Submit to JMMP Review for JMMP

Journal Menu

Journal Browser

► Journal Browser

J. Manuf. Mater. Process., Volume 9, Issue 11 (November 2025) – 6 articles

Issues are regarded as officially published after their release is announced to the table of contents alert mailing list.
You may sign up for e-mail alerts to receive table of contents of newly released issues.
PDF is the official format for papers published in both, html and pdf forms. To view the papers in pdf format, click on the "PDF Full-text" link, and use the free Adobe Reader to open them.

Order results

Result details

Show export options Show export options

Select all

Export citation of selected articles as:

25 pages, 10646 KB

Open AccessArticle

A Multimodal Fusion Method for Weld Seam Extraction Under Arc Light and Fume Interference

by Lei Cai and Han Zhao

J. Manuf. Mater. Process. 2025, 9(11), 350; https://doi.org/10.3390/jmmp9110350 (registering DOI) - 26 Oct 2025

Abstract

During the Gas Metal Arc Welding (GMAW) process, intense arc light and dense fumes cause local overexposure in RGB images and data loss in point clouds, which severely compromises the extraction accuracy of circular closed-curve weld seams. To address this challenge, this paper proposes a multimodal fusion method for weld seam extraction under arc light and fume interference. The method begins by constructing a weld seam edge feature extraction (WSEF) module based on a synergistic fusion network, which achieves precise localization of the weld contour by coupling image arc light-removal and semantic segmentation tasks. Subsequently, an image-to-point cloud mapping-guided Local Point Cloud Feature extraction (LPCF) module was designed, incorporating the Shuffle Attention mechanism to enhance robustness against noise and occlusion. Building upon this, a cross-modal attention-driven multimodal feature fusion (MFF) module integrates 2D edge features with 3D structural information to generate a spatially consistent and detail-rich fused point cloud. Finally, a hierarchical trajectory reconstruction and smoothing method is employed to achieve high-precision reconstruction of the closed weld seam path. The experimental results demonstrate that under severe arc light and fume interference, the proposed method achieves a Root Mean Square Error below 0.6 mm, a maximum error not exceeding 1.2 mm, and a processing time under 5 s. Its performance significantly surpasses that of existing methods, showcasing excellent accuracy and robustness. Full article

18 pages, 1011 KB

Open AccessArticle

Influence of Substrate Type Made of WC-Co on CrN/CrAlN Coatings’ Durability During Machining of Particleboard

by Paweł Czarniak, Beata Kucharska, Karol Szymanowski, Corinne Nouveau, Denis Lagadrillere, Marek Betiuk, Tomasz Rygier, Krzysztof Kulikowski, Zbigniew Kusznierewicz and Jerzy Robert Sobiecki

J. Manuf. Mater. Process. 2025, 9(11), 349; https://doi.org/10.3390/jmmp9110349 (registering DOI) - 24 Oct 2025

Abstract

This paper investigates the influence of substrate grain size on the behavior of a multilayer CrN/CrAlN coating, with the bilayer thickness varying across the cross-section in the range of 200–1000 nm. The substrate tools were made of WC-Co sintered carbide with three different grain sizes. The coatings were subjected to mechanical and tribological tests to assess their performance, including nanohardness, scratch resistance, and tribological testing. The coating’s roughness was measured using a 2D profilometer. Additionally, the chemical composition and surface morphology were analyzed using Scanning Electron Microscopy (SEM) and Energy Dispersive X-Ray Spectroscopy (EDX). The durability tests were performed on an industrial CNC machine tool on the particleboard. The results revealed that tools with ultra-fine nano-grain (S) and micro-grain (T) WC-Co substrates exhibited a significant increase in tool durability by 28% and 44%, respectively. Significant differences in the microgeometry of the substrate U, especially in relation to the tool based on substrate S, explain the lack of improvement in its durability despite the use of a multilayer coating. Full article

► Show Figures

Graphical abstract

24 pages, 38190 KB

Open AccessArticle

Effect of Electrically Assisted Heat Treatment on Crack Arrest and Healing in Laser-Cladded Ni–Based Coatings

by Xuxiang Song, Xiao Li, Wenping Wang and Zhicheng Zhao

J. Manuf. Mater. Process. 2025, 9(11), 348; https://doi.org/10.3390/jmmp9110348 - 23 Oct 2025

Viewed by 166

Abstract

Cracks in laser-cladded coatings represent a critical challenge that severely limits their industrial deployment. In this study, high-frequency pulsed direct current-assisted electrically assisted heat treatment (EAHT) was applied to repair cracks in laser-cladded Ni60/WC coatings deposited on 45# medium carbon steel. The influence of current density and treatment duration on crack arrest and healing behavior was systematically investigated. Dye penetrant testing and scanning electron microscopy (SEM) were employed to characterize the morphology and evolution of cracks before and after EAHT, while hardness, fracture toughness, and wear resistance tests were conducted to evaluate the mechanical properties. The results revealed that the crack repair process proceeds through three distinct stages: internal filling, nucleation and growth of healing points, and complete crack closure. The combined effects of Joule heating and current crowding induced by EAHT significantly facilitated progressive crack healing from the bottom upward. Optimal crack arrest and healing were achieved at a current density of 6.25 A/mm², resulting in a maximum fracture toughness of 10.74 MPa·m^1/2 and a transition of the wear mechanism from spalling to abrasive wear. This study demonstrates that EAHT promotes selective crack-tip heating and microstructural regulation through thermo-electro-mechanical coupling, thereby markedly enhancing the comprehensive performance of Ni-based WC coatings. Full article

