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Volume 9
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J. Manuf. Mater. Process., Volume 9, Issue 3 (March 2025) – 35 articles

Cover Story (view full-size image):  Additive manufacturing, or 3D printing, is widely used across industries for its versatility and customization. However, the process is time-consuming, with print durations ranging from hours to days depending on complexity and size. Errors often occur due to object misalignment, nozzle overflow causing stringing, or filament blockages, leading to material waste and lost time. This study applies computer vision, image processing, and machine learning for real-time error detection, focusing on stringing anomalies. To address data scarcity, we introduce a new dataset and enhance the Obico server model, a leading stringing detection tool. The work presented improves reliability, reduces waste, and optimizes efficiency in AM workflows. View this paper
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24 pages, 17096 KiB  
Article
Exploring the Nonlinear Mechanical Characteristics of 3D-Printed ABS with Varying Infill Densities
by Md Zisanul Haque Bhuiyan and Khalil Khanafer
J. Manuf. Mater. Process. 2025, 9(3), 103; https://doi.org/10.3390/jmmp9030103 - 20 Mar 2025
Viewed by 341
Abstract
This study investigates the mechanical behavior of ASTM D638-02a standard uniaxial tensile test specimens fabricated from 3D-printed acrylonitrile butadiene styrene (ABS) using fused deposition modeling (FDM) with a grid infill pattern at varying densities of 20%, 40%, 60%, and 100%. The research aims [...] Read more.
This study investigates the mechanical behavior of ASTM D638-02a standard uniaxial tensile test specimens fabricated from 3D-printed acrylonitrile butadiene styrene (ABS) using fused deposition modeling (FDM) with a grid infill pattern at varying densities of 20%, 40%, 60%, and 100%. The research aims to provide a deeper understanding of how infill density influences the mechanical properties of FDM-printed ABS, an area critical for optimizing structural performance in additive manufacturing applications. Experimental uniaxial tensile tests reveal that as the infill density increases from 20% to 60%, the strain at break decreases from 4.7% to 3.9%; however, at 100% infill, the strain at break rises to 5.8%. Meanwhile, the average Young’s modulus exhibits an exponential increase from 513.78 MPa at 20% infill to 2394.8 MPa at full density, indicating greater stiffness with higher infill. Due to the inherent nonlinear elastic deformation of 3D-printed ABS, this study further explores the material’s behavior through finite element analysis (FEA) using Ansys Mechanical. Four hyperelastic material models—Neo-Hookean, Mooney–Rivlin (two-parameter), Mooney–Rivlin (three-parameter), and Yeoh (third order)—were evaluated using inverse analysis to determine material constants. The results indicate that while all models exhibit good correlation with experimental data, the three-parameter Mooney–Rivlin and Yeoh models achieve the highest accuracy (higher R2 values) across all infill densities. However, the Neo-Hookean model, despite being a single-parameter approach, demonstrates a consistent trend where its parameter value increases with infill density. This study provides novel insights into the nonlinear elastic properties of 3D-printed ABS and establishes a foundation for selecting appropriate hyperelastic models to accurately predict mechanical behavior in FDM-printed structures. Full article
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26 pages, 13505 KiB  
Article
In Situ Active Contour-Based Segmentation and Dimensional Analysis of Part Features in Additive Manufacturing
by Tushar Saini and Panos S. Shiakolas
J. Manuf. Mater. Process. 2025, 9(3), 102; https://doi.org/10.3390/jmmp9030102 - 19 Mar 2025
Viewed by 303
Abstract
The evaluation of the geometric conformity of in-layer features in Additive Manufacturing (AM) remains a challenge due to low contrast between the features and the background, textural variations, imaging artifacts, and lighting conditions. This research presents a novel in situ vision-based framework for [...] Read more.
The evaluation of the geometric conformity of in-layer features in Additive Manufacturing (AM) remains a challenge due to low contrast between the features and the background, textural variations, imaging artifacts, and lighting conditions. This research presents a novel in situ vision-based framework for AM to identify in real-time in-layer features and estimate their shape and printed dimensions and then compare them with the as-processed layer features to evaluate geometrical differences. The framework employs a composite approach to segment features by combining simple thresholding for external features with the Chan–Vese (C–V) active contour model to identify low-contrast internal features. The effect of varying C–V parameters on the segmentation output is also evaluated. The framework was evaluated on a 20.000 mm × 20.000 mm multilayer part with internal features (two circles and a rectangle) printed using Fused Deposition Modeling (FDM). The segmentation performance of the composite method was compared with traditional methods with the results showing the composite method scoring higher in most metrics, including a maximum Jaccard index of 78.34%, effectively segmenting high- and low-contrast features. The improved segmentation enabled the identification of feature geometric differences ranging from 1 to 10 pixels (0.025 mm to 0.250 mm) after printing each layer in situ and in real time. This performance verifies the ability of the framework to detect differences at the pixel level on the evaluation platform. The results demonstrate the potential of the framework to segment features under different contrast and texture conditions, ensure geometric conformity and make decisions on any differences in feature geometry and shape. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies: Materials, Processes, and Applications)
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14 pages, 7297 KiB  
Article
Cost-Effective Surface Quality Measurement and Advanced Data Analysis for Reamed Bores
by Thomas Jäkel, Sebastian Unsin, Benedikt Müller and Frank Schirmeier
J. Manuf. Mater. Process. 2025, 9(3), 99; https://doi.org/10.3390/jmmp9030099 - 18 Mar 2025
Viewed by 245
Abstract
This paper presents a cost-effective approach for automated surface quality measurement in reamed bores. The study involved drilling 4000 holes into 42CrMo S4V steel, of which 3600 underwent subsequent reaming. Utilizing a CNC-controlled gantry coupled with a mobile roughness measurement device through a [...] Read more.
This paper presents a cost-effective approach for automated surface quality measurement in reamed bores. The study involved drilling 4000 holes into 42CrMo S4V steel, of which 3600 underwent subsequent reaming. Utilizing a CNC-controlled gantry coupled with a mobile roughness measurement device through a compliant mechanism, surface data of every bore were efficiently gathered and processed. Additionally, analytical methods are presented that extend beyond standardized, aggregated metrics. We propose the evaluation of retraction grooves by using autocovariance. In addition, the correlation between the phase position of the waviness profile and the positional deviation of the bore is analyzed. The position deviation is also associated with bending moments that occur during reaming using a sensory tool holder. Furthermore, a 360-degree surface scan is presented to visually inspect the retraction groove. This approach aims to enhance understanding of the reaming process, ultimately improving bore quality, reducing component rejects, and extending tool lifespan. Full article
(This article belongs to the Topic Measurement Strategies and Standardization in Manufacturing)
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17 pages, 22554 KiB  
Article
Static and Fatigue Strength of Graphene Nanoplatelet-Reinforced AA6061-T6 Friction Stir Spot-Welded Lap Joints
by Amir Alkhafaji, Daniel Camas and Hayder Al-Asadi
J. Manuf. Mater. Process. 2025, 9(3), 98; https://doi.org/10.3390/jmmp9030098 - 18 Mar 2025
Viewed by 297
Abstract
Despite the significant economic and environmental advantages of friction stir spot welding (FSSW) and its amazing results in welding similar and dissimilar metals and alloys, some of which were known as unweldable, it has some structural and characteristic defects such as keyhole formation, [...] Read more.
