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Advances in Metal Cutting, Casting, Forming and Heat Treatment

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

Deadline for manuscript submissions: 20 June 2024 | Viewed by 13072

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Dr. Rendi Kurniawan

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Guest Editor

Department of Mechanical Engineering, Yeungnam University, Gyeongsan 38541, Gyeongbuk, Korea
Interests: manufacturing; metal-cutting; surface-texturing; vibration-assisted cutting; machine-tools; ultrasonic-transducer; optimization; tribology

Dr. Hongchao Ji

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Guest Editor

College of Mechanical Engineering, North China University of Science and Technology, Tangshan 063210, China
Interests: metal plastic processing theory; technology and equipment; modeling and simulation of the whole process of plastic forming multi-field coupling; lightweight forming manufacturing technology of auto parts; carbon fiber material forming process and equipment

Dr. Ireneusz Szachogluchowicz

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Department of Machine Design, Military University of Technology, en. Sylwestra Kaliskiego 2, 00-908 Warsaw, Poland
Interests: multilayer materials; mechanical properties; strength of materials welded connections; additive manufacturing; digital image correlation; ballistic resistance; innovative joining
Special Issues, Collections and Topics in MDPI journals

Dr. Marek Matejka

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Guest Editor Assistant

Department of Technological Engineering, University of Zilina, Univerzitna 1, 010 26 Zilina, Slovak
Interests: casting technology; aluminum alloy recycling; microstructure and properties of aluminum alloys; mechanical and casting properties of aluminum alloys; high pressure casting; heat treatment of aluminum alloys; computer simulation of the casting process

Special Issue Information

Dear Colleagues,

We are pleased to invite you to publish original work, research articles, review articles, and short memos relating to “Advances in Metal Cutting, Casting, Forming, and Heat Treatment”. The focus of the contributed papers may be either on metal-cutting processing, casting, forming, and heat treatment which are relevant to practical analysis or industrial applications, such as experimental, numerical, optimization, or mathematical approaches. A hybrid approach analysis is encouraged.

In this Special Issue, articles regarding innovation in metal cutting, casting, forming, and heat treatment with various engineering materials are sought, especially those focused on micro-structure evolution, phase structure, changes in mechanical properties, and residual stress, to inform readers about recent research development activities and the latest ongoing research, or the current state of the art. Therefore, original works and unpublished materials which are concerned with the following subjects are requested:

Advances in traditional metal cutting (turning, milling, drilling, and boring), non-traditional cutting, hybrid cutting, vibration cutting, non-metallic cutting, and composite cutting.
Metallic/nonmetallic materials used in forming processes such as sheet metal forming, powder forming, bulk-forming, micro-forming, plastic deformation due to forming, tribology in the forming process, and innovative forming technology, such as incremental forming, laser forming, and hydroforming.
Casting technology, novel molding technology, moldless casting, casting formation, lost foam casting, molding technique, and iced casting forming.
Heat treatment (annealing, induction heating, surface hardening, quenching, etc.), laser/electron beams heat treatment, plasma treatment, surface treatment, surface characterization, and digitalized heat treatment, including online monitoring.
Rolling, shot peening (shot peening, blast peening, pressure peening, etc.), forging and joining or welding technology.

Dr. Rendi Kurniawan
Dr. Hongchao Ji
Dr. Ireneusz Szachogluchowicz
Guest Editors

Dr. Marek Matejka
Guest Editor Assistant

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

metal cutting
non-traditional cutting
composite cutting
metal forming
micro-forming
casting
molding technology
heat treatment
surface characterization
microstructure
innovative forming technology
molding technique
mechanical peening
pressure peening

Published Papers (10 papers)

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Research

16 pages, 5778 KiB

Open AccessArticle

Optimizing the Heat Treatment Method to Improve the Aging Response of Al-Fe-Ni-Sc-Zr Alloys

by Mingliang Wang, Zeyu Bian, Ailin Zhu, Yulong Cai, Dongdong Zhang, Yanlai Wu, Shuai Cui, Dong Chen and Haowei Wang