► Show Figures

Figure 1

12 pages, 1176 KB

Open AccessArticle

Characterizing Surface Waviness of Aluminum Alloy: An Approach to Minimize Post-Processing in Wire Arc Additive Manufacturing (WAAM) Production

by Shammas Mahmood Shafi, Anis Fatima and Nicholas V. Hendrickson

J. Manuf. Mater. Process. 2025, 9(11), 347; https://doi.org/10.3390/jmmp9110347 - 23 Oct 2025

Viewed by 164

Abstract

Wire Arc Additive Manufacturing (WAAM) offers high deposition rates and cost-effective production of large metal components but suffers from poor surface quality, particularly surface waviness, which increases post-processing requirements and limits industrial adoption. Since waviness directly impacts structural integrity, resource efficiency, and industrial applicability, understanding how process parameters govern this feature is critical for reducing post-processing requirement. This study systematically investigated the influence of voltage, travel speed, and wire feed speed on surface waviness in aluminum alloy walls fabricated by WAAM. A two-level factorial design with 16 experiments was conducted, and surface waviness was quantified using height gauge measurements relative to the expected bead height. Statistical analyses, including ANOVA and multiple linear regression, were applied to evaluate parameter significance. The results revealed that wire feed speed was the most influential parameter, showing a strong positive correlation with waviness due to excess material deposition. Voltage exhibited a weaker, stabilizing effect, with higher values marginally reducing waviness through improved arc stability, while travel speed had negligible influence within the studied range. The regression model achieved an

R^{2}

0.389, with validation tests indicating reasonable predictive accuracy. These findings demonstrate that controlling wire feed speed is critical for minimizing waviness, while higher voltage may serve as a secondary stabilizing factor. The study was limited to surface waviness; however, future work should consider the role of thermal accumulation, inter-pass temperature, and external disturbances on surface stability. Such insights could enable adaptive parameter control strategies to further reduce post-processing needs and enhance the industrial viability of WAAM. Full article

► Show Figures

Figure 1

13 pages, 5364 KB

Open AccessArticle

Improved Machinability of Pockets in a Liquid-Silicon-Infiltrated Silicon Carbide Composite Using Ultrasonic Assistance

by Achim Rösiger, Patricia León-Pérez, Joshua Macken and Ralf Goller

J. Manuf. Mater. Process. 2025, 9(11), 346; https://doi.org/10.3390/jmmp9110346 - 22 Oct 2025

Viewed by 134

Abstract

Surface finishing processes are required to produce the final shape of components made of the silicon-infiltrated silicon carbide composite Cesic^® from ECM (Engineered Ceramic Materials GmbH, 85452 Moosinning, Germany). Electrical discharge machining (EDM) is still the most effective method for manufacturing pockets and mounts in 3D-shaped ceramic satellite components for space applications. NC-grinding is not used, because it results in high grinding loads and rapid tool wear when applied to Cesic^®. In contrast to planar machining, tool wear during NC-grinding with small tools is particularly critical, as it alters the tool geometry and consequently causes deviations in the workpiece geometry. Ultrasonic-assisted grinding offers a promising alternative to overcome the low material removal rates and long processing times associated with EDM while simultaneously enhancing tool life, thus enabling more economical and reliable production. In this experimental study, both conventional grinding (CG) and ultrasonic-assisted grinding (UAG) processes are compared and used to machine Cesic^®. In order to verify the effect of the ultrasonic vibration, analyses of amplitude and frequency are performed. During machining experiments, the grinding loads are measured. The influence of different machining conditions on surface quality is evaluated concerning the roughness of the machined specimens. Compared to CG, UAG shows lower tool wear, owing to the self-cleaning effects caused by the ultrasonic oscillation of the tool. Consequently, the stability of the NC-grinding process is significantly improved. Full article

► Show Figures

Figure 1

3 pages, 150 KB

Open AccessEditorial

Advancing Injection Molding: Innovations in Process, Materials and Applications

by Rossella Surace, Vincenzo Bellantone and Irene Fassi

J. Manuf. Mater. Process. 2025, 9(11), 345; https://doi.org/10.3390/jmmp9110345 - 22 Oct 2025

Viewed by 93

Abstract

This Special Issue on Advances in Injection Molding: Process, Materials and Applications presents a curated collection of papers highlighting the dynamic evolution of this fundamental manufacturing technology [...] Full article

(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications)

Show export options Show export options

Select all

Export citation of selected articles as:

Displaying articles 1-6

Previous Issue

Volume 9, October

Journal Menu

Journal Browser

J. Manuf. Mater. Process., Volume 9, Issue 11 (November 2025) – 6 articles

Further Information

Guidelines

MDPI Initiatives

Follow MDPI