Despite the significant economic and environmental advantages of friction stir spot welding (FSSW) and its amazing results in welding similar and dissimilar metals and alloys, some of which were known as unweldable, it has some structural and characteristic defects such as keyhole formation, hook defects, and bond line oxidation. This has prompted researchers to focus on these defects and propose and investigate techniques to treat or compensate for their deteriorating effects on microstructural and mechanical properties under different loading conditions. In this experimental study, sheets of AA6061-T6 aluminum alloy with a thickness of 1.8 mm were employed to investigate the influence of reinforcement by graphene nanoplatelets (GNPs) with lateral sizes of 1–10 µm and thicknesses of 3–9 nm on the static and fatigue behavior of FSSW lap joints. The welding process was carried out with constant, predetermined welding parameters and a constant amount of nanofiller throughout the experiment. Cross-sections of as-welded specimens were tested by optical microscope (OM) and energy-dispersive spectroscopy (EDS) to ensure the incorporation of the nanographene into the matrix of the base alloy by measuring the weight percentage (wt.%) of carbon. Microhardness and tensile tests revealed a significant improvement in both tensile shear strength and micro-Vickers hardness due to the reinforcement process. The fatigue behavior of the GNP-reinforced FSSW specimens was evaluated under low and high cycle fatigue conditions. The reinforcement process had a detrimental effect on the fatigue life of the joints under cyclic loading conditions. The microstructural analysis and examinations conducted during this study revealed that this reduction in fatigue strength is attributed to the agglomeration of GNPs at the grain boundaries of the aluminum matrix, leading to porosity in the stir zone (SZ), the formation of continuous brittle phases, and a transition in the fracture mechanism from ductile to brittle. The experimental results, including fracture modes, are presented and thoroughly discussed. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)
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24 pages, 14414 KiB  
Article
Feasibility Study on Laser Powder Bed Fusion of Ferritic Steel in High Vacuum Atmosphere
by Steffen Fritz, Sven Sewalski, Stefan Weihe and Martin Werz
J. Manuf. Mater. Process. 2025, 9(3), 101; https://doi.org/10.3390/jmmp9030101 - 18 Mar 2025
Viewed by 238
Abstract
The boiling point of metals is dependent on the ambient pressure. Therefore, in laser-based fusion welding and additive manufacturing processes, the resulting process regime, ranging from heat conduction welding to the keyhole mode, is also influenced by the process pressure. While laser welding [...] Read more.
The boiling point of metals is dependent on the ambient pressure. Therefore, in laser-based fusion welding and additive manufacturing processes, the resulting process regime, ranging from heat conduction welding to the keyhole mode, is also influenced by the process pressure. While laser welding deliberately uses reduced process pressures to achieve the keyhole mode with a lower laser power input as well as a more stable keyhole, there are no positive findings on the laser powder bed fusion process (PBF-LB/M) under vacuum conditions so far. Furthermore, the literature suggests that the process window is significantly reduced, particularly in the high vacuum regime. However, this work demonstrates that components made of the ferritic steel 22NiMoCr3-7 can be successfully manufactured at low process pressures of 2 × 10−2 mbar using a double-scanning strategy. The strategy consists of a first scan with a defocused laser beam, where the powder is preheated and partially sintered, followed by a second scan with a slightly defocused laser beam, in which the material within a single layer is completely melted. To test this manufacturing strategy, 16 test cubes were manufactured to determine the achievable relative densities and tensile specimens were produced to assess the mechanical properties. Metallographic analysis of the test cubes revealed that relative densities of up to 98.48 ± 1.43% were achieved in the test series with 16 different process parameters. The tensile strength determined ranged from 722 to 724 MPa. Additionally, a benchmark part with complex geometric features was successfully manufactured in a high vacuum atmosphere without the need for a complex parameterization of individual part zones in the scanning strategy. Full article
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16 pages, 14466 KiB  
Article
Integrated CAD/CAM Approach for Parametric Design and High-Precision Microfabrication of Planar Functional Structures Comprising Radially Oriented V-Grooves
by Jonas T. Churchill-Baird, O. Remus Tutunea-Fatan and Evgueni V. Bordatchev
J. Manuf. Mater. Process. 2025, 9(3), 100; https://doi.org/10.3390/jmmp9030100 - 18 Mar 2025
Viewed by 222
Abstract
High-precision microfabrication is essential for enhancing or enabling new functionalities in parts and tooling surfaces. V-groove structures are commonly used in surface engineering for diverse applications. Selecting the optimal V-groove shape, array, and fabrication method is crucial for achieving the desired performance. This [...] Read more.
High-precision microfabrication is essential for enhancing or enabling new functionalities in parts and tooling surfaces. V-groove structures are commonly used in surface engineering for diverse applications. Selecting the optimal V-groove shape, array, and fabrication method is crucial for achieving the desired performance. This study integrates the parametric definition of V-groove structures in both design and fabrication modules using three main function blocks (MFBs). MFB1 defines a single V-groove’s parametric model using specific input parameters. MFB2 transforms these parameters into equations to generate a CAD model of the surface. MFB3 combines inputs from MFB1 with parameters related to cutting tool geometry, cutting strategy, and process planning, producing functional NC code for the machine tool. The approach focuses on micromachining radial V-grooves on planar surfaces, requiring precise alignment and multi-axis single-point diamond cutting (SPDC) with rotation tool center point (RTCP) support. Testing on acrylic samples achieved ±0.1° orientation accuracy and ±2 μm positional accuracy, demonstrating potential for applications in drag reduction, fouling resistance, light guiding, and open microfluidics. Full article
(This article belongs to the Special Issue Advances in High-Performance Machining Operations)
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20 pages, 7384 KiB  
Article
Z-Stitching Technique for Improved Mechanical Performance in Fused Filament Fabrication
by Ahmed Elsherbiny, Abdullah Mohiuddin, Shirin Dehgahi, Pierre Mertiny and Ahmed Jawad Qureshi
J. Manuf. Mater. Process. 2025, 9(3), 97; https://doi.org/10.3390/jmmp9030097 - 17 Mar 2025
Viewed by 407
Abstract
Fused filament fabrication (FFF) is a widely used additive manufacturing technique that enables the rapid, layer-by-layer creation of parts. However, its traditional planar deposition approach can produce strong material anisotropy in terms of moduli and strengths, especially when fiber-reinforced polymers are processed. These [...] Read more.
Fused filament fabrication (FFF) is a widely used additive manufacturing technique that enables the rapid, layer-by-layer creation of parts. However, its traditional planar deposition approach can produce strong material anisotropy in terms of moduli and strengths, especially when fiber-reinforced polymers are processed. These characteristics limit the application of FFF in high-performance fields. This study introduces a novel FFF printing technique, termed z-stitching, which incorporates interlocking stitch patterns to enhance interlayer interaction and reduce anisotropy. A z-stitching algorithm was developed to explain the toolpath and material deposition. Using polymer filaments, samples employing the z-stitching technique were produced as a proof of concept. Moreover, experiments were conducted to explore the mechanical properties of samples made using z-stitching. Test results in terms of moduli and strengths in different principal material directions, as well as an isotropy ratio, were contrasted with the mechanical properties of samples made using traditional FFF. The experiments showed an overall enhanced mechanical performance of parts made using z-stitching. A printing time analysis was also performed, revealing that z-stitching printing time is approximately 14% longer than that of the comparable traditional FFF processes. This study establishes a foundation for the further optimization of z-stitching and its adoption in industrial-scale additive manufacturing for structures in high-performance applications. Full article
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21 pages, 21473 KiB  
Article
The Method for Fabricating Proppant and Cenosphere Sand-Based Casting Molds Involving the Use of Binder Jetting 3D Printing with Furan Binder and Impregnation with Colloidal Silica Binder
by Viacheslav E. Bazhenov, Ksenia A. Deputatova, Andrey A. Rizhsky, Yuri V. Tselovalnik, Andrey I. Bazlov, Stanislav V. Chernyshikhin, Andrey V. Koltygin, Alexey S. Anishchenko, Vladimir D. Belov and Evgenii Yu. Shchedrin
J. Manuf. Mater. Process. 2025, 9(3), 96; https://doi.org/10.3390/jmmp9030096 - 15 Mar 2025
Viewed by 464
Abstract
Binder jetting is the most widely implemented additive technology for the fabrication of sand molds. However, the use of furan binder-jetting technology in the production of molds for vacuum casting is hindered by the thermal destruction of the furan binder accompanied by violent [...] Read more.