Materials 2024, 17(8), 1772; https://doi.org/10.3390/ma17081772 - 12 Apr 2024

Viewed by 341

Abstract

This work has studied the co-addition of Sc and Zr elements into the Al-1.75wt%Fe-1.25wt%Ni eutectic alloy. The changes in the microstructure, electrical conductivity, and Vickers hardness of the Al-1.75wt%Fe-1.25wt%Ni-0.2wt%Sc-0.2wt%Zr alloy during heat treatment were studied. The results showed that two-step aging can effectively improve the aging response of the alloy over the single-step aging method. This was ascribed to the minimization of the diffusion difference between Sc and Zr elements. Furthermore, the homogenization treatment can also improve the aging response of the alloy by alleviating the uneven distribution of Sc and Zr. Nevertheless, the micro-alloyed elements exceeded the solid solubility limit in the Al-1.75wt%Fe-1.25wt%Ni-0.2wt%Sc-0.2wt%Zr alloy, and their strengthening effect has ever achieved the best prospect. Finally, both Sc and Zr contents were reduced simultaneously, and the aging response of the Al-1.75wt%Fe-1.25wt%Ni-0.15wt%Sc-0.1wt%Zr alloy was improved by optimized heat treatment. The underlying mechanisms for this alloy design and the corresponding microstructure–mechanical property relationship were analytically discussed. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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16 pages, 23770 KiB

Open AccessArticle

Effect of Vanadium Addition on Solidification Microstructure and Mechanical Properties of Al–4Ni Alloy

by Xu Chen, Ji Chen, Weiguo Xi, Qizhou Cai, Jingfan Cheng and Wenming Jiang

Materials 2024, 17(2), 332; https://doi.org/10.3390/ma17020332 - 09 Jan 2024

Viewed by 716

Abstract

The effects of vanadium addition on the solidification microstructure and mechanical properties of Al–4Ni alloy were investigated via thermodynamic computation, thermal analysis, microstructural observations, and mechanical properties testing. The results show that the nucleation temperature of primary α-Al increased with increased vanadium addition. A transition from columnar to equiaxed growth took place when adding vanadium to Al–4Ni alloys, and the average grain size of primary α-Al was reduced from 1105 μm to 252 μm. When the vanadium addition was 0.2 wt%, the eutectic nucleation temperature increased from 636.2 °C for the Al–4Ni alloy to 640.5 °C, and the eutectic solidification time decreased from 310 s to 282 s. The average diameter of the eutectic Al₃Ni phases in the Al–4Ni–0.2V alloy reduced to 0.14 μm from 0.26 μm for the Al–4Ni alloy. As the vanadium additions exceeded 0.2 wt%, the eutectic nucleation temperature had no obvious change and the eutectic solidification time increased. The eutectic Al₃Ni phases began to coarsen, and the number of lamellar eutectic boundaries increased. The mechanical properties of Al–4Ni alloys gradually increased with vanadium addition (0–0.4 wt%). The Al–4Ni–0.4V alloy obtained the maximum tensile strength and elongation values, which were 136.4 MPa and 23.5%, respectively. As the vanadium addition exceeded 0.4 wt%, the strength and elongation decreased, while the hardness continued to increase. Fracture in the Al–4Ni–0.4V alloy exhibited ductile fracture, while fracture in the Al–4Ni–0.6V alloy was composed of dimples, tear edges, and cleavage planes, demonstrating mixed ductile–brittle fracture. The cleavage planes were caused by the primary Al₁₀V and coarse Al₃Ni phases at the boundary of eutectic cells. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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20 pages, 16169 KiB

Open AccessArticle

Experimental and Numerical Study of Al2219 Powders Deposition on Al2219-T6 Substrate by Cold Spray: Effects of Spray Angle, Traverse Speed, and Standoff Distance

by Zheng Zhang, Tzee Luai Meng, Coryl Jing Jun Lee, Fengxia Wei, Te Ba, Zhi-Qian Zhang and Jisheng Pan

