Journal of Manufacturing and Materials Processing

11 pages, 469 KiB

Open AccessEditor’s ChoiceArticle

Impact of Green Ceramic Hybrid Machining (GCHM) on Reliability and Repeatability of the Properties of Sintered Yttrium-Tetragonal Zirconia Polycrystal Parts

by François Ducobu, Anthonin Demarbaix, Edouard Rivière-Lorphèvre, Laurent Spitaels, Fabrice Petit, Nicolas Preux, Charles Duterte, Marylou Mulliez and Bert Lauwers

J. Manuf. Mater. Process. 2023, 7(3), 118; https://doi.org/10.3390/jmmp7030118 - 20 Jun 2023

Cited by 1 | Viewed by 1226

Abstract

The innovative Green Ceramic Hybrid Machining (GCHM) process sequentially combines milling with a cutting tool (GCM, Green Ceramic Machining) and laser beam machining (GCLBM) of a ceramic material (black Y-TZP in this study) at the green stage mainly to increase productivity, avoid taper [...] Read more.

The innovative Green Ceramic Hybrid Machining (GCHM) process sequentially combines milling with a cutting tool (GCM, Green Ceramic Machining) and laser beam machining (GCLBM) of a ceramic material (black Y-TZP in this study) at the green stage mainly to increase productivity, avoid taper angle limitations of laser beam machining, and obtain micro-features. The study focuses on the reliability and the repeatability of the properties of sintered parts obtained by three manufacturing processes (GCM, GCLBM, GCHM) to assess the performance of hybridisation. It turns out that GCHM is a compromise of both milling and laser beam processes; it increases the repeatability of the surface quality and it slightly reduces (less than 7%) the flexural strength by comparison to milling for a similar reliability. The study also highlights that the surface quality of GCLBM processed parts relies on of the surface generated by the previous operation. Milling that surface at the previous step is therefore recommended, corresponding to the sequence adopted by GCHM. Full article

(This article belongs to the Special Issue Advances in Machining of Difficult-to-Cut Materials)

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24 pages, 7107 KiB

Open AccessArticle

A Geometry-Dependent Void Closure Model Considering Void Deformation and Orientation Changes during Hot Metal Formation

by Jihyun Kim, Joonhee Park, Yosep Kim, Hyukjoon Kwon and Naksoo Kim

J. Manuf. Mater. Process. 2023, 7(3), 117; https://doi.org/10.3390/jmmp7030117 - 20 Jun 2023

Viewed by 1372

Abstract

In this paper, a void closure model applicable to the general hot forming process has been proposed. Through the representative volume element (RVE) method, the influences of void shape, orientation, and stress state on void closure tendency were analysed. The void closure model [...] Read more.

In this paper, a void closure model applicable to the general hot forming process has been proposed. Through the representative volume element (RVE) method, the influences of void shape, orientation, and stress state on void closure tendency were analysed. The void closure model was established so that it could consider these cross effects. The model calculates the changing void radius and orientation during deformation by considering the rate of change of the parameters affecting void deformation with respect to the effective strain. The model predicted the void closure tendency well on the RVE scale and predicted the void closure adequately in a multi-stage process with random voids. The results were compared with the stress-triaxiality-based (STB) model, which showed that the void closure model proposed in this study is applicable in general situations. A cogging process was analysed, and the degree of void closure at the end of each pass was compared with the calculated results of the void closure model. For the experimental verification of the proposed model, spherical and ellipsoid voids were placed in a rectangular specimen, and the radii of the voids after compression were measured. The measurement results were compared with the calculation results of the proposed model. Full article

(This article belongs to the Special Issue Advances in Material Forming)

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14 pages, 4347 KiB

Open AccessArticle

On Welding of High-Strength Steels Using Laser Beam Welding and Resistance Spot Weld Bonding with Emphasis on Seam Leak Tightness

by Tobias Schmolke, Christian Brunner-Schwer, Max Biegler, Michael Rethmeier and Gerson Meschut

J. Manuf. Mater. Process. 2023, 7(3), 116; https://doi.org/10.3390/jmmp7030116 - 19 Jun 2023

Cited by 1 | Viewed by 1498

Abstract

The design of most electric vehicles provides for the positioning of the heavy energy storage units in the underbody of the cars. In addition to crash safety, the battery housing has to meet high requirements for gas tightness. In order to test the [...] Read more.

The design of most electric vehicles provides for the positioning of the heavy energy storage units in the underbody of the cars. In addition to crash safety, the battery housing has to meet high requirements for gas tightness. In order to test the use of high-strength steels for this sub-assembly, this paper examines welded joints utilizing resistance spot weld bonding and laser remote welding, with special regard to the gas tightness of the welds. For this purpose, the pressure difference test and helium sniffer leak detection are presented and applied. The combination of both leak test methods has proven ideal in experimental investigations. For laser remote welding, gas-tight seams can be achieved with an inter-sheet gap of 0.1 mm, even if occasionally leaking samples cannot be prevented. Resistance spot welding suits gas-tight joining with both one- and two-component adhesives. Against the background of leak tightness, process fluctuations that lead to weld spatter and defects in the adhesive layer must be prevented with high priority. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies for High-Strength Steels)

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23 pages, 5550 KiB

Open AccessReview

Recent Advancements in Post Processing of Additively Manufactured Metals Using Laser Polishing

by Majed Ali, Abdalmageed Almotari, Anwar Algamal and Ala Qattawi

J. Manuf. Mater. Process. 2023, 7(3), 115; https://doi.org/10.3390/jmmp7030115 - 15 Jun 2023

Cited by 5 | Viewed by 2104

Abstract

The poor surface roughness associated with additively manufactured parts can influence the surface integrity and geometric tolerances of produced components. In response to this issue, laser polishing (LP) has emerged as a potential technique for improving the surface finish and producing parts with [...] Read more.