Binder jetting is the most widely implemented additive technology for the fabrication of sand molds. However, the use of furan binder-jetting technology in the production of molds for vacuum casting is hindered by the thermal destruction of the furan binder accompanied by violent gas emission that occurs during the mold heating process. This investigation explores the potential of using the molds obtained via furan binder jetting 3D printing and further impregnation in colloidal silica binder and sintering. Two distinct sands, proppant and cenosphere, were utilized in the fabrication of the mold components exhibiting different thermal properties. An examination of the structure of the initial sands and samples produced via different impregnation and sintering regimes was conducted via scanning electron microscopy with energy dispersive X-ray spectroscopy, X-ray diffractometry, thermogravimetric analysis, and micro computed tomography. Furthermore, the bending mechanical properties and linear shrinkage of the samples were determined. The experimental findings demonstrated that the specific impregnation and sintering regimes examined in this study yielded sufficient mechanical properties for the casting molds and the structure with cristobalite bridges. The mold assembly, composed of proppant and cenosphere sands-based parts, was produced, and impeller nickel-based superalloy castings were fabricated. The findings of this study demonstrate that the utilization of a furan binder-jetting technique, in conjunction with impregnation in colloidal silica binder, is a promising technology for the manufacture of high-melting-temperature alloy casting. Full article
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21 pages, 4612 KiB  
Article
Improvement of Material Removal Rate and Within Wafer Non-Uniformity in Chemical Mechanical Polishing Using Computational Fluid Dynamic Modeling
by Hafiz M. Irfan, Cheng-Yu Lee, Debayan Mazumdar, Yashar Aryanfar and Wei Wu
J. Manuf. Mater. Process. 2025, 9(3), 95; https://doi.org/10.3390/jmmp9030095 - 14 Mar 2025
Cited by 1 | Viewed by 482
Abstract
Chemical mechanical polishing (CMP) is a widely used technique in semiconductor manufacturing to achieve a flat and smooth surface on silicon wafers. A key challenge in CMP is enhancing the material removal rate (MRR) while reducing within-wafer non-uniformity (WIWNU). A computational fluid dynamics [...] Read more.
Chemical mechanical polishing (CMP) is a widely used technique in semiconductor manufacturing to achieve a flat and smooth surface on silicon wafers. A key challenge in CMP is enhancing the material removal rate (MRR) while reducing within-wafer non-uniformity (WIWNU). A computational fluid dynamics (CFD) model is employed to analyze the slurry flow between the wafer and the polishing pad. Several factors influence the CMP process, including the type of abrasives, slurry flow rate, pad patterns, and contact pressure distribution. In this study, two polishing pad patterns with concentric and radial grooves are proposed to address how morphology variations influence wafer removal rate and consistency. Under the same operating conditions, the CFD simulations show that (i) the radial grooves have higher wall shear stress, a more significant negative pressure region, and a more evenly distributed mass on the wafer surface than the concentric grooves, and (ii) the radial grooves exhibit superior slurry mass distribution. It is noted that reducing the negative pressure differential field area results in a less pronounced back-mixing effect. A comparison of radial and concentric polishing pad grooves reveals that radial grooves improve slurry distribution, reduce the slurry saturation time (SST), and increase wall shear stress, leading to higher MRR and improved non-uniformity (NU). Precisely, the errors between the experimental SST values of 21.52 s and 16.06 s for concentric circular and radial groove pads, respectively, and the simulated SST values of 22.23 s and 15.73 s are minimal, at 3.33% and 3.35%. Full article
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24 pages, 6013 KiB  
Article
Detection of Release Fabric Defects in Fiber-Reinforced Composites Using Through-Transmission Ultrasound
by Gary LeMay and Enkhsaikhan Boldsaikhan
J. Manuf. Mater. Process. 2025, 9(3), 94; https://doi.org/10.3390/jmmp9030094 - 14 Mar 2025
Viewed by 401
Abstract
The detection of foreign material residues in fiber-reinforced composites (FRCs) is crucial, as such residues weaken the structural performance, especially when the acoustic impedance of the foreign material closely matches that of the composite material. To date, no methodology has been developed to [...] Read more.
The detection of foreign material residues in fiber-reinforced composites (FRCs) is crucial, as such residues weaken the structural performance, especially when the acoustic impedance of the foreign material closely matches that of the composite material. To date, no methodology has been developed to improve the detection of such defects with similar acoustic impedance in the received signal without using echo-mode techniques. Release fabric was chosen because it is used in the fabrication of FRCs as a consumable, which must be removed after curing. An accidental residue of release fabric presents a significant challenge in detecting it within FRC laminates using through-transmission ultrasound (TTU) since its acoustic properties closely resemble the surrounding composite material, resulting in minimal impact on the transmitted signal and preventing accurate defect detection due to the lack of time-of-flight measurements. This paper leverages a novel threshold classifier to improve the detection of release fabric with through-transmission ultrasound (TTU), an inspection technique that operates without echo mode. Ultimately, this novel threshold classifier improves TTU inspection by offering greater sensitivity and detectability compared to conventional attenuation-based methods, particularly in the absence of echo mode and time-of-flight measurements. Future research will aim to investigate additional physical factors and deep learning approaches to further advance the TTU inspection method. Full article
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16 pages, 5148 KiB  
Article
Influence of Interlayer Temperature and Deposition Method on the Wall Geometry and Vickers Microhardness Profile of ER70S-6 Parts Manufactured by Additive Manufacturing Using CMT
by André Luis Silva da Costa, Raphael Lima de Paiva, Déborah de Oliveira and Maksym Ziberov
J. Manuf. Mater. Process. 2025, 9(3), 93; https://doi.org/10.3390/jmmp9030093 - 14 Mar 2025
Cited by 1 | Viewed by 428
Abstract
Wire and arc additive manufacturing (WAAM) stands out from other deposition techniques for being able to produce bigger parts and with higher deposition rates. However, due to the high thermal input, it is necessary to carefully select the deposition strategy and parameters to [...] Read more.
