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Recent Developments in Advanced Manufacturing Technology

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A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: closed (20 February 2024) | Viewed by 13242

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Special Issue Editors

Dr. Dezhi Li

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Guest Editor

Warwick Manufacturing Group (WMG), University of Warwick, Coventry CV4 7AL, UK
Interests: lightweighting; structure joining; mixed-material joining; ultrasonic additive manufacturing; Li-ion battery pack manufacturing

Dr. Xiaonan Hou

E-Mail Website
Guest Editor

Engineering department, Lancaster University, Lancaster LA1 4YW, UK
Interests: mechanics of materials/structures; design and manufacturing for light-weighting; numerical analysis and machine learning

Special Issue Information

Dear Colleagues,

With the ongoing fourth industrial revolution, digital technologies, such as the Internet of Things, artificial intelligent, machine learning, cloud computing, big data and analytics, remote sensing, virtual reality, digital modelling, etc., have been largely used to digitalize manufacturing. In the meantime, manufacturing processes themselves are also advancing in terms of process development, finite element modelling, automation, process monitoring, etc. This Special Issue aims to mainly focus on the field of advanced manufacturing technologies, including the development of manufacturing processes, simulations, applications of digital technologies in manufacturing, etc.

We hope that this Special Issue provides a platform for leading experts in advanced manufacturing technologies to communicate and network, potentially for research exchange and collaborations. In particular, the topics of interest in this Special Issue include, but are not limited to:

Advanced joining technologies.
Advanced forming technologies.
Subtractive manufacturing, including CNC, laser cutting, water jet cutting, EDM, etc.
Additive manufacturing.
Simulation of manufacturing processes.
Computer-integrated manufacturing.
Application of AI in advanced manufacturing.
Application of sensors in digitalization of manufacturing.

Dr. Dezhi Li
Dr. Xiaonan Hou
Guest Editors

Manuscript Submission Information

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

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

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

Keywords

advanced manufacturing
joining and forming
cutting and machining
additive manufacturing
simulation
digitalization of manufacturing

Published Papers (6 papers)

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Research

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14 pages, 5961 KiB

Open AccessArticle

Study on Improving Electrochemical Machining Performances through Energy Conversion of Electrolyte Fluid

by Zhenghui Ge, Maolong Chen, Wangwang Chen and Yongwei Zhu

Coatings 2024, 14(4), 406; https://doi.org/10.3390/coatings14040406 - 29 Mar 2024

Viewed by 599

Abstract

Electrochemical machining (ECM) is regarded as a promising and cost-effective manufacturing method for difficult-to-cut materials with complex shapes and structures. The flow-field state of machining gaps is considered a key factor affecting machining performance in ECM engineering practice and has been widely studied. However, little attention has been given to the fluid energy of electrolytes during the ECM process. This study mainly focuses on the influence of the conversion between dynamic and static pressure energy of electrolyte fluid on ECM performance. The simulation results show that by changing the degree of convergence of the electrolyte outlet, the dynamic and static pressure energy of the electrolyte can be effectively adjusted, and increased static pressure energy can be obtained by sacrificing dynamic pressure energy. The experimental results show that electrolyte energy conversion can achieve better surface quality and material removal rate (MRR). However, excessive sacrifice of fluid dynamic pressure energy will also worsen the ECM performance. By combining MRR and Ra, moderate fluid energy conversion can achieve better machining performance, with a degree of convergence of around 50%–70%. The experimental results also show that moderate energy conversion of the electrolyte fluid can improve the utilization efficiency of electrical energy in the ECM process. This may be because the static pressure of the electrolyte can effectively compress the volume of gas products and reduce the electrical resistivity of the machining gap. These conclusions can provide some useful assistance for ECM engineering practice. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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20 pages, 9886 KiB

Open AccessFeature PaperArticle

Experimental and Numerical Investigations on the Impact of Surface Conditions on Self-Piercing Riveted Joint Quality

by Huan Zhao, Li Han, Yunpeng Liu and Xianping Liu

Coatings 2023, 13(5), 858; https://doi.org/10.3390/coatings13050858 - 30 Apr 2023

Cited by 1 | Viewed by 1512

Abstract

In this study, experimental and numerical investigations were carried out to achieve a comprehensive understanding of the impact of surface conditions on self-piercing riveting (SPR) joint quality. Oil lubrication and sandpaper grinding were employed in experimental tests to change surface conditions at rivet/top sheet, top/bottom sheets and bottom sheet/die interfaces. A finite element (FE) model for the SPR process was also adopted to numerically assess the impact of surface conditions. Variations in surface conditions were modelled by changing friction coefficients at contact interfaces. The results revealed that the friction coefficient between the rivet and top sheet (μ₁) imposed significant influences on the interlock (I₁) by affecting the deformation of the rivet shank and top sheet. The friction coefficient between the rivet and bottom sheet (μ₂) showed a lower influence on the joint quality because of a smaller contact area and shorter interaction time. The friction coefficient between the top and bottom sheets (μ₃) led to opposite changing trends of remaining bottom sheet thickness at the joint centre (t_c) and under the rivet tip (t_tip). The friction coefficient between the bottom sheet and die (μ₄) demonstrated crucial influences on the remaining bottom sheet at the joint centre. The riveting force was significantly influenced throughout the whole riveting process by the μ₁, but only affected at the end of the joining process by the other three friction coefficients. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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Graphical abstract

13 pages, 4107 KiB

Open AccessArticle

Study on Deformation Force of Hard Aluminum Alloy Incremental Forming

by Liang Wen, Yongjie Li, Silai Zheng, Hao Xu, Yunshuang Liu, Qiaolong Yuan, Yuanpeng Zhang, Hao Wu, Yuzhou Shen, Jizhou Kong and Hongyu Wei

