The hardness and tensile strength of the final Cu were approximately 158% and 95% higher than the traditional coarse-grained Cu bar, respectively. This material also displayed a good electrical conductivity rate of 74% International Annealed Copper Standard (IACS), which is comparable to the current Cu materials used in railgun applications.
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Open AccessArticle
ANOVA Analysis and L9 Taguchi Design for Examination of Flat Slide Burnishing of Unalloyed Structural Carbon Steel
J. Manuf. Mater. Process. 2023, 7(4), 136; https://doi.org/10.3390/jmmp7040136 - 29 Jul 2023
Abstract
Diamond burnishing is a finishing precision machining that is often used to improve the quality characteristics of previously machined surfaces. With its help, the surface roughness can be reduced, the surface hardness can be increased, and the tensile stresses remaining in the surface
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Diamond burnishing is a finishing precision machining that is often used to improve the quality characteristics of previously machined surfaces. With its help, the surface roughness can be reduced, the surface hardness can be increased, and the tensile stresses remaining in the surface after cutting can be transformed into compressive ones, and these changes can increase the service life of the components. Diamond burnishing was typically developed for processing cylindrical surfaces and is most often used for this type of surface. In this manuscript, we present a new method with the help of sliding burnishing, which can also be used on flat surfaces. By using the clamping head of a special tool into the main spindle of the vertical milling machine and moving it along a suitable path, the flat surface can be burnished. Machining experiments were carried out with the new type of tool on general-purpose, unalloyed, structural carbon steel samples on which the flat surfaces were previously generated by face milling. The examined parameters were the burnishing force F, the feed fb, and the number of passes (NoP). The L9 Taguchi experiment design was applied for executing flat slide burnishing, and the examination was conducted by ANOVA analysis. This research contributes to the field by providing insights into optimizing the burnishing process parameters for achieving desired surface quality in milling operations.
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(This article belongs to the Special Issue Advances in Precision Machining Processes)
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A Novel Apparatus for the Simulation of Powder Spreading Procedures in Powder-Bed-Based Additive Manufacturing Processes: Design, Calibration, and Case Study
J. Manuf. Mater. Process. 2023, 7(4), 135; https://doi.org/10.3390/jmmp7040135 - 28 Jul 2023
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Powder-bed-based additive manufacturing processes (PBAM) are sensitive to variations in powder feedstock characteristics, and yet the link between the powder properties and process performance is still not well established, which complicates the powder selection, quality control, and process improvement processes. An accurate assessment
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Powder-bed-based additive manufacturing processes (PBAM) are sensitive to variations in powder feedstock characteristics, and yet the link between the powder properties and process performance is still not well established, which complicates the powder selection, quality control, and process improvement processes. An accurate assessment of the powder characteristics and behavior during recoating is important and must include the flow and packing properties of the powders, which are dependent on the application conditions. To fulfill the need for suitable powder testing techniques, a novel apparatus is developed to reproduce the generic PBAM powder spreading procedure and allow the measurements of the powder bed density, surface uniformity, and spreading forces as functions of the powder characteristics and spreading conditions, including the spreading speed and the type of spreading mechanism. This equipment could be used for research and development purposes as well as for the quality control of the PBAM powder feedstock, as showcased in this paper using a gas-atomized Ti-6Al-4V powder (D10 = 25.3 µm, D50 = 35.8 µm and D90 = 46.4 µm) spread using a rigid blade by varying the recoating speed from 100 to 500 mm/s and the layer thickness from 30 to 100 µm.
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Open AccessArticle
Influence of Carbon on Additively Manufactured Ti-6Al-4V
J. Manuf. Mater. Process. 2023, 7(4), 134; https://doi.org/10.3390/jmmp7040134 - 26 Jul 2023
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In this study, the Ti-6Al-4V powder material for additive manufacturing was mixed with amorphous carbon and processed by powder bed fusion using a laser beam. The specimens were subjected to mechanical and microstructural analyses to investigate the impact of the organic constituent that
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In this study, the Ti-6Al-4V powder material for additive manufacturing was mixed with amorphous carbon and processed by powder bed fusion using a laser beam. The specimens were subjected to mechanical and microstructural analyses to investigate the impact of the organic constituent that may become introduced unintentionally as an impurity along the powder handling chain. It is documented that hardness and tensile strength increase with increasing carbon content up to 0.2 wt.%. Above this carbon concentration, extensive crack formation in the samples prevents successful procession.