The poor surface roughness associated with additively manufactured parts can influence the surface integrity and geometric tolerances of produced components. In response to this issue, laser polishing (LP) has emerged as a potential technique for improving the surface finish and producing parts with enhanced properties. Many studies have been conducted to investigate the effect of LP on parts produced using additive manufacturing. The results showed that applying such a unique treatment can significantly enhance the overall performance of the part. In LP processes, the surface of the part is re-melted by the laser, resulting in smaller peaks and shallower valleys, which enable the development of smoother surfaces with the help of gravity and surface tension. Precise selection of laser parameters is essential to achieve optimal enhancement in the surface finish, microstructure, and mechanical properties of the treated parts. This paper aims to compile state-of-the-art knowledge in LP of additively manufactured metals and presents the optimal process parameters experimentally and modeling using artificial machine learning. The effects of laser power, the number of laser re-melting passes, and scanning speed on the final surface roughness and mechanical properties are comprehensively discussed in this work. Full article

(This article belongs to the Special Issue Smart and Advanced Manufacturing)

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14 pages, 12913 KiB

Open AccessArticle

Effect of Infill Pattern on Impact Toughness, Microstructure, and Surface Roughness of Inconel 625 Built via Filament-Based Material Extrusion Additive Manufacturing

by Gandjar Kiswanto, Ahmad Kholil and Jos Istiyanto

J. Manuf. Mater. Process. 2023, 7(3), 114; https://doi.org/10.3390/jmmp7030114 - 11 Jun 2023

Cited by 3 | Viewed by 1750

Abstract

Filament-based material extrusion additive manufacturing (FMEAM) is an additive manufacturing technique that uses 3D printing. Additive manufacturing could build parts with infill variations. Solid or triangular infill pattern could be selected as needed. The solid pattern will have the maximum material volume, while [...] Read more.

Filament-based material extrusion additive manufacturing (FMEAM) is an additive manufacturing technique that uses 3D printing. Additive manufacturing could build parts with infill variations. Solid or triangular infill pattern could be selected as needed. The solid pattern will have the maximum material volume, while the triangular pattern will contain a triangular lattice structure that fills the voids in the volume so the material requirement is reduced. This is valuable in optimizing the requirements of metallic materials for mechanical properties without changing the surface shape. The alloy Inconel 625, which is very popular in the aerospace industry have been developed as a feed material of FMEAM. However, for developing rotating parts, such as turbine blades, impact toughness, surface roughness and microstructure need to be investigated. This research was conducted to determine the effect of the infill pattern on the impact toughness, morphology of surface fracture, microstructure of side surface and surface roughness with Inconel 625 material built using FMEAM. The Charpy impact test, s ASTM 23, with v-notch testing method and SEM with EDS were performed. The results showed that the impact toughness for solids was higher than the value for the triangular infill pattern. It was discovered that the cavities in the triangular lattice structure within the specimen reduced the impact toughness to 57.6%. Micropores and residual polymer trapped on the surface reduce impact toughness. However, the same surface shape on solid and triangular infill patterns with surface roughness of 2.44 and 10.03 µm is still feasible for manufacture. Full article

(This article belongs to the Topic Additive Manufacturing: Design, Opportunities, and Applications)

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14 pages, 4963 KiB

Open AccessArticle

Assessment of Plasma Deposition Parameters for DED Additive Manufacturing of AA2319

by Paula Rodríguez-González, Erich Neubauer, Enrique Ariza, Leandro Bolzoni, Elena Gordo and Elisa María Ruiz-Navas

J. Manuf. Mater. Process. 2023, 7(3), 113; https://doi.org/10.3390/jmmp7030113 - 08 Jun 2023

Viewed by 1391

Abstract

Arc-directed energy deposition using wire as feedstock is establishing itself as a 3D printing method capable of obtaining additively manufactured large structures. Contrasting results are reported in the literature about the effect of the deposition parameters on the quality of the deposited tracks, [...] Read more.

Arc-directed energy deposition using wire as feedstock is establishing itself as a 3D printing method capable of obtaining additively manufactured large structures. Contrasting results are reported in the literature about the effect of the deposition parameters on the quality of the deposited tracks, as it is highly dependent on the relationship and intercorrelations between the individual input parameters, which are generally deposition-technique-dependent. This study comprehensively analysed the effect of several deposition parameters and clarified their interactions in plasma metal deposition of Al alloys. It was found that, although no straightforward correlation between the individual input parameters investigated and the measured output deposition track’s quality aspects existed, the input current had the greatest effect, followed by the wire feed speed and its interaction with the input current. Moreover, the greatest effect of changing the shielding gas atmosphere, including the gas mixture, flow rate and plasma flow, was on the penetration depth, and fine-tuning the frequency/balance ratio and the preheating of the deposition substrates reduced the amount of porosity. This study demonstrates that well-deposited multi-layer walls made out of Al alloys can successfully be achieved via plasma metal deposition. Full article

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15 pages, 4029 KiB

Open AccessArticle

Cooling Rate Modeling and Evaluation during Centrifugal Atomization Process

by Sasha A. Cegarra, Jordi Pijuan and María D. Riera

J. Manuf. Mater. Process. 2023, 7(3), 112; https://doi.org/10.3390/jmmp7030112 - 07 Jun 2023

Cited by 1 | Viewed by 1810

Abstract

Centrifugal atomization is a rapid solidification technique involving fast cooling rates to produce high-quality powders. The final microstructure of the atomized particles is closely linked with the thermal history and cooling rates experienced during the atomization process. However, there is insufficient research on [...] Read more.

Centrifugal atomization is a rapid solidification technique involving fast cooling rates to produce high-quality powders. The final microstructure of the atomized particles is closely linked with the thermal history and cooling rates experienced during the atomization process. However, there is insufficient research on the temperature evolution of metal particles produced by this technique, and most works evaluate the thermal history of the droplet through semi-empirical correlations that lie outside the conditions where they were derived. In this work, the cooling rate of centrifugally atomized Al-4%Cu was studied via mathematical modelling and experimental validation. A heat transfer model was implemented, and the value of the convective heat transfer coefficient was obtained from the Whitaker semi-empirical correlation considering three cases of study for the thermophysical properties of the gas. The validity of the Whitaker correlation was experimentally evaluated by means of cooling rates based on the Secondary Dendrite Arm Spacing (SDAS) technique. The Whitaker correlation with the Reynolds and Prandtl numbers evaluated at the ambient temperature and the gas conductivity evaluated at the film temperature gave the best agreement with the experimental results, with cooling rates in the order of 10⁵ Ks⁻¹ for <32.5 µm powders atomized in He atmosphere. Full article

(This article belongs to the Topic Advanced Processes in Metallurgical Technologies)

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17 pages, 2787 KiB

Open AccessArticle

Multi-Response Optimization and Influence of Expanded Graphite on Performance of WEDM Process of Ti6Al4V

by Jay Vora, Yug Shah, Sakshum Khanna, Vivek K. Patel, Manoj Jagdale and Rakesh Chaudhari

J. Manuf. Mater. Process. 2023, 7(3), 111; https://doi.org/10.3390/jmmp7030111 - 07 Jun 2023

Cited by 3 | Viewed by 1252

Abstract

Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (T_off), and pulse-on-duration (T_off) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate [...] Read more.

