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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Physics".

Deadline for manuscript submissions: closed (20 January 2024) | Viewed by 7736

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Special Issue Editors

Prof. Dr. Qigang Han

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Guest Editor

School of Materials Science and Engineering, Jilin University, Changchun, China
Interests: flexible forming; stretching forming; metal material, fiber-reinforced composite; bionic design; bionic manufacturing

Dr. Ce Liang

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Guest Editor

College of Materials Science and Engineering, Jilin University, Changchun 130025, Jilin, China
Interests: flexible forming; 3D stretching forming; rotary draw bending; continuous roll forming

Special Issue Information

Dear Colleagues,

Various types of metallic and composite structures are used in modern engineering practice. For aerospace, car industry, or civil engineering applications, the most important are complex spatial structures made of different types of metallic alloys, fibrous composites, and functional materials with reinforcement. The current applications in modern engineering require various non-traditional processing technologies combining smart manufacturing technologies and systems, including plastic forming, liquid forming, materials joining, micro-nano fabrication, sustainable and green manufacturing, additive manufacturing, smart manufacturing, virtual manufacturing, etc.

This Special Issue focuses on advanced manufacturing technology for metal and composite forming and aims at solving the key and difficult problems in the forming processing of advanced metal and composite structures. In recent years, with the complex use of new materials and structural design optimization of engineering application products, the traditional forming process suffered great challenges and is unable to meet the preparation requirements (forming precision control, mechanical properties, etc.). Research on how to realize the formation of functional structures under the action of multiple dimensions, coupled force fields, thermal fields, and magnetic fields play an important role in the development of industrial applications.

Prof. Dr. Qigang Han
Dr. Ce Liang
Guest Editors

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Keywords

advanced manufacturing technology
metal forming
composite forming

Published Papers (7 papers)

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Research

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16 pages, 13141 KiB

Open AccessArticle

Numerical Study on Electromagnetic Hydraulic Forming Process to Overcome Limitations of Electromagnetic Forming Process

by Yeon-Bok Kim and Jeong Kim

Materials 2024, 17(7), 1586; https://doi.org/10.3390/ma17071586 - 30 Mar 2024

Viewed by 470

Abstract

This paper provides a comparison between the conventional Electromagnetic Forming (EMF) technique and the novel Electromagnetic Hydraulic Forming (EMHF) approach. The EMHF involves the use of finite element analysis coupled with the EM and arbitrary Lagrangian–Eulerian techniques analyzed through LS-DYNA. In the free-bulge configuration, EMF is influenced by the forming coil, resulting in a dead zone and uneven forming. Additionally, EMF can only be used to shape materials with high electrical conductivity. In contrast, EMHF, driven by induced hydraulic pressure from the electromagnetic field-affected drive sheet, is independent of the electrical conductivity of the material and produces dome-shaped workpieces. For rectangular die shapes, EMF is prone to collision owing to the acceleration of the blank, which results in a reduced quality owing to bouncing. However, EMHF exhibits no bouncing effect and successfully achieves the target shape in most cases. The two techniques differ in the strain rate, with EMF at 4850/s, whereas EMHF operates at approximately 1250/s. Despite being slower, EMHF is still a high-speed forming technique. In conclusion, EMHF is a promising technique capable of addressing the shortcomings of conventional EMF and achieving improvements in forming processes. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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14 pages, 3669 KiB

Open AccessArticle

Finite Element Simulation and Microstructural Evolution Investigation in Hot Stamping Process of Ti6Al4V Alloy Sheets

by Mingjia Qu, Zhengwei Gu, Xin Li, Jianbo Wang, Ge Yu and Lingling Yi

Materials 2024, 17(6), 1388; https://doi.org/10.3390/ma17061388 - 18 Mar 2024

Viewed by 639

Abstract

Titanium alloy hot stamping technology has a wide range of application prospects in the field of titanium alloy part processing due to its high production efficiency and low manufacturing cost. However, the challenges of forming titanium alloy parts with large depths and deformations have restricted its development. In this study, the hot stamping process of a Ti6Al4V alloy box-shaped part was investigated using ABAQUS 2020 software. The thermodynamic properties of a Ti6Al4V alloy sheet were explored at different temperatures (400 °C, 500 °C, 600 °C, 700 °C, 800 °C) and different strain rates (0.1 s⁻¹, 0.05 s⁻¹, 0.01 s⁻¹). In addition, the influence law of hot stamping process parameters on the minimum thickness of the formed part was revealed through the analysis of response surface methodology (RSM), ultimately obtaining the optimal combination of process parameters for Ti6Al4V alloy hot stamping. The experimental results of the hot stamping process exhibited a favorable correlation with the simulated outcomes, confirming the accuracy of the numerical simulation. The study on the microstructure evolution of the formed parts showed that grain refinement strengthening occurred in the part with large deformation, and the formed box-shaped parts exhibited a uniform and fine microstructure overall, demonstrating high forming quality. The achievements of the work provide important guidance for the fabrication of titanium alloy parts with large depths and deformations used in heavy industrial production. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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15 pages, 2601 KiB