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(This article belongs to the Topic Additive Manufacturing: Design, Opportunities, and Applications)
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Open AccessArticle
Innovative Process Strategies in Powder-Based Multi-Material Additive Manufacturing
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, , , , , , and
J. Manuf. Mater. Process. 2023, 7(4), 133; https://doi.org/10.3390/jmmp7040133 - 24 Jul 2023
Abstract
Multi-material additive manufacturing (AM) attempts to utilize the full benefits of complex part production with a comprehensive and complementary material spectrum. In this context, this research article presents new processing strategies in the field of polymer- and metal-based multi-material AM. The investigation highlights
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Multi-material additive manufacturing (AM) attempts to utilize the full benefits of complex part production with a comprehensive and complementary material spectrum. In this context, this research article presents new processing strategies in the field of polymer- and metal-based multi-material AM. The investigation highlights the current progress in powder-based multi-material AM based on three successfully utilized technological approaches: additive and formative manufacturing of hybrid metal parts with locally adapted and tailored properties, material-efficient AM of multi-material polymer parts through electrophotography, and the implementation of UV-curable thermosets within the laser-based powder bed fusion of plastics. Owing to the complex requirements for the mechanical testing of multi-material parts with an emphasis on the transition area, this research targets an experimental shear testing set-up as a universal method for both metal- and polymer-based processes. The method was selected based on the common need of all technologies for the sufficient characterization of the bonding behavior between the individual materials.
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(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)
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Open AccessArticle
Mechanical and Microstructure Characterisation of the Hypoeutectic Cast Aluminium Alloy AlSi10Mg Manufactured by the Twin-Roll Casting Process
J. Manuf. Mater. Process. 2023, 7(4), 132; https://doi.org/10.3390/jmmp7040132 - 23 Jul 2023
Abstract
Multi-material designs (MMD) are more frequently used in the automotive industry. Hereby, the combination of different materials, metal sheets, or cast components, is mechanically joined, often by forming joining processes. The cast components mostly used are high-strength, age-hardenable aluminium alloys of the Al–Si
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Multi-material designs (MMD) are more frequently used in the automotive industry. Hereby, the combination of different materials, metal sheets, or cast components, is mechanically joined, often by forming joining processes. The cast components mostly used are high-strength, age-hardenable aluminium alloys of the Al–Si system. Here, the low ductility of the AlSi alloys constitutes a challenge because their brittle nature causes cracks during the joining process. However, by using suitable solidification conditions, it is possible to achieve a microstructure with improved mechanical and joining properties. For this study, we used the twin-roll casting process (TRC) with water-cooled rollers to manufacture the hypoeutectic AlSi10Mg for the first time. Hereby, high solidification rates are realisable, which introduces a microstructure that is about four times finer than in the sand casting process. In particular, it is shown that a fine microstructure close to the modification with Na or Sr is achieved by the high solidification rate in the TRC process without using these elements. Based on this, the mechanical properties increase, and especially the ductility is enhanced. Subsequent joining investigations validate the positive influence of a high solidification rate since cracks in joints can be avoided. Finally, a microstructure-property-joint suitability correlation is presented.
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(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)
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Open AccessArticle
Performance Evaluation of Graphene Nanofluid to Mitigate the Wear of a Diamond Tool in Micro-Machining of Ti6Al4V Alloy
J. Manuf. Mater. Process. 2023, 7(4), 131; https://doi.org/10.3390/jmmp7040131 - 19 Jul 2023
Abstract
Diamond tools are extensively used in ultra-precision machining due to their exceptional performance. However, when machining challenging materials like Ti6Al4V, diamond tools experience significant wear due to poor machining properties and catalytic effects. Tool wear not only impacts machining quality but also escalates
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Diamond tools are extensively used in ultra-precision machining due to their exceptional performance. However, when machining challenging materials like Ti6Al4V, diamond tools experience significant wear due to poor machining properties and catalytic effects. Tool wear not only impacts machining quality but also escalates machining costs and energy consumption. Cutting fluids are commonly employed to mitigate interfacial reactions and suppress tool wear. However, traditional cutting fluids are difficult to penetrate the cutting area and have limited lubrication and cooling capabilities. Therefore, in this paper, a technique combining graphene nanofluid and minimum-quantity lubrication (MQL) is used to suppress diamond tool wear. Firstly, micro-milling experiments for Ti6Al4V alloy are conducted using diamond tools in the graphene nanofluid MQL and under a dry environment. The experimental results show that tool wear is effectively suppressed by graphene nanofluids. Subsequently, the cutting process in both environments (graphene nanofluid MQL, dry) is simulated. The suppression mechanism of graphene nanofluid MQL for diamond tool wear is evaluated from phase transition, atomic transfer process, and amorphous behavior of diamond structure. The simulation results show that the contact characteristics, cutting force, and cutting temperature are improved by graphene nanofluids. Tool wear is effectively reduced. In addition, the removal efficiency of workpiece materials has also been improved. This work provides a technical basis for exploring the application of graphene nanofluids in diamond tool damage suppression and micro-milling.