Materials 2023, 16(15), 5240; https://doi.org/10.3390/ma16155240 - 26 Jul 2023

Cited by 1 | Viewed by 813

Abstract

Cold spray (CS) is an emerging technology for repairing and 3D additive manufacturing of a variety of metallic components using deformable metal powders. In CS deposition, gas type, gas pressure, gas temperature, and powder feed rate are the four key process parameters that have been intensively studied. Spray angle, spray gun traverse speed, and standoff distance (SoD) are the other three process parameters that have been less investigated but are also important, especially when depositing on uneven substrates or building up 3D freeform structures. Herein, the effects of spray angle, traverse speed, and SoD during CS deposition have been investigated holistically on a single material system (i.e., Al2219 powders on Al2219-T6 substrate). The coatings’ mass gain, thickness, porosity, and residual stress have been characterized, and the results show that spray angle and traverse speed exercise much more effects than SoD in determining coatings’ buildup. Finite element method (FEM) modeling and computational fluid dynamic (CFD) simulation have been carried out to understand the effects of these three parameters for implementing CS as repairing and additive manufacturing using aluminum-based alloy powders. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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13 pages, 3973 KiB

Open AccessArticle

Effect of Temperature and Load on Tribological Behavior in Laser-Cladded FeCrSiNiCoC Coatings

by Haiyang Long, Wei Hao, Rucheng Ma, Yongliang Gui, Chunyan Song, Tieyu Qin and Xuefeng Zhang

Materials 2023, 16(8), 3263; https://doi.org/10.3390/ma16083263 - 21 Apr 2023

Viewed by 1052

Abstract

The FeCrSiNiCoC coatings with fine macroscopic morphology and uniform microstructure were made on 1Cr11Ni heat resistant steel substrate by a laser-based cladding technique. The coating consists of dendritic γ-Fe and eutectic Fe-Cr intermetallic with an average microhardness of 467 HV_0.5 ± 22.6 HV_0.5. At the load of 200 N, the average friction coefficient of the coating dropped as temperature increased, while the wear rate decreased and then increased. The wear mechanism of the coating changed from abrasive wear, adhesive wear and oxidative wear to oxidative wear and three-body wear. Apart from an elevation in wear rate with increasing load, the mean friction coefficient of the coating hardly changed at 500 °C. Due to the coating’s transition from adhesive wear and oxidative wear to three-body wear and abrasive wear, the underlying wear mechanism also shifted. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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18 pages, 17293 KiB

Open AccessArticle

Development of Preliminary Precision Forging Technology and Concept for Tools Used to Reforge 60E1A6 Profile Needle Rails with the Use of Numerical and Physical Modeling

by Marek Hawryluk, Piotr Cygan, Jakub Krawczyk, Artur Barełkowski, Jacek Ziemba, Filip Lewandowski and Igor Wieczorek

Materials 2023, 16(5), 2103; https://doi.org/10.3390/ma16052103 - 05 Mar 2023

Cited by 1 | Viewed by 1471

Abstract

This study examines the possibilities of applying numerical and physical modeling to the elaboration of technology and design of tools used in the hot forging of needle rails for railroad turnouts. First, a numerical model of a three-stage process for forging a needle from lead was built in order to develop a proper geometry of the tools’ working impressions for physical modeling. Based on preliminary results of the force parameters, a decision was made to verify the numerical modeling at 1:4 scale due to forging force values as well as agreement of the numerical and physical modeling results, which was confirmed by the similar courses of forging forces and a comparison of the 3D scan image of the forged lead rail with the CAD model obtained from FEM. The final stage of our research was modeling an industrial forging process in order to determine the preliminary assumptions of this newly developed method of precision forging using a hydraulic press as well as preparing tools to reforge a needle rail from the target material, i.e., 350HT steel with a 60E1A6 profile to the 60E1 profile used in railroad turnouts. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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10 pages, 3321 KiB

Open AccessArticle

Fabrication of Micro-Ball Sockets in C17200 Beryllium Copper Alloy by Micro-Electrical Discharge Machining Milling

by Shuliang Dong, Hongchao Ji, Jian Zhou, Xianzhun Li, Lan Ding and Zhenlong Wang

