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Advances in Metal Forming and Thermomechanical Processing

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A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (30 June 2023) | Viewed by 19074

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Dr. Olexandr Grydin

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Guest Editor

Department of Materials Science, Paderborn University, Warburger Str. 100, 33098 Paderborn, Germany
Interests: twin-roll casting; high-strength steels and aluminum alloys; thermomechanical treatment; process-microstructure-properties relationships
Special Issues, Collections and Topics in MDPI journals

Dr. Florian Nürnberger

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Guest Editor

Institut für Werkstoffkunde (Materials Science), Leibniz Universität Hannover, An der Universität 2, 30823 Garbsen, Germany
Interests: microstructure-property-relationships; thermomechanical treatment; damage evolution; oxygen-free production

Special Issue Information

Dear Colleagues,

Efficient processes of metal forming in combination with thermomechanical treatment enable the adjustment of a prodcut's most advantageous microstructures and provide advanced mechanical and technological properties. Such characteristics as strength, ductility, toughness, corrosion resistance, etc., can be improved using novel processing technique and adopted process parameters. For the Special Issue “Advances in Metal Forming and Thermomechanical Processing”, manuscripts dealing with new methods, optimized or extended process routes in metal forming and thermomechanical treatment resulting in a better product performance are welcomed. All metal alloys, metallic clads and hybrid materials are considered without limitations. Research on the numerical simulation of such processes is relevant in conjunction with experimental results.

The Special Issue is devoted to the further development of forming processes in which the resulting microstructure and properties are specifically influenced in order to improve product characteristics. The goal is to derive a fundamental understanding of process–microstructure–property relationships. This is in line with the objectives of the Journal of Manufacturing and Materials Processing. We are pleased to invite you to submit your manuscripts to this Special Issue.

Dr. Olexandr Grydin
Dr. Florian Nürnberger
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. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

metal forming processes
mechanical joining
heat treatment
thermomechanical treatment
microstructure
mechanical properties
alloys
clads
hybrid materials

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Published Papers (10 papers)

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Research

13 pages, 3841 KiB

Open AccessArticle

Pressing and Sintering of Titanium Aluminide Powder after Ball Milling in Silane-Doped Atmosphere

by Bernd-Arno Behrens, Kai Brunotte, Julius Peddinghaus, Jonathan Ursinus, Sebastian Döring, Wolfgang Maus-Friedrichs, René Gustus and Maik Szafarska

J. Manuf. Mater. Process. 2023, 7(5), 171; https://doi.org/10.3390/jmmp7050171 - 19 Sep 2023

Cited by 1 | Viewed by 1817

Abstract

Due to the high specific surface area of titanium aluminide powders, significant and unavoidable surface oxidation takes place during processing. The resulting oxides disrupt the conventional powder metallurgical process route (pressing and sintering) by reducing the green strength and sintered properties. Oxide-free particle surfaces offer the potential to significantly increase particle bond strength and enable the processing of difficult-to-press material powders. In this work, the effect of milling titanium aluminide powder in a silane-doped atmosphere on the component properties after pressing and the subsequent sintering was investigated. Ball milling was used to break up the oxide layers and create bare metal surfaces on the particles. With the help of silane-doped inert gas, the oxygen partial pressure was greatly reduced during processing. It was investigated whether oxide-free surfaces could be produced and maintained by milling in silane-doped atmospheres. Furthermore, the resulting material properties after pressing and sintering were analysed using density measurements, hardness tests, EDX measurements, and micrographs. It was concluded that ball milling in a silane-doped atmosphere produces and maintains oxide-free particle surfaces. These oxide-free surfaces and smaller particle sizes improve the component properties after pressing and sintering. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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32 pages, 11788 KiB

Open AccessArticle

A Comparative Study of a Machine Learning Approach and Response Surface Methodology for Optimizing the HPT Processing Parameters of AA6061/SiCp Composites

by Waleed H. El-Garaihy, Abdulrahman I. Alateyah, Mahmoud Shaban, Mohammed F. Alsharekh, Fahad Nasser Alsunaydih, Samar El-Sanabary, Hanan Kouta, Yasmine El-Taybany and Hanadi G. Salem