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(This article belongs to the Special Issue Advances in Precision Machining Processes)
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Open AccessArticle
Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process
J. Manuf. Mater. Process. 2023, 7(4), 130; https://doi.org/10.3390/jmmp7040130 - 13 Jul 2023
Abstract
The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle
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The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle intermetallic phase is formed that reduces the service life of the component. After welding, the workpiece is heated inhomogeneously and hot-formed in a cross-wedge rolling process. Since the intermetallic phase grows depending on the temperature during hot forming, temperature control is of great importance. In this paper, the possibility of process-integrated contact temperature measurement with thin-film sensors is investigated. For this purpose, the initial temperature distribution after induction heating of the workpiece is determined. Subsequently, cross-wedge rolling is carried out, and the data of the thin-film sensors are compared to the temperature measurements after heating. It is shown that thin-film sensors inserted into the tool are capable of measuring surface temperatures even at a contact time of 0.041 s. The new process monitoring of the temperature makes it possible to develop a better understanding of the process as well as to further optimize the temperature distribution. In the long term, knowledge of the temperatures in the different materials also makes it possible to derive quality characteristics as well as insights into the causes of possible process errors (e.g., fracture of the joining zone).
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(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)
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Open AccessReview
Tool Wear Monitoring with Artificial Intelligence Methods: A Review
J. Manuf. Mater. Process. 2023, 7(4), 129; https://doi.org/10.3390/jmmp7040129 - 11 Jul 2023
Abstract
Tool wear is one of the main issues encountered in the manufacturing industry during machining operations. In traditional machining for chip removal, it is necessary to know the wear of the tool since the modification of the geometric characteristics of the cutting edge
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Tool wear is one of the main issues encountered in the manufacturing industry during machining operations. In traditional machining for chip removal, it is necessary to know the wear of the tool since the modification of the geometric characteristics of the cutting edge makes it unable to guarantee the quality required during machining. Knowing and measuring the wear of tools is possible through artificial intelligence (AI), a branch of information technology that, by interpreting the behaviour of the tool, predicts its wear through intelligent systems. AI systems include techniques such as machine learning, deep learning and neural networks, which allow for the study, construction and implementation of algorithms in order to understand, improve and optimize the wear process. The aim of this research work is to provide an overview of the recent years of development of tool wear monitoring through artificial intelligence in the general and essential requirements of offline and online methods. The last few years mainly refer to the last ten years, but with a few exceptions, for a better explanation of the topics covered. Therefore, the review identifies, in addition to the methods, the industrial sector to which the scientific article refers, the type of processing, the material processed, the tool used and the type of wear calculated. Publications are described in accordance with PRISMA-P (Preferred Reporting Items for Systematic review and Meta-Analysis Protocols).
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(This article belongs to the Special Issue Industry 4.0 and Smart Materials Processing for Enhanced Manufacturing)
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Open AccessArticle
Modeling of Energy Consumption and Print Time for FDM 3D Printing Using Multilayer Perceptron Network
J. Manuf. Mater. Process. 2023, 7(4), 128; https://doi.org/10.3390/jmmp7040128 - 07 Jul 2023
Abstract
Given the recognized advantages of additive manufacturing (AM) printing systems in comparison with conventional subtractive manufacturing systems, AM technology has become increasingly adopted in 3D manufacturing, with usage rates increasing dramatically. This strong growth has had a significant and direct impact not only
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Given the recognized advantages of additive manufacturing (AM) printing systems in comparison with conventional subtractive manufacturing systems, AM technology has become increasingly adopted in 3D manufacturing, with usage rates increasing dramatically. This strong growth has had a significant and direct impact not only on energy consumption but also on manufacturing time, which in turn has generated significant costs. As a result, this problem has attracted the attention of industry actors and the research community, and several studies have focused on predicting and reducing energy consumption and additive manufacturing time, which has become one of the main objectives of research in this field. However, there is no effective model yet for predicting and optimizing energy consumption and printing time in a fused deposition modeling (FDM) process while taking into account the correct part orientation that minimizes both of these costs. In this paper, a neural-network-based model has been proposed to solve this problem using experimental data from isovolumetrically shaped mechanical parts. The data will serve as the basis for proposing the appropriate model using a specific methodology based on five performance criteria with the following statistical values: R2-squared > 99%, explained variance > 99%, MAE < 0.99%, MSE < 0.02% and RMSE < 1.36%. These values show just how effective the proposed model will be in estimating energy consumption and FDM printing time, taking into account the best choice of part orientation for the lowest cost. This model provides a global understanding of the primary energy and time requirements for manufacturing while also improving the system’s cost efficiency. The results of this work can be extended and applied to other additive manufacturing processes in future work.