Open AccessArticle

CO₂ Adsorption Behaviors of Biomass-Based Activated Carbons Prepared by a Microwave/Steam Activation Technique for Molecular Sieve

by Jin-Young Lee, Byeong-Hoon Lee, Dong-Chul Chung and Byung-Joo Kim

Materials 2023, 16(16), 5625; https://doi.org/10.3390/ma16165625 - 15 Aug 2023

Cited by 1 | Viewed by 965

Abstract

In this study, the activated carbon was prepared with superior CO₂ selective adsorption properties using walnut shells, a biomass waste, as a precursor. The activations were conducted at various times using the microwave heating technique in a steam atmosphere. The surface morphology and chemical composition of activated carbon were analyzed using a scanning electron microscope and energy-dispersive X-ray spectroscopy. The textural properties were investigated using the N₂/77K isothermal method, and the structural characteristics were examined using X-ray diffraction analysis. The CO₂ and H₂ adsorption properties of activated carbon were analyzed using a thermogravimetric analyzer and a high-pressure isothermal adsorption apparatus, respectively, under atmospheric and high-pressure conditions. Depending on the activation time, the specific surface area and total pore volume of the activated carbon were 570–690 m²/g and 0.26–0.34 cm³/g, respectively. The adsorption behaviors of CO₂ of the activated carbon were different under atmospheric and high-pressure conditions. At atmospheric pressure, a significant dependence on micropores with diameters less than 0.8 nm was observed, whereas, at high pressure, the micropores and mesopores in the range of 1.6–2.4 nm exhibited a significant dependence. However, H₂ adsorption did not occur at relatively low pressures. Consequently, the prepared activated carbon exhibited superior selective adsorption properties for CO₂. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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14 pages, 4696 KiB

Open AccessArticle

A Simplified Dynamic Strength Analysis of Cardboard Packaging Subjected to Transport Loads

by Damian Mrówczyński, Tomasz Gajewski and Tomasz Garbowski

Materials 2023, 16(14), 5131; https://doi.org/10.3390/ma16145131 - 20 Jul 2023

Viewed by 1358

Abstract

The article presents a simplified method for determining the strength of corrugated board packaging subjected to dynamic transport loads. The proposed algorithm consists of several calculation steps: (1) a static analysis of the compressive strength of the package, (2) an analysis of random vibrations in the frequency domain used to determine the resonance frequencies and (3) a dynamic analysis of the package loaded with computed resonant frequencies. For this purpose, numerical models of the static compression test of the packaging before and after the dynamic analysis of the package subjected to general transport loads were developed. In order to validate the model, laboratory packaging compression tests were also performed for samples of boxes using three-layer cardboard. Due to this, it was possible to verify the numerical simulation results of the compression tests for several box geometries. This, in turn, allowed for the development of a method based on dynamic and post-dynamic (static) numerical analyses, permitting a high-accuracy determination of the resistance of the selected packaging to vibrations and dynamic loads. The results of the (experimentally validated) numerical analysis proved the usefulness of the simplified method presented herein for precise estimation of the load capacity of various packages dynamically loaded during transport. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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22 pages, 26818 KiB

Open AccessArticle

Production of Workpieces from Martensitic Stainless Steel Using Electron-Beam Surfacing and Investigation of Cutting Forces When Milling Workpieces

by Nikita V. Martyushev, Victor N. Kozlov, Mengxu Qi, Vadim S. Tynchenko, Roman V. Kononenko, Vladimir Yu. Konyukhov and Denis V. Valuev