Wire electrical discharge machining (WEDM) is widely preferred for machining difficult-to-cut materials like Ti6Al4V. In the present study, current, pulse-off-duration (T_off), and pulse-on-duration (T_off) were identified as vital input factors for the WEDM process of Ti6Al4V. Material removal rate (MRR) and surface roughness (SR) were selected as output measures for the study. The experiments were carried out by employing Taguchi’s L9 design at three levels. Empirical models were generated, which give the relationship between the input and output factors of the process. To check the acceptability of the model terms, analysis of variance (ANOVA) was used. The regression mode was observed to be significant for the output measures. For MRR, Toff was recorded as the highly significant factor affecting the response values with 74.95% impact, followed by Ton with 16.39%, and current with 6.56%. In the case of SR, Ton was found to be a highly significant factor with a 50.24% impact, followed by current with 43.99%, and Toff with 1.47%. Further, multi-objective optimization by using the HTS technique was performed. The effect of expanded graphite (EG) nano-powder has been studied on the output factors of MRR and SR. The use of EG nano-powder was found to improve WEDM operations as MRR was increased by 45.35%, and simultaneously, SR was reduced by 36.16%. Lastly, the surface morphology of the machined surface was investigated by employing SEM to understand the effect of EG nano-powder. The results have shown a reduction in surface defects by using EG nano-powder compared to the conventional WEDM process. Full article

(This article belongs to the Special Issue Electrical Discharge Machining (EDM) and EDM-Based Hybrid Machining)

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21 pages, 18729 KiB

Open AccessEditor’s ChoiceArticle

Influence of the Chemical Composition on the Solidification Path, Strengthening Mechanisms and Hardness of Ni-Cr-Si-Fe-B Self-Fluxing Alloys Obtained by Laser-Directed Energy Deposition

by Juan Carlos Pereira, Mari Carmen Taboada, Andrea Niklas, Emilio Rayón and Jerome Rocchi

J. Manuf. Mater. Process. 2023, 7(3), 110; https://doi.org/10.3390/jmmp7030110 - 05 Jun 2023

Cited by 3 | Viewed by 1642

Abstract

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) and gas-atomized powders as a material feedstock is presented as [...] Read more.

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) and gas-atomized powders as a material feedstock is presented as a potential manufacturing route for the complex processing of these alloys. This research deals with the advanced material characterization of these alloys obtained by LMD and the study and understanding of their solidification paths and strengthening mechanisms. The as-built microstructure, the Vickers hardness at room temperature and at high temperatures, the nanoindentation hardness and elastic modulus of the main phases and precipitates, and the strengthening mechanisms were studied in bulk cylinders manufactured under different chemical composition grades and DED-LB/p process parameter sets (slow, normal, and fast deposition speeds), with the aim of determining the influence of the chemical composition in commercial Ni-Cr-Si-Fe-B alloys. The hardening of Ni-Cr-Si-Fe-B alloys obtained by LMD is a combination of the solid solution hardening of gamma nickel dendrites and eutectics and the contribution of the precipitation hardening of small chromium-rich carbides and hard borides evenly distributed in the as-built microstructure. Full article

(This article belongs to the Special Issue Advances in Metal Additive Manufacturing/3D Printing)

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Graphical abstract

15 pages, 4263 KiB

Open AccessArticle

Metrology of Sheet Metal Distortion and Effects of Spot-Welding Sequences on Sheet Metal Distortion

by Enkhsaikhan Boldsaikhan, Michael Milhon, Shintaro Fukada, Mitsuo Fujimoto and Kenichi Kamimuki

J. Manuf. Mater. Process. 2023, 7(3), 109; https://doi.org/10.3390/jmmp7030109 - 04 Jun 2023

Viewed by 1709

Abstract

Refill friction stir spot welding (RFSSW) is an emerging solid-state welding technology that demonstrates an outstanding ability to join aerospace aluminum alloys. The thermomechanical processing of RFSSW may cause variations in the workpiece in the form of distortion. This study aims to establish [...] Read more.

Refill friction stir spot welding (RFSSW) is an emerging solid-state welding technology that demonstrates an outstanding ability to join aerospace aluminum alloys. The thermomechanical processing of RFSSW may cause variations in the workpiece in the form of distortion. This study aims to establish a metrology method for sheet metal distortion with the intent to investigate the effects of RFSSW sequences on sheet metal distortion. The approach employs a robotic metrology system and the least squares method to measure and estimate the flatness of sheet metal before RFSSW and after RFSSW. The RFSSW experimentation produces five 10-spot-weld panels with five different RFSSW sequences, whereas the RFSSW sequences are based on the common practice of making sheet metal assemblies. A panel consists of two lap-welded sheets where the top sheet, a 6013-T6 aluminum alloy, is refill friction stir spot welded onto the bottom sheet, a 2029-T8 aluminum alloy. The results suggest that RFSSW sequences do have effects on sheet metal distortion. The panel with the worst distortion has a root-mean-square error of 0.8 mm as an average deviation from the ideal flatness. Full article

(This article belongs to the Special Issue Frontiers in Friction Stir Welding and Processing)

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14 pages, 6187 KiB

Open AccessConcept Paper

Communication of Design Data in Manufacturing Democratization

by Bhairavsingh Ghorpade and Shivakumar Raman

J. Manuf. Mater. Process. 2023, 7(3), 108; https://doi.org/10.3390/jmmp7030108 - 01 Jun 2023

Viewed by 1200

Abstract

Part design is the principal source of communicating design intent to manufacturing and inspection. Design data are often communicated through computer-aided design (CAD) systems. Modern analytics tools and artificial intelligence integration into manufacturing have significantly advanced machine recognition of design specification and manufacturing [...] Read more.