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(This article belongs to the Topic Additive Manufacturing: Design, Opportunities, and Applications)
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Fracture Characterisation and Modelling of AHSS Using Acoustic Emission Analysis for Deep Drawing
J. Manuf. Mater. Process. 2023, 7(4), 127; https://doi.org/10.3390/jmmp7040127 - 05 Jul 2023
Abstract
Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the
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Driven by high energy prices, AHSS are still gaining importance in the automotive industry regarding electric vehicles and their battery range. Simulation-based design of forming processes can contribute to exploiting their potential for lightweight design. Fracture models are frequently used to predict the material’s failure and are often parametrised using different tensile tests with optical measurements. Hereby, the fracture is determined by a surface crack. However, for many steels, the fracture initiation already occurs inside the specimen prior to a crack on the surface. This leads to inaccuracies and more imprecise fracture models. Using a method that detects the fracture initiation within the specimen, such as acoustic emission analysis, has a high potential to improve the modelling accuracy. In the presented paper, tests for fracture characterisation with two AHSS were performed for a wide range of stress states and measured with a conventional optical as well as a new acoustical measurement system. The tests were analysed regarding the fracture initiation using both measurement systems. Numerical models of the tests were created, and the EMC fracture model was parametrised based on the two evaluation areas: a surface crack as usual and a fracture from the inside as a novelty. The two fracture models were used in a deep drawing simulation for analysis, comparison and validation with deep drawing experiments. It was shown that the evaluation area for the fracture initiation had a significant impact on the fracture model. Hence, the failure prediction of the EMC fracture model from the acoustic evaluation method showed a higher agreement in the numerical simulations with the experiments than the model from the optical evaluation.
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(This article belongs to the Special Issue Selected Papers from the 20th International Conference on Sheet Metal (SHEMET 2023))
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Open AccessArticle
Improving Material Formability and Tribological Conditions through Dual-Pressure Tube Hydroforming
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and
J. Manuf. Mater. Process. 2023, 7(4), 126; https://doi.org/10.3390/jmmp7040126 - 02 Jul 2023
Abstract
Dual-pressure tube hydroforming (THF) is a tube-forming process that involves applying fluid pressure to a tube’s inner and outer surfaces to achieve deformation. This study investigates the effect of dual-pressure loading paths on material formability and tribological conditions. Specifically, pear-shaped and triangular cross-sectional
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Dual-pressure tube hydroforming (THF) is a tube-forming process that involves applying fluid pressure to a tube’s inner and outer surfaces to achieve deformation. This study investigates the effect of dual-pressure loading paths on material formability and tribological conditions. Specifically, pear-shaped and triangular cross-sectional parts were formed using dual-pressure modes where fluid pressure on the inside of the tubular blank was alternated with pressure on the outside surface of the tubular blank, causing the tube to expand/stretch and contract. During expansion, the tube conformed to the die’s cavity, while during contraction, the contact area between the die and the workpiece reduced, leading to decreased friction stress at the tube–die interface. Additionally, the reversal of pressure loadings caused the tubular blank to buckle, altering the stress state and potentially increasing local shear stress, improving material formability. Dual-pressure THF has demonstrated that the pressure loading paths chosen can substantially influence material formability. Comparing the geometries of parts formed by dual-pressure THF and conventional THF shows a significant increase in the protrusion height of both the pear-shaped and triangular specimens using dual-pressure THF.
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(This article belongs to the Special Issue Advances in Material Forming)
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