Materials 2023, 16(1), 323; https://doi.org/10.3390/ma16010323 - 29 Dec 2022

Cited by 2 | Viewed by 1016

Abstract

Micro-liquid floated gyroscopes are widely used in nuclear submarines, intercontinental missiles, and strategic bombers. The machining accuracy of micro-ball sockets determined the motion accuracy of the rotor. However, it was not easily fabricated by micro-cutting because of the excellent physical and chemical properties of beryllium copper alloy. Here, we presented a linear compensation of tool electrode and a proportional variable thickness method for milling micro-ball sockets in C17200 beryllium copper alloy by micro-electrical discharge machining. The machining parameters were systematically investigated and optimized to achieve high-precision micro-ball sockets when the k value was 0.98 and the initial layer thickness was 0.024 mm. Our method provided a new way to fabricate micro-ball sockets in C17200 with high efficiency for micro-liquid floated gyroscopes. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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17 pages, 13649 KiB

Open AccessArticle

Mechanical Properties and Fracture Behavior of a TC4 Titanium Alloy Sheet

by Zeling Zhao, Hongchao Ji, Yingzhuo Zhong, Chun Han and Xuefeng Tang

Materials 2022, 15(23), 8589; https://doi.org/10.3390/ma15238589 - 01 Dec 2022

Cited by 4 | Viewed by 1917

Abstract

TC4 titanium alloy has excellent comprehensive properties. Due to its light weight, high specific strength, and good corrosion resistance, it is widely used in aerospace, military defense, and other fields. Given that titanium alloy components are often fractured by impact loads during service, studying the fracture behavior and damage mechanism of TC4 titanium alloy is of great significance. In this study, the Johnson–Cook failure model parameters of TC4 titanium alloy were obtained via tensile tests at room temperature. The mechanical behavior of TC4 titanium alloy during the tensile process was determined by simulating the sheet tensile process with the finite element software ABAQUS. The macroscopic and microscopic morphologies of tensile fracture were analyzed to study the deformation mechanism of the TC4 titanium alloy sheet. The results provide a theoretical basis for predicting the fracture behavior of TC4 titanium alloy under tensile stress. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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14 pages, 7078 KiB

Open AccessArticle

Multi-Objective Optimization of Process Parameters in 6016 Aluminum Alloy Hot Stamping Using Taguchi-Grey Relational Analysis

by Binghe Jiang, Jianghua Huang, Hongping Ma, Huijun Zhao and Hongchao Ji

Materials 2022, 15(23), 8350; https://doi.org/10.3390/ma15238350 - 24 Nov 2022

Cited by 3 | Viewed by 1342

Abstract

The hot stamping technology of aluminum alloy is of great significance for realizing the light weight of the automobile body, and the proper process parameters are important conditions to obtain excellent aluminum alloy parts. In this paper, the thermal deformation behavior of 6016 aluminum alloy at a high temperature is experimentally studied to provide a theoretical basis for a finite element model. With the help of blank stamping finite element software, a numerical model of a 6016 aluminum alloy automobile windshield beam during hot stamping was established. The finite element model was verified by a forming experiment. Then, the effect of the process parameters, including blank holder force, die gap, forming temperature, friction coefficient, and stamping speed on aluminum alloy formability were investigated using Taguchi design, grey relational analysis (GRA), and analysis of variance (ANOVA). Stamping tests were arranged at temperatures between 480 and 570 °C, blank holder force between 20 and 50 kN, stamping speed between 50 and 200 mm/s, die gap between 1.05 t and 1.20 t (t is the thickness of the sheet), and friction coefficient between 0.15 and 0.60. It was found that the significant factors affecting the forming quality of the hot-stamped parts were blank holder force and stamping speed, with influence significance of 28.64% and 34.09%, respectively. The optimal parameters for hot stamping of the automobile windshield beam by the above analysis are that the die gap is 1.05 t, the blank temperature is 540 °C, the coefficient of friction is 0.15, stamping speed is 200 mm/s, and blank holder force is 50 kN. The optimized maximum thickening rate is 4.87% and the maximum thinning rate is 9.00%. The optimization method used in this paper and the results of the process parameter optimization provide reference values for the optimization of hot stamping forming. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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16 pages, 5572 KiB