Coatings 2023, 13(3), 571; https://doi.org/10.3390/coatings13030571 - 7 Mar 2023

Cited by 1 | Viewed by 1280

Abstract

The deformation force is an important factor affecting the forming accuracy of parts in the incremental forming process of sheet metal. This paper proposes an analytical calculation method of the deformation force based on pure shear deformation. After assuming and simplifying the factors affecting the deformation force, a graphical method is used to approximate the contact area between the forming tool and the sheet metal. A forming test is also designed. In addition, the deformation force is measured in the experiment, and its theoretical analysis value is compared with the actual measurement value of the forming test to validate the analytical method of deformation force calculation. The results show that the radial forming deviations are 28.5% and 22.5%, the axial deformation force deviations are 9.8% and 16.1%, and the forming force deviations are 6.3% and 10.3%, which demonstrates the effectiveness of using the analytical method to calculate the deformation force. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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12 pages, 8174 KiB

Open AccessFeature PaperArticle

Effects of Process Parameters and Heat Treatment on Microstructure and Mechanical Characteristics of Laser Powder Bed Fusion Alloy Inconel 718

by Hongbing Liu, Wenhao Cheng, Yiming Sun, Rui Ma, Yajun Wang, Jie Bai, Linan Xue, Xiaoguo Song and Caiwang Tan

Coatings 2023, 13(1), 189; https://doi.org/10.3390/coatings13010189 - 15 Jan 2023

Cited by 1 | Viewed by 2149

Abstract

A laser powder bed fusion (LPBF) Inconel 718 (IN718) alloy was fabricated under different process parameters, and the samples with optimal process parameters were treated by subsequent heat treatment. The outcomes demonstrated that the pores’ size and shape were influenced by the process parameters. The porosity of the samples first grew and subsequently reduced as the volume energy density increased, and the types of pores changed from lack-of-fusion pores to gas holes and keyhole pores. The porosity of the samples with three process parameters were 3.46%, 0.15% and 1.26%, respectively. The sample of 60.0 J/mm³ was chosen for a single solution (heat treatment at 980 °C for 1 h, SS) and direct aging (heat treatment at 720 °C for 8 h and then 620 °C for 8 h, DA), and the microstructure evolution of the samples was examined. Because of the segregation of the elements Nb and Mo, the Laves phase was distributed among the dendrites in the as-built (AB) sample. The solution heat treatment dissolved the Laves phase and precipitated the δ phase, while aging heat treatment precipitated the γ′/γ” phases. Additionally, the impact of the second phase on the tensile characteristics was looked into. The DA sample had the highest strength, with a tensile strength of 1458 MPa and a yield strength of 1271 MPa. With tensile and yield strengths of 980 MPa and 620 MPa, respectively, the AB sample had the lowest strength due to the Laves phase’s role as the crack initiator. The Laves phase dissolved and the γ′/γ”-strengthened phase precipitated, leading to an increase in the strength of the heat-treated specimens. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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Review

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65 pages, 13363 KiB

Open AccessReview

Joining Technologies for Aluminium Castings—A Review

by Dezhi Li, Carl Slater, Huisheng Cai, Xiaonan Hou, Yongbing Li and Qudong Wang

Coatings 2023, 13(5), 958; https://doi.org/10.3390/coatings13050958 - 19 May 2023

Cited by 4 | Viewed by 4164

Abstract

Aluminium castings have been widely used in many industries, including automotive, aerospace, telecommunication, construction, consumer products, etc., due to their lightweight, good electric and thermal conductivity, and electromagnetic interference/radio frequency interference (EMI/RFI) shielding properties. The main applications of aluminium castings are in automotive industry. For lighweighting purposes, more and more aluminium castings are used in the automotive vehicle structures to reduce weight, improve fuel efficiency, and reduce greenhouse gas emissions. However, due to the features of cast aluminium, such as porosity, poor surface quality, a tendency toward hot cracking, and low ductility, joining these materials is problematic. In this paper, the joining technologies for aluminium castings and the related issues, mainly cracking and porosity, are reviewed. The current state-of-the-art of joining technologies is summarized, and areas for future research are recommended. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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31 pages, 8579 KiB

Open AccessReview

Research Status of Stability in Dynamic Process of Laser-Arc Hybrid Welding Based on Droplet Transfer Behavior: A Review

by Qingyong Liu, Di Wu, Qingzhao Wang, Peilei Zhang, Hua Yan, Tianzhu Sun, Jie Zeng, Mingliang Yan, Zhenyu Liu and Ruifeng Li

Coatings 2023, 13(1), 205; https://doi.org/10.3390/coatings13010205 - 16 Jan 2023

Cited by 7 | Viewed by 2533

Abstract

With the synergistic effect of laser and arc heat sources, laser-arc hybrid welding (LAHW) technology can improve welding speed and penetration depth, and enhance gap-bridging ability. This review describes the fundamental concepts and characteristics of droplet transfer behavior in LAHW. Emphasis was placed on the physical interaction between the laser and arc and the effect of the combined laser/arc heat sources on the welding process. However, the physical understanding of these multivariable and complex interactions is still evolving. Through numerous research findings and summary, it is found that there are several critical factors, including the laser-to-arc distance, heat source leading mode, shielding gas composition, and laser power, affecting the droplet transfer characteristics. This review critically interprets the latest development in the basic understanding of LAHW. It lays great stress on the coupling effect of laser and arc in droplet transfer dynamic process of LAHW, and offers a direction for the future study and progress of LAHW. Significant fields for future research are also confirmed. Full article

(This article belongs to the Special Issue Recent Developments in Advanced Manufacturing Technology)

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