Part design is the principal source of communicating design intent to manufacturing and inspection. Design data are often communicated through computer-aided design (CAD) systems. Modern analytics tools and artificial intelligence integration into manufacturing have significantly advanced machine recognition of design specification and manufacturing constraints. These algorithms require data to be uniformly structured and easily consumable; however, the design data are represented in a graphical structure and contain a nonuniform structure, which limits the use of machine learning algorithms for a variety of tasks. This paper proposes an algorithm for extracting dimensional data from three-dimensional (3D) part designs in a structured manner. The algorithm extracts face dimensions and their relationships with other faces, enabling the recognition of underlying patterns and expanding the applicability of machine learning for various tasks. The extracted part dimensions can be stored in a dimension-based numeric extensible markup language (XML) file, allowing for easy storage and use in machine-readable formats. The resulting XML file provides a dimensional representation of the part data based on their features. The proposed algorithm reads and extracts dimensions with respect to each face of the part design, preserving the dimensional and face relevance. The uniform structure of the design data facilitates the processing of data by machine learning algorithms, enabling the detection of hidden patterns and the development of pattern-based predictive algorithms. Full article

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17 pages, 10348 KiB

Open AccessEditor’s ChoiceArticle

Characterization of the Fracture Forming Limits by Radial Extrusion

by Rui F. V. Sampaio, João P. M. Pragana, Ivo M. F. Bragança, Carlos M. A. Silva, Chris V. Nielsen and Paulo A. F. Martins

J. Manuf. Mater. Process. 2023, 7(3), 107; https://doi.org/10.3390/jmmp7030107 - 01 Jun 2023

Cited by 2 | Viewed by 1497

Abstract

This paper introduces a new formability test based on double-action radial extrusion to characterize material formability in the three-dimensional to plane-stress material flow transitions that are found in bulk metal-formed parts. The presentation draws from a multidirectional tool, which was designed to convert [...] Read more.

This paper introduces a new formability test based on double-action radial extrusion to characterize material formability in the three-dimensional to plane-stress material flow transitions that are found in bulk metal-formed parts. The presentation draws from a multidirectional tool, which was designed to convert the vertical press stroke into horizontal movement of the compression punches towards each other, aspects of experimental strain determination, fractography, and finite element analysis. Results show that three-dimensional to plane-stress material flow transitions at the radially extruded flanges lead to different modes of fracture (by tension and by shear) that may or may not be preceded by necking, such as in sheet metal forming. The new formability test also reveals adequate characteristics to characterize the failure limits of very ductile wrought and additively manufactured metallic materials, which cannot be easily determined by conventional upset compression tests, and to facilitate the identification of the instant of cracking and of the corresponding fracture strains by combination of the force vs. time evolutions with the in-plane strains obtained from digital image correlation. Full article

(This article belongs to the Special Issue Selected Papers from the 20th International Conference on Sheet Metal (SHEMET 2023))

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13 pages, 8453 KiB

Open AccessArticle

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

by Arménio N. Correia, Paulo A. M. Santos, Daniel F. O. Braga, Ricardo Baptista and Virgínia Infante

J. Manuf. Mater. Process. 2023, 7(3), 106; https://doi.org/10.3390/jmmp7030106 - 01 Jun 2023

Cited by 2 | Viewed by 1552

Abstract

An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control [...] Read more.

An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control on the joints’ mechanical performance. To this end, a series of welds with a fixed 3° tilt angle, a travel speed of 120 mm/min, and 600 RPM of rotational speed was carried out. The analysis encompassed the mechanical strength of the fabricated joints and the mechanical energy input throughout the joining processes, the resulting cross-sectional interfaces, both on macro and micro scales, and the observed defects. The quasi-static shear tensile tests resulted in average tensile strengths varying between 5.5 and 26.1 MPa, representing joint efficiencies ranging from 10.1% to 47.4%, respectively. The joints that exhibited the lowest mechanical performance were fabricated with the highest level of tool penetration (higher pin length) with the process being position-controlled, while the best performance was recorded in joints welded with the lowest tool penetration and a force-controlled process. Nonetheless, the joint welded with a 2 mm long pin and position-controlled process exhibited a mechanical strength comparable with the highest one with a significantly lower standard deviation, a promising attribute for technological industrialization. In this way, it was found that the tool penetration, controlled by adjusting the pin length, played a significant role in the development of the joints’ morphology and, consequently, mechanical performance, whereas the process control exhibited a minor influence on the mechanical performance of the joints, but a considerable effect on process repeatability. Full article

(This article belongs to the Special Issue Frontiers in Friction Stir Welding and Processing)

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16 pages, 11481 KiB

Open AccessArticle

Investigation of Effect of Processing Parameters for Direct Energy Deposition Additive Manufacturing Technologies

by Kyu Taek Cho, Luis Nunez, John Shelton and Federico Sciammarella

J. Manuf. Mater. Process. 2023, 7(3), 105; https://doi.org/10.3390/jmmp7030105 - 24 May 2023

Cited by 3 | Viewed by 3131

Abstract

In order to capitalize on the cost-effectiveness of additive manufacturing (AM), it is critical to understand how to build components with consistency and high quality. Directed energy deposition (DED) is an AM method for creating parts layer by layer through the use of [...] Read more.

In order to capitalize on the cost-effectiveness of additive manufacturing (AM), it is critical to understand how to build components with consistency and high quality. Directed energy deposition (DED) is an AM method for creating parts layer by layer through the use of a moving heat source and powder material inserted into the melt pool generated on the substrate. DED, like most AM processes, is highly complex due to the rapid thermal gradients experienced during processing. These thermal gradients are determined by a variety of processing parameters, which include laser power, powder feed rate, travel speed, layer height hatch spacing, etc. A lot of effort has been carried out in the additive manufacturing community to understand what these critical parameters are and how they influence the thermal gradients. Despite all these efforts, AM industries rely on a trial-and-error-based approach to find the right set of parameters to produce a quality part. This is time-consuming and not a cost-effective use of AM technology. The aim of our research is to reduce the amount of experimental data in combination with numerical analysis to optimize this relationship. Physics-based two-dimensional melt-pool modeling and experimental results from an OPTOMEC 850M LENS will be utilized to investigate the effects of processing parameters on melt-pool geometry, and the results from this study will provide key processing guidelines to achieve desirable clad geometry and powder efficiency for the DED method. Full article

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18 pages, 6801 KiB

Open AccessArticle

Theoretical Analysis of Rolling Force during Cold Rolling with Roll Crossing and Shifting System

by Abdulrahman Aljabri, Hasan Tibar, Essam R. I. Mahmoud, Hamad Almohamadi, Feijun Qu and Zhengyi Jiang

J. Manuf. Mater. Process. 2023, 7(3), 104; https://doi.org/10.3390/jmmp7030104 - 24 May 2023

Cited by 4 | Viewed by 2775

Abstract

A precise prediction of the rolling force is critical to ensure the quality of the final product, especially in the cold rolling of thin strips. Based on this, a new mathematical model is developed to work out the rolling force when considering the [...] Read more.