Materials 2023, 16(13), 4529; https://doi.org/10.3390/ma16134529 - 22 Jun 2023

Cited by 7 | Viewed by 1110

Abstract

The aim of this study was to investigate cutting force when milling 40 × 13 stainless steel samples obtained via electron-beam surfacing. The samples were obtained by surfacing the wire made from the martensitic 40 × 13 stainless steel. The microstructure of the samples and the hardness are discussed in the present study. Emphasis is placed on the study of cutting forces when handling the samples. The structure of the samples obtained by electron-beam surfacing consisted of tempered martensite. The average hardness of the samples was similar to the hardness obtained after quenching and tempering the samples—576 HV for horizontally printed workpieces and 525 HV for vertically printed workpieces. High-speed milling, high-efficiency milling, and conventional milling have been proven to be suitable for handling such workpieces. This study shows that an increase in milling width leads to a gradual decrease in specific cutting force. As the milling depth increases, the specific cutting force decreases intensively at first but then more slowly with time. Machining the workpieces made of the martensitic stainless steel and produced by electron-beam surfacing requires the use of purely carbide mills with a diameter of at least 12 mm. Using a high-speed steel as a tool material results in the rapid failure of the tool. The cutting conditions during the investigation allowed for a decrease in the temperature of the cutting edge, cutting force, and the low-rigid end mill bending. Therefore, this study has made it possible to select modes that allow for a reduction in the vibration of the lathe-fixture-tool-part system. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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15 pages, 4711 KiB

Open AccessEditor’s ChoiceArticle

In Situ Reactive Formation of Mixed Oxides in Additively Manufactured Cobalt Alloy

by Jack Lopez, Rok Cerne, David Ho, Devin Madigan, Qing Shen, Bo Yang, Joseph Corpus, William Jarosinski, Haiyan Wang and Xinghang Zhang

Materials 2023, 16(10), 3707; https://doi.org/10.3390/ma16103707 - 13 May 2023

Cited by 2 | Viewed by 1330

Abstract

Oxide-dispersion-strengthened (ODS) alloys have long been considered for high temperature turbine, spacecraft, and nuclear reactor components due to their high temperature strength and radiation resistance. Conventional synthesis approaches of ODS alloys involve ball milling of powders and consolidation. In this work, a process-synergistic approach is used to introduce oxide particles during laser powder bed fusion (LPBF). Chromium (III) oxide (Cr₂O₃) powders are blended with a cobalt-based alloy, Mar-M 509, and exposed to laser irradiation, resulting in reduction–oxidation reactions involving metal (Ta, Ti, Zr) ions from the metal matrix to form mixed oxides of increased thermodynamic stability. A microstructure analysis indicates the formation of nanoscale spherical mixed oxide particles as well as large agglomerates with internal cracks. Chemical analyses confirm the presence of Ta, Ti, and Zr in agglomerated oxides, but primarily Zr in the nanoscale oxides. Mechanical testing reveals that agglomerate particle cracking is detrimental to tensile ductility compared to the base alloy, suggesting the need for improved processing methods to break up oxide particle clusters and promote their uniform dispersion during laser exposure. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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Review

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20 pages, 5408 KiB

Open AccessReview

The Application of Finite Element Method for Analysis of Cross-Wedge Rolling Processes—A Review

by Zbigniew Pater

Materials 2023, 16(13), 4518; https://doi.org/10.3390/ma16134518 - 21 Jun 2023

Cited by 1 | Viewed by 1257

Abstract

The aim of this article is to review the application of the finite element method (FEM) to cross-wedge rolling (CWR) modeling. CWR is a manufacturing process which is used to produce stepped axles and shafts as well as forged parts for further processing on forging presses. Although the concept of CWR was developed 140 years ago, it was not used in industry until after World War 2. This was due to the limitations connected with wedge tool design and the high costs of their construction. As a result, until the end of the twentieth century, CWR tools were constructed by rolling mill manufacturers as they employed engineers with the most considerable experience in CWR process design. The situation has only changed recently when FEM became widely used in CWR analysis. A vast number of theoretical studies have been carried out in recent years, and their findings are described in this overview article. This paper describes nine research areas in which FEM is effectively applied, namely: the states of stress and strain; force parameters; failure modes in CWR; material fracture; microstructure modeling; the formation of concavities on the workpiece ends; CWR formation of hollow parts; CWR formation of parts made of non-ferrous materials; and new CWR methods. Finally, to show the potential of FEM on CWR modeling, a CWR process for manufacturing a stepped shaft used in car gearboxes is simulated numerically. This numerical simulation example shows that FEM can be used to model very complex cases of CWR, which should lead to a growing interest in this advanced manufacturing technique in the future. Full article

(This article belongs to the Special Issue Advances in Materials Processing Engineering)

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