Open AccessArticle

Solid Particle Erosion Studies of Varying Tow-Scale Carbon Fibre-Reinforced Polymer Composites

by Suresh Kumar Shanmugam, Thirumalai Kumaran Sundaresan, Temel Varol and Rendi Kurniawan

Materials 2022, 15(21), 7534; https://doi.org/10.3390/ma15217534 - 27 Oct 2022

Cited by 2 | Viewed by 1289

Abstract

Solid particle erosion inevitably occurs if a gas–solid or liquid–solid mixture is in contact with a surface, e.g., in pneumatic conveyors. Nowadays, an erosive failure of the component after the usage of a long period has been gaining the interest of the researchers. In this research work, carbon fibre-reinforced polymer (CFRP) composites are prepared by varying the tow sizes of fibres, such as 5k, 10k, and 15k. The prepared composites are subjected to erosion studies by varying the process parameters, such as the impact angle (30, 60, and 90 degrees) and velocity (72, 100, and 129 m/s). The Taguchi orthogonal array design has been employed for the experimental plan and the erosion rate and surface roughness are observed for each run. The changes in the responses are reported for varying process parameters. The higher erodent velocity of 129m/s leads to higher erosion rates and forms poor surface quality. The minimum impact angle of 30 degrees provides higher erosion rates and higher surface roughness than the other impingement angles. Finally, the eroded surface of each sample is examined through microscopic and 3D profilometer images and the erosion mechanism is analysed at different conditions. The eroded particles supplied at lower speeds do not penetrate the composite surface. However, it is well-known that the lower the collision force, the harder the traces on the surface, yet no sign of fibre breaking or pull-out is observed. The passage of erodent particles on the composite caused surface waviness (flow trace), which prevents the surface from degrading. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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15 pages, 5552 KiB

Open AccessArticle

Research on the Corrosion Behavior of Q235 Pipeline Steel in an Atmospheric Environment through Experiment

by Shuo Cai, Hongchao Ji, Fengyun Zhu, Weichi Pei, Wenchao Xiao and Xuefeng Tang

Materials 2022, 15(18), 6502; https://doi.org/10.3390/ma15186502 - 19 Sep 2022

Cited by 11 | Viewed by 1900

Abstract

Low-carbon steel pipelines are frequently used as transport pipelines for various media. As the pipeline transport industry continues to develop in extreme directions, such as high efficiency, long life, and large pipe diameters, the issue of pipeline reliability is becoming increasingly prominent. This study selected Q235 steel, a typical material for low-carbon steel pipelines, as the research object. In accordance with the pipeline service environment and the accelerated corrosion environment test spectrum, cyclic salt spray accelerated corrosion tests that simulated the effects of the marine atmosphere were designed and implemented. Corrosion properties, such as corrosion weight loss, morphology, and product composition of samples with different cycles, were characterized through appearance inspection, scanning electron microscopy analysis, and energy spectrum analysis. The corrosion behavior and mechanism of Q235 low-carbon steel in the enhanced corrosion environment were studied, and the corrosion weight loss kinetics of Q235 steel was verified to conform to the power function law. During the corrosion process, the passivation film on the surface of the low-carbon steel and the dense and stable α-FeOOH layer formed after the passivation film was peeled off played a role in corrosion resistance. The passivation effect, service life, and service limit of Q235 steel were studied and determined, and an evaluation model for quick evaluation of the corrosion life of Q235 low-carbon steel was established. This work provides technical support to improve the life and reliability of low-carbon steel pipelines. It also offers a theoretical basis for further research on the similitude and relevance of cyclic salt spray accelerated corrosion testing. Full article

(This article belongs to the Special Issue Advances in Metal Cutting, Casting, Forming and Heat Treatment)

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