A precise prediction of the rolling force is critical to ensure the quality of the final product, especially in the cold rolling of thin strips. Based on this, a new mathematical model is developed to work out the rolling force when considering the roll crossing angle and work roll shifting values at speed ratios of 1.1, 1.2 and 1.3. An iterative method was used to indicate the contact area shape, from which the rolling force was automatically calculated using the Matlab™ code for the cases of work roll cross angles of 0.5° and 1°. Experimental measurements and analysis were carried out to validate the theoretical calculations. The result shows that the theoretical analysis and experimental results are in good agreement, which indicates that the developed theoretical model can predict the rolling force well with a consideration of roll crossing during the cold rolling process. Full article

(This article belongs to the Special Issue Advances in Material Forming)

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8 pages, 2632 KiB

Open AccessCommunication

Investigation of the Shape and Detectability of Pores with X-ray Computed Tomography

by Benjamin Baumgärtner, Juan Hussein and Tino Hausotte

J. Manuf. Mater. Process. 2023, 7(3), 103; https://doi.org/10.3390/jmmp7030103 - 23 May 2023

Cited by 1 | Viewed by 1699

Abstract

Component porosity is a quality attribute in additive manufacturing (AM). One possibility for the non-destructive three-dimensional determination of porosity or pore shape is X-ray computed tomography (CT), which enables an investigation of the influence of AM process parameters on the appearance and characteristics [...] Read more.

Component porosity is a quality attribute in additive manufacturing (AM). One possibility for the non-destructive three-dimensional determination of porosity or pore shape is X-ray computed tomography (CT), which enables an investigation of the influence of AM process parameters on the appearance and characteristics of the pores. Since there is no porosity standard for CT, a traceable determination of the measurement uncertainty is not possible. Using a digital twin of the CT system, an estimation of the CT measurement uncertainty is in principle possible. In this contribution, experimental CT analyses of powder bed fusion samples made of Ti64 and PA12 are compared with CT simulations. The results show a size-dependent influence on the shape and detectability of the pores. Using the CT model, a simulated shape- and material-dependent probability of detection (POD) is calculated. Full article

(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)

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18 pages, 6628 KiB

Open AccessArticle

Possibilities of Artificial Intelligence-Enabled Feedback Control System in Robotized Gas Metal Arc Welding

by Sakari Penttilä, Hannu Lund and Tuomas Skriko

J. Manuf. Mater. Process. 2023, 7(3), 102; https://doi.org/10.3390/jmmp7030102 - 23 May 2023

Cited by 2 | Viewed by 1598

Abstract

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization of an intelligent welding system (IWS) for feedback [...] Read more.

In recent years, welding feedback control systems and weld quality estimation systems have been developed with the use of artificial intelligence to increase the quality consistency of robotic welding solutions. This paper introduces the utilization of an intelligent welding system (IWS) for feedback controlling the welding process. In this study, the GMAW process is controlled by a backpropagation neural network (NN). The feedback control of the welding process is controlled by the input parameters; root face and root gap, measured by a laser triangulation sensor. The NN is trained to adapt NN output parameters; wire feed and arc voltage override of the weld power source, in order to achieve consistent weld quality. The NN is trained offline with the specific parameter window in varying weld conditions, and the testing of the system is performed on separate specimens to evaluate the performance of the system. The butt-weld case is explained starting from the experimental setup to the training process of the IWS, optimization and operating principle. Furthermore, the method to create IWS for the welding process is explained. The results show that the developed IWS can adapt to the welding conditions of the seam and feedback control the welding process to achieve consistent weld quality outcomes. The method of using NN as a welding process parameter optimization tool was successful. The results of this paper indicate that an increased number of sensors could be applied to measure and control the welding process with the developed IWS. Full article

(This article belongs to the Special Issue Advances in Welding Technology)

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18 pages, 11701 KiB

Open AccessArticle

Dynamic Analysis of the Thermo-Deformation Treatment Process of Flat Surfaces of Machine Parts

by Volodymyr Gurey, Pavlo Maruschak, Ihor Hurey, Volodymyr Dzyura, Tetyana Hurey and Weronika Wojtowicz

J. Manuf. Mater. Process. 2023, 7(3), 101; https://doi.org/10.3390/jmmp7030101 - 20 May 2023

Cited by 1 | Viewed by 1181

Abstract

Thermo-deformation treatment refers to methods of strengthening during which strengthened layers with a nanocrystalline structure are formed in the surface layers by modifying the metal surface layer, which changes its phase and structural and chemical compositions, reduces grain size, and improves performance. Grinding [...] Read more.

Thermo-deformation treatment refers to methods of strengthening during which strengthened layers with a nanocrystalline structure are formed in the surface layers by modifying the metal surface layer, which changes its phase and structural and chemical compositions, reduces grain size, and improves performance. Grinding of the metal structure was achieved by combining two methods simultaneously during this treatment: the action of a highly concentrated energy source on the surface layer and intense plastic deformation. The source of highly concentrated energy was generated in the contact zone of the tool-disc, which rotates at high speed during friction on the treated surface. Intense deformation was achieved due to the grooves on the tool’s working surface. Dynamic analysis of the thermo-deformation treatment process of flat surfaces of machine parts and a calculation scheme of the surface grinder machine’s elastic system, which is the three-mass model, were developed. When the groove width increased from 4 mm to 8 mm, the force amplitude in the contact zone increased from 10 N to 75 N. Accordingly, the thickness of the nanocrystalline layer increased from 190–220 μm to 250–260 μm, and its hardness increased from 9.3 GPa to 11.1 GPa. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology)

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15 pages, 3142 KiB

Open AccessEditor’s ChoiceArticle

Determination of the Cutting-Edge Microgeometry Based on Process Forces during Peripheral Milling of Ti-6Al-4V Using Machine Learning

by Matthias Wimmer, Roman Hartl and Michael F. Zaeh

J. Manuf. Mater. Process. 2023, 7(3), 100; https://doi.org/10.3390/jmmp7030100 - 19 May 2023

Cited by 2 | Viewed by 1563

Abstract

The residual stress state of the machined sub-surface influences the service quality indicators of a component, such as fatigue life, tribological properties, and distortion. During machining, the radius of the cutting edge changes due to tool wear. The cutting-edge rounding significantly affects the [...] Read more.