Wire and arc additive manufacturing (WAAM) stands out from other deposition techniques for being able to produce bigger parts and with higher deposition rates. However, due to the high thermal input, it is necessary to carefully select the deposition strategy and parameters to achieve good geometry, low defects and adequate mechanical properties. As a recent technology, different studies have been developed comprehending the deposition approach, aiming to achieve parts with specific characteristics, usually evaluating the geometry, microstructure and mechanical properties, such as yield and tensile strengths, residual stresses and microhardness; however, the last is usually presented by mean values, requiring more details to comprehend its behavior further. In this sense, this work aims to evaluate the microhardness variation on walls of ER70S-6 deposited by WAAM-CMT in detail, with different deposition strategies, unidirectional and bidirectional, and with and without interlayer temperature control. The wall’s geometry was also assessed in terms of height and width. The results showed that both bidirectional deposition and temperature control contributed to improving the wall’s geometry. Combining methods led to a 26% increase in the wall width and 9% in the height; combining both methods also led to a more homogeneous distribution of microhardness throughout the wall with less than 15 HV variation. For all the deposition strategies, the wall region influenced the microhardness, and relatively higher values were obtained on the upper region of the wall, followed by the central and lower regions. Full article
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26 pages, 7284 KiB  
Article
Prediction and Modelling with Taguchi, ANN and ANFIS of Optimum Machining Parameters in Drilling of Al 6082-T6 Alloy
by İbrahim Turan, Barış Özlü, Hasan Basri Ulaş and Halil Demir
J. Manuf. Mater. Process. 2025, 9(3), 92; https://doi.org/10.3390/jmmp9030092 - 13 Mar 2025
Viewed by 1471
Abstract
In this study, the drilling of an Al 6082-T6 alloy and the effects of cutting tool coating and cutting parameters on surface roughness, cutting temperature, hole diameter, circularity, and cylindrical variations was investigated. In addition, the prediction accuracy of Taguchi, artificial neural networks [...] Read more.
In this study, the drilling of an Al 6082-T6 alloy and the effects of cutting tool coating and cutting parameters on surface roughness, cutting temperature, hole diameter, circularity, and cylindrical variations was investigated. In addition, the prediction accuracy of Taguchi, artificial neural networks (ANNs), and adaptive neuro-fuzzy inference system (ANFIS) methods was compared using both experimental results and Signal/Noise (S/N) ratios derived from the experimental results. The experimental design was prepared according to Taguchi L27 orthogonal indexing. As a result, it was observed that increasing the cutting speed and feed rate increases the cutting temperature hole error, circularity error and cylindricity error. Increasing the cutting speed positively affected the surface roughness, while increasing the feed rate led to an increase in the surface roughness. The lowest surface roughness, cutting temperature, hole diameter error and hole circularity error values were measured for the uncoated cutting tool. The minimum cylindricity variation was measured for drilling with TiAlN-coated cutting tools. The optimum cutting parameters were A1B1C3 (Uncoated, 0.11 mm/rev, 200 m/min) for surface roughness, A1B1C1 (Uncoated, 0.11 mm/rev, 120 m/min) for cutting temperature, hole error, circularity error and cylindricity error. In the estimation of the output parameters with Taguchi, ANNs and ANFIS, it was observed that the estimates made by converting the experimental values into S/N ratios were more accurate than the estimates made with the experimental results. The reliability coefficient and prediction ability of the ANN model were found to be higher than Taguchi and ANFIS models in estimating the output parameters. Full article
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17 pages, 4177 KiB  
Article
Method for Quantifying the Criticality of Laser Cutting Defects: Influence of Morphologies on Design Parameters
by Maria Ramard, Romain Laniel, Mathieu Miroir and Olivier Kerbrat
J. Manuf. Mater. Process. 2025, 9(3), 91; https://doi.org/10.3390/jmmp9030091 - 13 Mar 2025
Viewed by 414
Abstract
Laser cutting is an established, multi-physical process widely adopted by the metallurgical industry. However, this fast industrialisation has had a significant impact on quality control. Reviews from 2008 to 2022 primarily focus on single-criterion quality approaches, targeting defects like the Heat-Affected Zone, surface [...] Read more.
Laser cutting is an established, multi-physical process widely adopted by the metallurgical industry. However, this fast industrialisation has had a significant impact on quality control. Reviews from 2008 to 2022 primarily focus on single-criterion quality approaches, targeting defects like the Heat-Affected Zone, surface roughness, or kerf geometry, rather than adopting comprehensive methods. In addition, these studies show that cutting quality can be improved by selecting laser manufacturing parameters and part parameters such as thickness or material. However, the influence of part morphology remains underexplored. Following this observation, this study proposes a generic and complete method adapted from the Failure Modes, Effects and Criticality Analysis, allowing the evaluation of the criticality of all cutting defects in a part. It focuses on six laser cutting defects defined in an international standard and three types of morphology: arcs, angles and segments. The aim is to establish a holistic approach linking morphologies to all defect types. Industrial application reveals that thermal defects are highly influenced by morphology. Burrs and adherent slag are particularly critical in arcs and angles, while segments are less sensitive. This analysis establishes design limits and offers practical tools to improve industrial laser cutting through detailed quality assessments. Full article
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23 pages, 10666 KiB  
Article
Weldability Assessment of Austenitic/Ferritic Clad Plates Joined by a Combined Laser Beam–Electric Arc Process
by Girolamo Costanza, Fabio Giudice, Severino Missori, Cristina Scolaro, Andrea Sili and Maria Elisa Tata
J. Manuf. Mater. Process. 2025, 9(3), 90; https://doi.org/10.3390/jmmp9030090 - 11 Mar 2025
Viewed by 584
Abstract
The combined use of laser beam and electric arc for welding thick clad steel plates in a single pass has been developed to solve the issues concerning the individual applications of the heat sources, such as the low filling efficiency of conventional electric [...] Read more.
The combined use of laser beam and electric arc for welding thick clad steel plates in a single pass has been developed to solve the issues concerning the individual applications of the heat sources, such as the low filling efficiency of conventional electric arc methods and the drawbacks concerning laser beam defects due to rapid cooling and solidification. This work was addressed to the weldability assessment of ferritic steel plates, clad with austenitic stainless steel, under the laser-leading configuration, testing the effects of two different values of the inter-distance between the laser beam and the electric arc. Specimens of the welded zone were investigated by metallographic observations and EDS measurements; mechanical properties were characterized by the Vickers microhardness test and by the FIMEC instrumented indentation test to obtain the local values of the yield strength. Welding simulations by theoretical modelling were also carried out to outline the differences in the thermal fields generated by the two heat sources, their interaction, and their effect on the configurations of the weld pool and the thermal profiles to which the materials are subjected. The welding setup with higher inter-distance was more suitable for joining clad steel plates, since the action of the deep keyhole mode is substantially separated from that of the shallower electric arc. In this way, the addition of alloying elements, performed by melting the filler wire, concentrated in the cladding layer, helping maintain the austenitic microstructure, while the laser beam acts in depth along the thickness, autogenously welding the base steel. Full article
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13 pages, 4204 KiB  
Article
Use of Biobased Resins Derived from Renewable Monomers for Sustainable 3D Fabrication Through Two-Photon Polymerization
by Francisco Gontad, Jaime Cuartero, Sara Vidal, Nerea Otero, Natalia M. Schulz and Tobias Robert
J. Manuf. Mater. Process. 2025, 9(3), 89; https://doi.org/10.3390/jmmp9030089 - 10 Mar 2025
Viewed by 496
Abstract
This work demonstrates the fabrication of microstructures with formulations containing bio-based prepolymers derived from itaconic acid, commercial reactive diluents, photo initiators, and inhibitors, through two-photon polymerization. Lateral and vertical resolutions within the micron range can be achieved by the adjustment of laser scanning [...] Read more.