The residual stress state of the machined sub-surface influences the service quality indicators of a component, such as fatigue life, tribological properties, and distortion. During machining, the radius of the cutting edge changes due to tool wear. The cutting-edge rounding significantly affects the residual stress state in the part and the occurring process forces. This paper presents a tool wear prediction model based on in-process measured cutting forces. The effects of the cutting-edge geometry on the force behavior and the machining-induced residual stresses were examined experimentally. The resulting database was used to realize a Machine Learning algorithm to calculate the hidden value of tool wear. The predictions were validated by milling experiments using rounded cutting edges for different process parameters. The microgeometry of the cutting edge could be determined with a Root Mean Square Error of 8.94 μm. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology)

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11 pages, 2775 KiB

Open AccessArticle

Reduction in Total Production Cycle Time by the Tool Holder for the Automated Cutting Insert Quick Exchange and by the Double Cutting Tool Holder

by Karol Vasilko and Zuzana Murčinková

J. Manuf. Mater. Process. 2023, 7(3), 99; https://doi.org/10.3390/jmmp7030099 - 16 May 2023

Viewed by 1311

Abstract

The time taken to exchange a cutting tool and the actual machining time are the components in a total production cycle time for a part, that affects productivity. Automated plate exchange systems strive for the simplest possible principles to achieve the shortest possible [...] Read more.

The time taken to exchange a cutting tool and the actual machining time are the components in a total production cycle time for a part, that affects productivity. Automated plate exchange systems strive for the simplest possible principles to achieve the shortest possible tool exchange time with sufficient accuracy. The tool holder in the presented article is based on the principle of a combination of translational, rotational movement, and stop surfaces by using a single pull–push rod for simple control. The article provides alternative tool holder designs and turning results of such holders using Rz-f dependence. The results of the time reduction are satisfactory and give a prerequisite for using a tool holder for the automated exchange of triangular cutting inserts. Moreover, the article provides the approach to reduce the mentioned total production cycle time by a reduction in the actual machining time for a part by use of tooltip radii, not by increasing the cutting speed. The triangular cutting insert can have three tooltips of three different tooltip radii for roughing and finishing. In addition, for reduction of the actual machining time, the double cutting tool with both the small tooltip radius for rouging and the large tooltip radius for finishing is presented. The double tool holders showed a 2.4-times reduction in the actual machining time for a part with Rz = 20 µm. Full article

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13 pages, 5941 KiB

Open AccessArticle

Process Window and Repeatability of Thermomechanical Tangential Ring Rolling

by Rémi Lafarge, Sebastian Hütter, Thorsten Halle and Alexander Brosius

J. Manuf. Mater. Process. 2023, 7(3), 98; https://doi.org/10.3390/jmmp7030098 - 15 May 2023

Cited by 3 | Viewed by 1254

Abstract

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a final calibration step via cold forming are combined into one single step. The [...] Read more.

International objectives towards improved resource and energy efficiency require new manufacturing processes, such as the proposed thermomechanical tangential profiled ring rolling process. A rapid cooling-down for microstructural adjustment and a final calibration step via cold forming are combined into one single step. The reduction of process steps and the reduced number of heating cycles present opportunities for improved energy efficiency compared to traditional processes. Based on a series of experiments, this paper aims at showing the potential of this new process in terms of obtainable hardness and microstructure. The influence of the active cooling system and the rolling feed is demonstrated. They are identified as essential with regard to both the geometry and the microstructural properties of the produced part. Finally, the repeatability of the process is analyzed, and potential disturbances are identified and ranked. Full article

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30 pages, 6138 KiB

Open AccessEditor’s ChoiceReview

A Review of the Recent Developments and Challenges in Wire Arc Additive Manufacturing (WAAM) Process

by Abid Shah, Rezo Aliyev, Henning Zeidler and Stefan Krinke

J. Manuf. Mater. Process. 2023, 7(3), 97; https://doi.org/10.3390/jmmp7030097 - 14 May 2023

Cited by 8 | Viewed by 5984

Abstract

Wire arc additive manufacturing (WAAM) is an emerging and promising technology for producing medium-to-large-scale metallic components/structures for different industries, i.e., aerospace, automotive, shipbuilding, etc. It is now a feasible alternative to traditional manufacturing processes due to its shorter lead time, low material waste, [...] Read more.

Wire arc additive manufacturing (WAAM) is an emerging and promising technology for producing medium-to-large-scale metallic components/structures for different industries, i.e., aerospace, automotive, shipbuilding, etc. It is now a feasible alternative to traditional manufacturing processes due to its shorter lead time, low material waste, and cost-effectiveness. WAAM has been widely used to produce components using different materials, including copper-based alloy wires, in the past decades. This review paper highlights the critical aspects of WAAM process in terms of technology, various challenges faced during WAAM process, different in-process and post-process operations, process monitoring methods, various gases, and different types of materials used in WAAM process. Furthermore, it briefly overviews recent developments in depositing different copper-based alloys via WAAM process. Full article

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16 pages, 5737 KiB

Open AccessArticle

Thin-Walled Part Properties in Powder Bed Fusion of Polymers—A Comparative Study on Temperature Development and Part Performance Depending on Part Thickness and Orientation

by Andreas Jaksch, Simon Cholewa and Dietmar Drummer

J. Manuf. Mater. Process. 2023, 7(3), 96; https://doi.org/10.3390/jmmp7030096 - 11 May 2023

Viewed by 1783

Abstract

To develop new areas of application for laser-based powder bed fusion of polymers (PBF-LB/P), a deeper process understanding of the resulting mechanical properties, particularly for thin-walled and complex structures, is needed. This work addresses the influence of part thickness and orientation in detail. [...] Read more.

To develop new areas of application for laser-based powder bed fusion of polymers (PBF-LB/P), a deeper process understanding of the resulting mechanical properties, particularly for thin-walled and complex structures, is needed. This work addresses the influence of part thickness and orientation in detail. For a general understanding, two PBF systems were used. For comparison, the normalized energy density was determined for specimens of various thicknesses and orientations. It could be seen that the normalized energy density exhibited opposing trends for the two systems for progressively thinner samples. During the process, the exposure temperature development was observed using an infrared camera for a greater understanding of the developing part properties. To further investigate the fracture behavior, an infrared camera was used during tensile testing, which revealed various patterns depending on the PBF-System used. The results showed a machine-dependent difference in the exposure temperatures and elongation at break for z-oriented parts. While the surface roughness was independent of the thickness, the density, porosity, and the mechanical properties were affected significantly by the part thickness. The parts showed a brittle breaking behavior with a crack initiation from the short side of the tensile bar. These results improved process expertise, and in particular the mechanical performance of thin-walled structures caused by temperature variations in PBF-LB/P. Full article

(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)

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17 pages, 7196 KiB

Open AccessEditor’s ChoiceArticle

Evaluation of Additively-Manufactured Internal Geometrical Features Using X-ray-Computed Tomography

by Benjamin Baumgärtner, Richard Rothfelder, Sandra Greiner, Christoph Breuning, Jakob Renner, Michael Schmidt, Dietmar Drummer, Carolin Körner, Matthias Markl and Tino Hausotte

J. Manuf. Mater. Process. 2023, 7(3), 95; https://doi.org/10.3390/jmmp7030095 - 10 May 2023

Viewed by 1777

Abstract

X-ray-computed tomography (CT) is today’s gold standard for the non-destructive evaluation of internal component defects such as cracks and porosity. Using automated standardized evaluation algorithms, an analysis can be performed without knowledge of the shape, location, or size of the defects. Both the [...] Read more.

X-ray-computed tomography (CT) is today’s gold standard for the non-destructive evaluation of internal component defects such as cracks and porosity. Using automated standardized evaluation algorithms, an analysis can be performed without knowledge of the shape, location, or size of the defects. Both the measurement and the evaluation are based on the fact that the component has no internal structures or cavities. However, additive manufacturing (AM) and hybrid subtractive procedures offer the possibility of integrating internal structures directly during the building process. The examination of powder bed fusion (PBF) samples made of Ti64 and PA12 showed that the standardized evaluation methods were not able to identify internal structures correctly. Different evaluation methods for the CT-measured values were analyzed and recommendations on a procedure for measuring internal structures are given. Full article

(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)

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26 pages, 4456 KiB

Open AccessReview

Laser Scribing of Photovoltaic Solar Thin Films: A Review

by Farzad Jamaatisomarin, Ruqi Chen, Sajed Hosseini-Zavareh and Shuting Lei

J. Manuf. Mater. Process. 2023, 7(3), 94; https://doi.org/10.3390/jmmp7030094 - 10 May 2023

Cited by 5 | Viewed by 4950

Abstract

The development of thin-film photovoltaics has emerged as a promising solution to the global energy crisis within the field of solar cell technology. However, transitioning from laboratory scale to large-area solar cells requires precise and high-quality scribes to achieve the required voltage and [...] Read more.

The development of thin-film photovoltaics has emerged as a promising solution to the global energy crisis within the field of solar cell technology. However, transitioning from laboratory scale to large-area solar cells requires precise and high-quality scribes to achieve the required voltage and reduce ohmic losses. Laser scribing has shown great potential in preserving efficiency by minimizing the drop in geometrical fill factor, resistive losses, and shunt formation. However, due to the laser induced photothermal effects, various defects can initiate and impact the quality of scribed grooves and weaken the module’s efficiency. In this regard, much research has been conducted to analyze the geometrical fill factor, surface integrity, and electrical performance of the laser scribes to reach higher power conversion efficiencies. This comprehensive review of laser scribing of photovoltaic solar thin films pivots on scribe quality and analyzes the critical factors and challenges affecting the efficiency and reliability of the scribing process. This review also covers the latest developments in using laser systems, parameters, and techniques for patterning various types of solar thin films to identify the optimized laser ablation condition. Furthermore, potential research directions for future investigations at improving the quality and performance of thin film laser scribing are suggested. Full article

(This article belongs to the Special Issue Laser-Based Manufacturing II)

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16 pages, 3605 KiB

Open AccessArticle

Influence of Novel Beam Shapes on Laser-Based Processing of High-Strength Aluminium Alloys on the Basis of EN AW-5083 Single Weld Tracks

by Florian Nahr, Dominic Bartels, Richard Rothfelder and Michael Schmidt

J. Manuf. Mater. Process. 2023, 7(3), 93; https://doi.org/10.3390/jmmp7030093 - 09 May 2023

Cited by 4 | Viewed by 2041

Abstract

The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major factor in limiting production rates of [...] Read more.

The commonly used Gaussian intensity distribution during the laser-based processing of metals can negatively affect melt pool stability, which might lead to defects such as porosity, hot cracking, or poor surface quality. Hot cracking is a major factor in limiting production rates of high-strength aluminium alloys in laser-based processes such as welding or the powder bed fusion of metals (PBF-LB/M). Going away from a Gaussian intensity distribution to ring-shaped profiles allows for a more even heat distribution during processing, resulting in more stable melt pools and reduced defect formations. Therefore, the aim of this study is to investigate the influence of different laser beam profiles on the processing of high-strength aluminium alloys by using a multicore fiber laser, allowing for in-house beam shaping. Single weld tracks on the aluminium alloy EN AW-5083 are produced with varying laser powers and weld speeds, as well as different beam profiles, ranging from Gaussian intensity distribution to point/ring profiles. The molten cross sections are analyzed regarding their geometry and defects, and the surface roughness of the weld tracks is measured. By using point/ring beam profiles, the processing window can be significantly increased. Hot cracking is considerably reduced for weld speeds of up to 1000 mm/s compared to the Gaussian beam profile. Furthermore, the melt pool width and depth are more stable, with varying parameters for the point/ring profiles, while the Gaussian beam tends to keyhole formation at higher beam powers. Finally, a strong decrease in surface roughness for the point/ring profiles, accompanied by a significantly reduced humping effect, starting even at lower beam powers of 200 W, can be observed. Therefore, these results show the potential of beam shaping for further applications in laser-based processing of high-strength aluminium alloys. Full article

(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)

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20 pages, 7381 KiB

Open AccessArticle

A Data-Based Tool Failure Prevention Approach in Progressive Die Stamping

by Daniele Farioli, Ertuğrul Kaya, Andrea Fumagalli, Paolo Cattaneo and Matteo Strano

J. Manuf. Mater. Process. 2023, 7(3), 92; https://doi.org/10.3390/jmmp7030092 - 08 May 2023

Cited by 2 | Viewed by 2385

Abstract

The research on methods for monitoring sheet metal stamping is benefiting from the increased availability of enabling technologies such as sensors, data mining software, cloud computing, and artificial intelligence. The predictive maintenance policies of tools (punches and dies) can be targeted at monitoring [...] Read more.