This work demonstrates the fabrication of microstructures with formulations containing bio-based prepolymers derived from itaconic acid, commercial reactive diluents, photo initiators, and inhibitors, through two-photon polymerization. Lateral and vertical resolutions within the micron range can be achieved by the adjustment of laser scanning speed and pulse energy, and through the use of microscope objectives with high magnification and numerical aperture. The fabrication throughput can be slightly increased by simultaneously increasing the laser pulse energy and scanning speed, with special care to keep the resolution of the features that can be written via two-photon polymerization. Feasibility for the fabrication of 3D microstructures is demonstrated, through the fabrication of benchmark structures like woodpiles and pyramidal structures. Thus, this work proves that resins based on biobased formulations, originally designed for UV-curing 3D printing, can be adapted for two-photon polymerization, obtaining 3D microstructures with resolutions within the micron range. Full article
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14 pages, 68479 KiB  
Article
Design Guide for Hybrid-Additive Manufacturing of Inconel 718 Combining PBF-LB/M and In Situ High-Speed Milling
by David Sommer, Simon Hornung, Cemal Esen and Ralf Hellmann
J. Manuf. Mater. Process. 2025, 9(3), 88; https://doi.org/10.3390/jmmp9030088 - 10 Mar 2025
Viewed by 549
Abstract
As the correlation between design rules and process limitations is of the upmost importance for the full exploitation of any manufacturing technology, we report a design guide for hybrid-additive manufacturing of Inconel 718. Basic limitations need to be evaluated for this particular hybrid [...] Read more.
As the correlation between design rules and process limitations is of the upmost importance for the full exploitation of any manufacturing technology, we report a design guide for hybrid-additive manufacturing of Inconel 718. Basic limitations need to be evaluated for this particular hybrid approach that combines laser powder bed fusion (PBF-LB/M) and in situ high-speed milling. Fundamental geometric limitations are examined with regard to the minimum feasible wall thickness, cylinders, overhanging structures, and chamfers. Furthermore, geometrical restrictions due to the integrated three-axis milling process with respect to inclinations, inner angles, notches, and boreholes are investigated. From these findings, we derive design guidelines for a reliable build process using this hybrid manufacturing. Additionally, a design guideline for the hybrid-additive manufacturing approach is presented, depicting a step-to-step guide for the adjustment of constructions. To demonstrate this, a powder nozzle for a direct energy deposition (DED-LB/M) process is redesigned following the previously defined guidelines. This redesign encompasses analysis of the existing component and identification of problematic areas such as flat angles, leading to a new construction that is suitable for a hybrid-additive manufacturing approach. Full article
(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)
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16 pages, 51289 KiB  
Article
Characterization and Modelling of Biomimetic Bone Through Additive Manufacturing
by Niranjan Srinivasan, Mohsen Barmouz and Bahman Azarhoushang
J. Manuf. Mater. Process. 2025, 9(3), 87; https://doi.org/10.3390/jmmp9030087 - 10 Mar 2025
Viewed by 464
Abstract
The long-term success of bone implant scaffolds depends on numerous factors, such as their porosity, mechanical properties, and biocompatibility. These properties depend on the type of material, such as metals and their alloys or ceramics, and the procedure used to create the scaffolds. [...] Read more.
The long-term success of bone implant scaffolds depends on numerous factors, such as their porosity, mechanical properties, and biocompatibility. These properties depend on the type of material, such as metals and their alloys or ceramics, and the procedure used to create the scaffolds. This study aims to find the biomimetic properties of aluminum 6061 (Al 6061) alloy through Digital Light Processing (DLP) and sintering. Hollow cylindrical Al 6061 samples are printed through the DLP process at 90, 110, and 130 Wt.% aluminum powder concentrations inside a photocurable resin. The ideal temperature at which the material is sintered is 550 °C for 130 and 110 Wt.% and 530 °C for 90 Wt.%. The overall pore size ranges in the Al 6061 of these three concentrations from 30 μm to 700 μm. The compression test revealed the materials’ Ultimate Tensile Strengths (UTSs) to be 1.72, 2.2, and 1.78 MPa for the 90, 110, and 130 Wt.% materials, respectively. A simulation of the Al 6061 material as linear isotropic resulted in the UTS being 2.2 MPa. This novel hybrid of the additive manufacturing method and sintering created a scaffold model with anisotropic properties closer to trabecular bone, which could be used to observe fracture progression and could be tested for implant capabilities. Full article
(This article belongs to the Special Issue Emerging Methods in Digital Manufacturing)
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15 pages, 11290 KiB  
Article
Prediction of Residual Stresses During the Hot Forging Process of Spherical Shells Based on Microstructural Evolution
by Yupeng Wu, Jiasheng Li, Zhaocheng Wei, Yuxin Fang, Hongxia Li and Ming Huang
J. Manuf. Mater. Process. 2025, 9(3), 86; https://doi.org/10.3390/jmmp9030086 - 10 Mar 2025
Viewed by 397
Abstract
A unified viscoplastic constitutive model based on internal physical variables was proposed to predict the viscoplastic mechanical behavior and microstructure evolution of metals during hot forging. Based on the phase transformation theory of materials under the effect of temperature, the evolution mechanism of [...] Read more.
A unified viscoplastic constitutive model based on internal physical variables was proposed to predict the viscoplastic mechanical behavior and microstructure evolution of metals during hot forging. Based on the phase transformation theory of materials under the effect of temperature, the evolution mechanism of residual stress during the cooling process after hot forging and stamping was explored. The determined unified viscoplastic constitutive equation was written in the VUMAT subroutine and employed for the explicit FE analysis of the hot forging and stamping process of thin-walled spherical shells. In the data transfer process, the stress field, temperature field, and deformation characteristics calculated during the high-temperature transient of the hot forging and stamping process were inherited. Meanwhile, the thermoplastic constitutive equation considering the influence of phase transformation was written in the UMAT subroutine and utilized for the implicit FE analysis of the cooling process of thin-walled spherical shells. Through comparison with the measured stress results of the spherical shells after actual forging, it was shown that the proposed constitutive model can effectively predict the microstructural evolution and the final residual stress distribution pattern of medium-carbon steel during the hot forging process. Full article
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17 pages, 4994 KiB  
Article
Basic Properties of High-Dynamic Beam Shaping with Coherent Combining of High-Power Laser Beams for Materials Processing
by Rudolf Weber, Jonas Wagner, Alexander Peter, Christian Hagenlocher, Ami Spira, Benayahu Urbach, Eyal Shekel and Yaniv Vidne
J. Manuf. Mater. Process. 2025, 9(3), 85; https://doi.org/10.3390/jmmp9030085 - 6 Mar 2025
Viewed by 943
Abstract
Lasers with average powers of several kilowatts have become an important tool for industrial applications. Temporal and spatial beam shaping was demonstrated to improve existing and enable novel applications. A very promising technology for both highly dynamic beam shaping and power scaling is [...] Read more.
Lasers with average powers of several kilowatts have become an important tool for industrial applications. Temporal and spatial beam shaping was demonstrated to improve existing and enable novel applications. A very promising technology for both highly dynamic beam shaping and power scaling is the coherent combining of the beams of an array of high-power fundamental mode fibers. However, the limited number of fibers allows only limited spatial resolution of the common phase front. It is therefore favorable to work with plane or spherical common phase fronts, which generate a “point”, i.e., a diffraction pattern with a strong main lobe in the focal plane. By applying a tilt to the common phase front, points can be positioned in the focal plane with high spatial resolution. The Civan DBL 6–14 kW investigated in this work allows switching between positions of the points with 80 MHz. Sequences of points can be used to create arbitrary shapes. The time constants of points and shapes are very critical for this type of shape generation. The current paper analyzes the relevant time constants for setting points and creating shapes and relates them to time constants in laser processes. This is mandatory to deterministically influence laser processes. Full article
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24 pages, 2282 KiB  
Review
In-Space Manufacturing: Technologies, Challenges, and Future Horizons
by Subin Antony Jose, Jordan Jackson, Jayden Foster, Terrence Silva, Ethan Markham and Pradeep L. Menezes
J. Manuf. Mater. Process. 2025, 9(3), 84; https://doi.org/10.3390/jmmp9030084 - 5 Mar 2025
Viewed by 1407
Abstract
In-space manufacturing represents a transformative frontier in space exploration and industrial production, offering the potential to revolutionize how goods are produced and resources are utilized beyond Earth. This paper explores the multifaceted aspects of in-space manufacturing, including its evolution, technologies, challenges, and future [...] Read more.