The research on methods for monitoring sheet metal stamping is benefiting from the increased availability of enabling technologies such as sensors, data mining software, cloud computing, and artificial intelligence. The predictive maintenance policies of tools (punches and dies) can be targeted at monitoring progressive wear or at the detection of sudden failures or anomalies. Early detection of tool failure is the method preferred by the recent literature on data management in sheet metal stamping. However, the stamping of small parts poses challenges due to multiple tools and signals and limited visibility of die wear, requiring management of multiple sensors and data sources. This paper proposes a failure prevention approach for progressive die stamping using global and local force sensors with upper bounds for maximum values to indicate unhealthy conditions. The methodology was tested on millions of small washers made of carbon steel. The stamping process was implemented using a servo-press with a high rate. The press was equipped with eight in-process sensors, including strain gauges, thin foil force sensors, and acoustic sensors. The data of material properties, maintenance reports, statistical process control data, and in-process sensors were collected and stored in a data lake. By combining the in-process sensor acquisition with the corresponding log events and maintenance data in the same time span, it is possible to look for correlations among the variables and build an effective tool health prevention policy. Full article

(This article belongs to the Special Issue Industry 4.0: Manufacturing and Materials Processing)

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15 pages, 6656 KiB

Open AccessArticle

Numerical and Experimental Investigations on Tube Section Flattening for Parameter Identification and Advanced Material Modeling of Tubes

by Franz Reuther, Sven Winter, Sebastian Fritsch, Verena Kräusel, Martin F.-X. Wagner and Verena Psyk

J. Manuf. Mater. Process. 2023, 7(3), 91; https://doi.org/10.3390/jmmp7030091 - 08 May 2023

Viewed by 1671

Abstract

At present, there are no experimental methods that allow for the complete direction-dependent mechanical characterization of tubes. This considerably limits the parameterization of complex, anisotropic material models. The present study introduces a new approach to overcome these limitations: tube sections are first flattened [...] Read more.

At present, there are no experimental methods that allow for the complete direction-dependent mechanical characterization of tubes. This considerably limits the parameterization of complex, anisotropic material models. The present study introduces a new approach to overcome these limitations: tube sections are first flattened into a planar geometry; then, samples for uniaxial testing are taken out of the flattened tube section and used for parameter identification. In this paper, special emphasis is placed on the intermediate step of flattening, which is investigated in detail both numerically and experimentally. Flattening by pressing is identified as the most advantageous of several options, and the procedure is optimized by numerical simulations that address springback compensation. Experimental validation is performed on tubes (steel E235) with a diameter of 60 mm and an average wall thickness of 1.524 mm. Tube sections are successfully flattened in a custom-built tool with only small remaining out-of-plane displacements after flattening. The numerically predicted pressing force curves agree very well with the experimental data. Full article

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21 pages, 10759 KiB

Open AccessEditor’s ChoiceArticle

Alternating Additive Manufacturing and Forming—An Innovative Manufacturing Approach

by Thomas Papke, Jan Hafenecker, David Römisch, Raphaela März, Oliver Hentschel, Dominic Bartels, Michael Schmidt and Marion Merklein

J. Manuf. Mater. Process. 2023, 7(3), 90; https://doi.org/10.3390/jmmp7030090 - 06 May 2023

Viewed by 2300

Abstract

In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of [...] Read more.

In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of a DED-LB/M process using a laser power of 600 W and a feed rate of 400 mm/min and a subsequent forming process, in which the structure is upset with a hydraulic press using a constant forming force of 500 kN in order to smooth the surface and influence the accuracy of the components. For the generation of a fundamental process understanding, a cuboid, basic shape was chosen as geometry for the investigations. The aim is to improve part properties by applying the process steps to generate part properties, which are superior to solely additive manufactured material. It is shown that the geometry of additive manufactured structures can be adapted, and the top surface can be smoothed due to the forming operation. The mean roughness value Rz decreases up to 50% after the forming operation. The hardness can be increased by work hardening. Of special interest is that the higher hardness can be kept up even though a further DED-LB/M process step and forming operation are applied to the additively manufactured and formed structure again. Finally, an analysis of the new manufacturing approach regarding its potential is given. Full article

(This article belongs to the Special Issue Progress in Powder-Based Additive Manufacturing)

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43 pages, 29178 KiB

Open AccessEditor’s ChoiceReview

Ultrafast Laser Additive Manufacturing: A Review

by Jacob Saunders, Mohammad Elbestawi and Qiyin Fang

J. Manuf. Mater. Process. 2023, 7(3), 89; https://doi.org/10.3390/jmmp7030089 - 05 May 2023

Cited by 5 | Viewed by 4062

Abstract

Ultrafast lasers are proven and continually evolving manufacturing tools. Concurrently, additive manufacturing (AM) has emerged as a key area of interest for 3D fabrication of objects with arbitrary geometries. Use of ultrafast lasers for AM presents possibilities for next generation manufacturing techniques for [...] Read more.

Ultrafast lasers are proven and continually evolving manufacturing tools. Concurrently, additive manufacturing (AM) has emerged as a key area of interest for 3D fabrication of objects with arbitrary geometries. Use of ultrafast lasers for AM presents possibilities for next generation manufacturing techniques for hard-to-process materials, transparent materials, and micro- and nano-manufacturing. Of particular interest are selective laser melting/sintering (SLM/SLS), multiphoton lithography (MPL), laser-induced forward transfer (LIFT), pulsed laser deposition (PLD), and welding. The development, applications, and recent advancements of these technologies are described in this review as an overview and delineation of the burgeoning ultrafast laser AM field. As they mature, their adoption by industry and incorporation into commercial systems will be facilitated by process advancements such as: process monitoring and control, increased throughput, and their integration into hybrid manufacturing systems. Recent progress regarding these aspects is also reviewed. Full article

(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing)

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J. Manuf. Mater. Process., Volume 7, Issue 3 (June 2023) – 39 articles

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