In-space manufacturing represents a transformative frontier in space exploration and industrial production, offering the potential to revolutionize how goods are produced and resources are utilized beyond Earth. This paper explores the multifaceted aspects of in-space manufacturing, including its evolution, technologies, challenges, and future prospects, while also addressing ethical and legal dimensions critical to its development. Beginning with an overview of its significance and historical context, this paper underscores key concepts such as resource optimization and the reduction of launch costs. It examines terrestrial and space-based manufacturing processes, emphasizing additive manufacturing, advanced materials processing, autonomous robotic systems, and biomanufacturing for pharmaceuticals. Unique challenges posed by the space environment, such as microgravity, vacuum conditions, and radiation exposure, are analyzed alongside issues related to supply chains, quality assurance, and energy management. Drawing from case studies, including missions aboard the International Space Station, this paper evaluates the lessons learned over six decades of innovation in in-space manufacturing. It further explores the potential for large-scale production to support deep-space missions and assesses the commercial and economic feasibility of these technologies. This paper also delves into the policy, legal, and ethical considerations to address as space-based manufacturing becomes integral to future space exploration and the global space economy. Ultimately, this work provides a comprehensive roadmap for advancing in-space manufacturing technologies and integrating them into humanity’s pursuit of sustainable and scalable space exploration. Full article
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15 pages, 3667 KiB  
Article
Mechanical Behavior of SLS-Printed Parts and Their Structural Simulation
by Tamara van Roo and Conor Jörg Mager
J. Manuf. Mater. Process. 2025, 9(3), 83; https://doi.org/10.3390/jmmp9030083 - 5 Mar 2025
Viewed by 434
Abstract
This study aims to assess the mechanical tensile properties of Polyamide produced via selective laser sintering (SLS). The research focuses on the effects of post-processing, positional dependency, anisotropy, and the repeatability of SLS print jobs on material properties. Understanding this anisotropy is crucial [...] Read more.
This study aims to assess the mechanical tensile properties of Polyamide produced via selective laser sintering (SLS). The research focuses on the effects of post-processing, positional dependency, anisotropy, and the repeatability of SLS print jobs on material properties. Understanding this anisotropy is crucial for reliable component simulation. A design-appropriate simulation method is developed. A total of 27 identical specimens were fabricated in various orientations and positions within the build chamber, repeated across three print jobs, alongside standard specimens for different post-processing treatments and tempering durations. The mechanical tensile properties were evaluated through tensile tests and compared with simulation outcomes. A new material modeling concept was formulated in the finite element (FE) program ANSYS, employing an orthotropic approach based on linear elastic initial deformation. The Hill Yield Criterion was utilized to model the transition to the plastic region, characterized by a nonlinear strain hardening curve. The print direction was integrated into the FE simulation mesh via a local material coordinate system. Surface treatment via glass bead blasting resulted in slight increases in mechanical response, while tempering had a minor influence. Significant anisotropy was observed, with only the z-position in the build chamber affecting mechanical properties. Successful mapping of anisotropy in structural simulations was achieved. This research did not address optimization of the printing process, recyclate effects, powder aging, or fatigue. The findings provide a comprehensive analysis of the mechanical behavior of SLS-printed specimens, serving as a foundation for treatment methodologies and simulation strategy development. Full article
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19 pages, 6532 KiB  
Article
Effect of T6 Tempering on the Wear and Corrosive Properties of Graphene and B4C Reinforced Al6061 Matrix Composites
by Bharathiraja Parasuraman and Anthony Xavior Michael
J. Manuf. Mater. Process. 2025, 9(3), 82; https://doi.org/10.3390/jmmp9030082 - 5 Mar 2025
Viewed by 625
Abstract
This research study aims to evaluate the wear and corrosive behaviour of aluminum 6061 alloy hybrid metal matrix composites after reinforcing them with graphene (0.5, 1 wt.%) and boron carbide (6 wt.%) at varying weight percentages. The hybrid composites were processed through ball [...] Read more.
This research study aims to evaluate the wear and corrosive behaviour of aluminum 6061 alloy hybrid metal matrix composites after reinforcing them with graphene (0.5, 1 wt.%) and boron carbide (6 wt.%) at varying weight percentages. The hybrid composites were processed through ball milling and powder compaction, followed by a microwave sintering process, and T6 temper heat treatment was carried out to improve the properties. The properties were evaluated and analyzed using FE-SEM, Pin-on-Disc tribometer, surface roughness, salt spray test, and electrochemical tests. The results were evaluated prior to and subsequent to the T6 heat-treatment conditions. The T6 tempered sample S1 (Al6061-0.5% Gr-6% B4C) exhibits a wear rate of 0.00107 mm3/Nm at 10 N and 0.00127 mm3/Nm at 20 N for 0.5 m/s sliding velocity. When the sliding velocity is 1 m/s, the wear rate is 0.00137 mm3/Nm at 10 N and 0.00187 mm3/Nm at 20 N load conditions. From the Tafel polarization results, the as-fabricated (F) condition demonstrates an Ecorr of −0.789 and an Icorr of 3.592 µA/cm2 and a corrosion rate of 0.039 mm/year. Transitioning to the T6 condition further decreases Icorr to 2.514 µA/cm2, Ecorr value of −0.814, and the corrosion rate to 0.027 mm/year. The results show that an increase in the addition of graphene wt.% from 0.5 to 1 to the Al 6061 alloy matrix deteriorated the wear and corrosive properties of the hybrid matrix composites. Full article
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20 pages, 6813 KiB  
Article
Fatigue Enhancement Mechanism and Process Optimization of the Direct Mandrel Cold Expansion Technique on Lightweight and High-Strength Alloys
by Hansong Ji, Kanghua Huang, Li He, Zefeng Chen, Mingjun Tang, Pingfa Feng and Jianfu Zhang
J. Manuf. Mater. Process. 2025, 9(3), 81; https://doi.org/10.3390/jmmp9030081 - 3 Mar 2025
Viewed by 537
Abstract
Lightweight and high-strength alloys such as Al and Ti alloys are commonly employed materials for aviation structural components. A “hole-fastener” is commonly used for their connection, and DMCE (direct mandrel cold expansion) is a reliable technique in industries to enhance the fatigue properties [...] Read more.
Lightweight and high-strength alloys such as Al and Ti alloys are commonly employed materials for aviation structural components. A “hole-fastener” is commonly used for their connection, and DMCE (direct mandrel cold expansion) is a reliable technique in industries to enhance the fatigue properties of hole-involved components due to its advantages, i.e., convenient, efficient and cost-effective. However, an inadequate understanding of the DMCE process leads to a vast amount of waste in industries when any materials or structural parameters are changed. In order to promote the application efficiency of the DMCE process in aviation industries and reduce the energy and resource waste caused by repeated attempts, taking Al7050 and TB6 as examples, this paper comprehensively investigates the fatigue enhancement mechanism of the DMCE process on lightweight and high-strength alloys. Numerical models with 12.9%, 36.9% residual stress prediction errors and 9.98%, 14.8% radial plastic deformation prediction errors for Al and Ti holes were established, and then simulations were performed to screen out five significant influence parameters from eleven independent parameters. On this basis, DMCE experiments with significant parameters were carried out, and the improvement mechanisms of the DMCE process on the tangential residual stress, radial plastic deformation and surface morphology of Al and Ti hole walls were comparatively analyzed. Furthermore, fatigue life prediction models for two-hole-involved specimens were generated via multiple linear regression, which exhibit, respectively, 13.5% and 33.9% mean prediction errors for Al and Ti alloys. Moreover, the optimal DMCE schemes were obtained and 2.33 and 4.12 times fatigue lifetime improvements were achieved for the Al and the Ti specimens. Full article
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12 pages, 5401 KiB  
Article
Comparison of 2D and 3D Surface Roughness Parameters of AlMgSi0.5 Aluminium Alloy Surfaces Machined by Abrasive Waterjet
by Csaba Felhő, Krisztina Kun-Bodnár and Zsolt Maros
J. Manuf. Mater. Process. 2025, 9(3), 80; https://doi.org/10.3390/jmmp9030080 - 2 Mar 2025
Viewed by 485
Abstract
The use of 3D roughness parameters is increasingly gaining ground in various areas of engineering, especially in academic research. In many cases, however, these studies primarily cover the illustration of the character of the surfaces, the interpretation of areal numerical roughness values is [...] Read more.
The use of 3D roughness parameters is increasingly gaining ground in various areas of engineering, especially in academic research. In many cases, however, these studies primarily cover the illustration of the character of the surfaces, the interpretation of areal numerical roughness values is often disputed. The goal of this paper is to examine how the 2D and 3D roughness parameters change in the case of anisotropic surfaces, such as surfaces cut with an abrasive water jet. For this purpose, abrasive water jet cutting experiments were performed on AlMgSi0.5 aluminum alloy using different technological parameters. After the experiments, two amplitude-type 3D roughness parameters (Sa and Sz) of the cut surface and four profile parameters (Ra, Rz for roughness and Pa, Pz for raw profile) were measured at five different depths. Our conducted research indicates that the 3D parameters represent a kind of average value for certain roughness characteristics and a maximum value for others. The paper also reports on how these roughness characteristics change as a function of feed speed. Full article
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31 pages, 6044 KiB  
Article
Transforming Manufacturing Quality Management with Cognitive Twins: A Data-Driven, Predictive Approach to Real-Time Optimization of Quality
by Asif Ullah, Muhammad Younas and Mohd Shahneel Saharudin
J. Manuf. Mater. Process. 2025, 9(3), 79; https://doi.org/10.3390/jmmp9030079 - 28 Feb 2025
Viewed by 673
Abstract
In the ever-changing world of modern manufacturing, maintaining product quality is of great importance, yet extremely difficult due to complexities and the dynamic production paradigm. Currently, quality is rather reactively measured through periodic inspections and manual assessments. Traditional quality management systems (QMS), through [...] Read more.
In the ever-changing world of modern manufacturing, maintaining product quality is of great importance, yet extremely difficult due to complexities and the dynamic production paradigm. Currently, quality is rather reactively measured through periodic inspections and manual assessments. Traditional quality management systems (QMS), through these reactive measures, are often inefficient because of their higher operational cost and delayed defect detection and mitigation. The paper introduces a novel cognitive twin (CT) framework, which is the next evolved version of digital twin (DT). It is designed to advance the current quality management in flexible manufacturing systems (FMSs) through real-time, data-driven, and predictive optimization. This proposed framework uses four data types, namely feedstock quality (Qf), machine degradation (Qm), product processing quality (Qp), and quality inspection (Qi). By utilizing the power of machine learning algorithms, the cognitive twin constantly monitors and then analyzes real-time data. The cognitive twin optimizes the above quality components. This enables a very proactive decision making through an augmented reality (AR) interface by providing real-time visual insights and alerts to the operators. Thorough experimentation was conducted on the aforementioned FMS. Through the experiments, it was revealed that the proposed cognitive twin outperforms conventional QMSs by a great margin. The cognitive twin achieved a 2% improvement in the total quality scores. A 60% decrease in defects per unit (DPU) is observed as well as a sharp 40% decrease in scrap rate. Furthermore, the overall equipment efficiency (OEE) increased to 93–96%. The overall equipment efficiency increased by 11.8%, on average, from 82% to 93%, and the scrap rate decreased by 33.3% from 60% to 40%. The excellent results showcase the effectiveness of cognitive twin quality management via minimum wastage, continuous quality improvement, and enhancement in operational efficiency in the paradigm of smart manufacturing. This research study contributes to the field of industry 4.0 by providing a comprehensive, scalable, and adaptive quality management solution, thus leading the way for further advancements in intelligent manufacturing systems. Full article
(This article belongs to the Special Issue Smart Manufacturing in the Era of Industry 4.0)
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19 pages, 5484 KiB  
Article
Effects of Scanning Strategies, Part Orientation, and Hatching Distance on the Porosity and Hardness of AlSi10Mg Parts Produced by Laser Powder Bed Fusion
by Naol Dessalegn Dejene, Wakshum Mekonnen Tucho and Hirpa G. Lemu
J. Manuf. Mater. Process. 2025, 9(3), 78; https://doi.org/10.3390/jmmp9030078 - 27 Feb 2025
Cited by 1 | Viewed by 682
Abstract
Laser powder bed fusion (L-PBF) shows potential in metal additive manufacturing for producing complex components. However, achieving ideal hardness and minimizing porosity poses a significant challenge. This study explores the impact of part orientation, scanning methods, and hatching distance on the hardness and [...] Read more.
Laser powder bed fusion (L-PBF) shows potential in metal additive manufacturing for producing complex components. However, achieving ideal hardness and minimizing porosity poses a significant challenge. This study explores the impact of part orientation, scanning methods, and hatching distance on the hardness and porosity of AlSi10Mg alloy produced through L-PBF. Utilizing a Box–Behnken design of experiments (DOE), cubic samples were systematically produced. Hardness was quantitatively assessed using Vickers hardness tests, while porosity measurements involved 2D image analysis of polished scanning electron microscopy (SEM) samples, the porosity percentages analyzed using ImageJ software. The results demonstrate that both scanning strategy and hatching distance significantly influence hardness and porosity. The spiral scanning pattern notably enhances hardness and reduces porosity. In contrast, the bidirectional scanning strategy results in lower hardness and more pronounced porosity formations. An inverse correlation between grain size distribution and hardness was observed, with finer grain sizes leading to higher hardness values, indicating that grain refinement improves mechanical properties. Additionally, a negative relationship between hardness and porosity was established, emphasizing the importance of minimizing porosity to enhance material hardness. These findings contribute to the overall understanding of the L-PBF additive manufacturing process, providing valuable insights for optimizing material properties and ensuring the mechanical integrity of high-performance L-PBF produced metal parts. Full article
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16 pages, 11669 KiB  
Article
Deposition Strategies for Bar Intersections Using Dot-by-Dot Wire and Arc Additive Manufacturing
by Niccolò Grossi, Flavio Lazzeri and Giuseppe Venturini
J. Manuf. Mater. Process. 2025, 9(3), 77; https://doi.org/10.3390/jmmp9030077 - 27 Feb 2025
Cited by 1 | Viewed by 383
Abstract
Dot-by-dot Wire and Arc Additive Manufacturing (WAAM) is a promising technique for producing large-scale lattice structures, offering significant benefits in terms of deposition rate and material utilization. This study explores strategies for fabricating bar intersections using the dot-by-dot WAAM technology, focusing on creating [...] Read more.
Dot-by-dot Wire and Arc Additive Manufacturing (WAAM) is a promising technique for producing large-scale lattice structures, offering significant benefits in terms of deposition rate and material utilization. This study explores strategies for fabricating bar intersections using the dot-by-dot WAAM technology, focusing on creating robust and predictable structures without requiring parameter modifications or real-time monitoring during the deposition. Two different deposition strategies were proposed, that can be, at least geometrically, applied to a general intersection with multiple bars with different angles. In this work such strategies were only experimentally tested on two-bar intersections, assessing their performance in terms of geometrical accuracy, symmetry, and material efficiency. Strategies which utilize layer-by-layer deposition with multiple overlapping dots, called B here, demonstrated the best results in terms of the geometrical features in the intersection zone, assessed by different metrics obtained through an analysis of pictures, such as low asymmetry and high material volume in the intersection zone. In addition, the findings suggest that removing cooling pauses during the deposition of multiple dots on the same layer slightly improves the joint by minimizing excess material buildup. The proposed approach offers a scalable framework for optimizing intersection deposition, paving the way for improved large-scale metal lattice structure manufacturing. Full article
(This article belongs to the Special Issue Large-Scale Metal Additive Manufacturing)
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15 pages, 2256 KiB  
Article
Influence of Grinding Parameters on the Removal Depth of 42CrMo Steel and Its Prediction in Robot Electro-Hydraulic-Actuated Abrasive Belt Grinding
by Dequan Shi, Youen Xu, Xuhui Wang and Huajun Zhang
J. Manuf. Mater. Process. 2025, 9(3), 76; https://doi.org/10.3390/jmmp9030076 - 27 Feb 2025
Viewed by 414
Abstract
Robotic grinding serves as a pivotal embodiment and key technological support of Industry 4.0. Elucidating the influence of robotic grinding parameters on the material removal depth (MRD) of 42CrMo steel and optimizing these parameters are critical to enhancing grinding efficiency and quality. In [...] Read more.
Robotic grinding serves as a pivotal embodiment and key technological support of Industry 4.0. Elucidating the influence of robotic grinding parameters on the material removal depth (MRD) of 42CrMo steel and optimizing these parameters are critical to enhancing grinding efficiency and quality. In this study, the influences of revolution speed, feed speed, grinding force, and grit designation on MRD and surface Vickers hardness of 42CrMo steel were investigated by using an adaptive electro-hydraulic-actuated triangular abrasive belt in robot grinding. A predictive model for MRD of 42CrMo steel has been established using the orthogonal central composite design method. The results indicated that as the revolution speed or grinding increases, both MRD and surface hardness increase. However, as the revolution speed surpasses 4000 RPM or the grinding force exceeds 60 N, the increase of MRD becomes slower due to the increase in surface hardness. Both the MRD and surface hardness decrease continuously as the feed speed increases, and once it exceeds 15 mm·s−1, the decrease of the MRD becomes slow. The rise in grit designation of the abrasive belt makes the MRD reduce gradually while the surface hardness rises slightly. The correlation coefficient of the predictive model is 0.9387, and the relative error between the predicted and experimental MRD is within 10%, indicating a relatively high accuracy. At the optimal grinding parameters (grinding force of 81 N, revolution speed of 4739 RPM, and feed speed of 7.6 mm·s−1), the maximum MRD of 42CrMo steel achieved by an abrasive belt of 60 grit designation is 0.934 mm. This work provides a basis for high-precision robot abrasive belt grinding of 42CrMo steel. Full article
(This article belongs to the Special Issue Industry 4.0: Manufacturing and Materials Processing)
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15 pages, 4385 KiB  
Article
Effect of Strain Path on Retained Austenite Transformation Rates and Material Ductility in Transformation-Induced Plasticity-Assisted Advanced High-Strength Steel
by Parker Gibbs, Derrik Adams, David T. Fullwood, Eric R. Homer, Anil K. Sachdev and Michael P. Miles
J. Manuf. Mater. Process. 2025, 9(3), 75; https://doi.org/10.3390/jmmp9030075 - 27 Feb 2025
Viewed by 520
Abstract
TBF 1180 steel was plastically deformed under different strain paths in order to study both the ductility and RA transformation rates. Specimens were prepared from a 1 mm thick sheet and then tested incrementally under uniaxial tension, plane-strain tension, and biaxial tension. The [...] Read more.
TBF 1180 steel was plastically deformed under different strain paths in order to study both the ductility and RA transformation rates. Specimens were prepared from a 1 mm thick sheet and then tested incrementally under uniaxial tension, plane-strain tension, and biaxial tension. The retained austenite (RA) levels were measured, as a function of the plastic strain, using electron backscatter diffraction (EBSD). The plane-strain tension specimens had the fastest rate of RA transformation as a function of strain, followed by uniaxial tension, and then biaxial tension. The forming limits were measured for each strain path, yielding major limit strains of 0.12 under uniaxial tension, 0.09 under plane-strain tension, and 0.16 under biaxial tension. These results were compared to prior work on a 1.2 mm Q&P 1180 steel sheet, which had a similar yield and ultimate tensile strength, but exhibited slightly greater forming limits than the TBF material. The visual inspection of the micrographs appeared to show an equiaxed RA morphology in the Q&P 1180 steel and a mixture of equiaxed and lamellar RA grains in the TBF 1180 steel. However, the statistics generated by EBSD revealed that both alloys had RA grains with essentially the same aspect ratios. The average RA grain size in the Q&P alloy was found to be about three times larger than that of the TBF alloy. As such, the small but consistent formability advantage exhibited by the Q&P 1180 alloy along all three strain paths can be attributed to its larger average RA grain size, where larger RA grain sizes correlated with a more gradual transformation rate. Full article
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18 pages, 22377 KiB  
Article
Real-Time Stringing Detection for Additive Manufacturing
by Oumaima Charia, Hayat Rajani, Inés Ferrer Real, Miquel Domingo-Espin and Nuno Gracias
J. Manuf. Mater. Process. 2025, 9(3), 74; https://doi.org/10.3390/jmmp9030074 - 25 Feb 2025
Viewed by 590
Abstract
Additive Manufacturing (AM), commonly known as 3D printing, has gained significant traction across various industries due to its versatility and customization potential. However, the process remains time-consuming, with print durations ranging from hours to days depending on the complexity and size of the [...] Read more.
Additive Manufacturing (AM), commonly known as 3D printing, has gained significant traction across various industries due to its versatility and customization potential. However, the process remains time-consuming, with print durations ranging from hours to days depending on the complexity and size of the object. In many cases, errors occur due to object misalignment, material stringing due to nozzle overflow, and filament blockages, which can lead to complete print failures. Such errors often go undetected for extended periods, resulting in substantial losses of time and material. This study explores the implementation of traditional computer vision, image processing, and machine learning techniques to enable real-time error detection, specifically focusing on stringing-related anomalies. To address data scarcity in training machine learning models, we also release a new dataset and improve upon the results achieved by the Obico server model, one of the most prominent tools for stringing detection. Our contributions aim to enhance process reliability, reduce material wastage, and optimize time efficiency in AM workflows. Full article
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