J. Manuf. Mater. Process. 2023, 7(4), 148; https://doi.org/10.3390/jmmp7040148 - 10 Aug 2023

Cited by 7 | Viewed by 1950

Abstract

This work investigates the efficacy of high-pressure torsion (HPT), as a severe plastic deformation mechanism for processing plain and silicon-carbide-reinforced AA6061, with the broader objective of using the technique for improving the properties of lightweight materials for a range of objectives. The interactions between input variables, such as the pressure and equivalent strain (ε_eq) applied during HPT processing, and the presence of SiCp and response variables, like the relative density, grain refinement, homogeneity of the structure, and the mechanical properties of the AA6061 aluminum matrix, were investigated. Hot compaction (HC) of the mixed powders followed by HPT were employed to produce AA6061 discs with and without 15% SiCp. The experimental findings were then analyzed statistically using the response surface methodology (RSM) and a machine learning (ML) approach to predict the output variables and to optimize the input parameters. The optimum combination of HPT process parameters was confirmed by the genetic algorithm (GA) and ML approaches. Furthermore, the constructed ML and RSM models were validated experimentally by HPT processing the same material under new conditions not fed into the models and comparing the experimental results to those predicted by the model. From the ML and RSM models, it was found that processing the AA6061/SiCp composite HPT via four revolutions at 3 GPa produced the highest mechanical properties coupled with significant grain refinement compared to the HC condition. ML analysis revealed that the equivalent strain induced by the number of revolutions was the most effective parameter for grain refinement, whereas the presence of SiCp played the highest role in improving both the hardness values and the compressive strength of the AA6061 matrices. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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11 pages, 1255 KiB

Open AccessArticle

Investigations on the Influences of the Thermomechanical Manufacturing of Aluminium Auxiliary Joining Elements

by Thomas Borgert, Maximilian Henke and Werner Homberg

J. Manuf. Mater. Process. 2023, 7(4), 147; https://doi.org/10.3390/jmmp7040147 - 10 Aug 2023

Cited by 1 | Viewed by 1511

Abstract

The demands on joining technology are constantly increasing due to the consistent lightweight construction and the associated increasing material mix. To meet these requirements, the adaptability of the joining processes must be improved to be able to process different material combinations and to react to challenges caused by deviations in the process chain. One example of a highly adaptable process due to the two-step process sequence is thermomechanical joining with Friction Spun Joint Connectors (FSJCs) that can be individually adapted to the joint. In this paper, the potentials of the adaption in the two-stage joining process with aluminium auxiliary joining elements are investigated. To this end, it is first investigated whether a thermomechanical forming process can be used to achieve a uniform and controlled manufacturing regarding the process variable of the temperature as well as the geometry of the FSJC. Based on the successful proof of the high and good repeatability in the FSJC manufacturing, possibilities, and potentials for the targeted influencing of the process and FSJC geometry are shown, based on an extensive variation of the process input variables (delivery condition and thus mechanical properties of the raw parts as well as the process parameters of rotational speed and feed rate). Here it can be shown that above all, the feed rate of the final forming process has the strongest influence on the process and thus also offers the strongest possibilities for influencing it. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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9 pages, 3079 KiB

Open AccessCommunication

Correlating Ultrasonic Velocity in DC04 with Microstructure for Quantification of Ductile Damage

by Steffen Wackenrohr, Sebastian Herbst, Patrick Wöbbeking, Gregory Gerstein and Florian Nürnberger

J. Manuf. Mater. Process. 2023, 7(4), 142; https://doi.org/10.3390/jmmp7040142 - 7 Aug 2023

Viewed by 1436

Abstract

The detection of ductile damage by image-based methods is time-consuming and typically probes only small areas. It is therefore of great interest for various cold forming processes, such as sheet-bulk metal forming, to develop new methods that can be used during the forming process and that enable an efficient detection of ductile damage. In the present study, ductile damage in DC04 was examined using ultrasonic testing. First, different grain sizes were set by heat treatment. Subsequently, the sheet metal was formed by cold rolling. A clear correlation between the average void diameter and the measured ultrasonic velocity could be shown. The ultrasonic velocity showed a clear decrease when the average void size increased because of the increasing forming degree. The ultrasonic measurements were finally employed to calculate a damage parameter D to determine the amount of ductile damage in the microstructure for different grain sizes after cold rolling. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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15 pages, 3504 KiB

Open AccessArticle

Mechanical and Microstructure Characterisation of the Hypoeutectic Cast Aluminium Alloy AlSi10Mg Manufactured by the Twin-Roll Casting Process

by Moritz Neuser, Mirko Schaper and Olexandr Grydin

J. Manuf. Mater. Process. 2023, 7(4), 132; https://doi.org/10.3390/jmmp7040132 - 23 Jul 2023

Cited by 2 | Viewed by 1575

Abstract

Multi-material designs (MMD) are more frequently used in the automotive industry. Hereby, the combination of different materials, metal sheets, or cast components, is mechanically joined, often by forming joining processes. The cast components mostly used are high-strength, age-hardenable aluminium alloys of the Al–Si system. Here, the low ductility of the AlSi alloys constitutes a challenge because their brittle nature causes cracks during the joining process. However, by using suitable solidification conditions, it is possible to achieve a microstructure with improved mechanical and joining properties. For this study, we used the twin-roll casting process (TRC) with water-cooled rollers to manufacture the hypoeutectic AlSi10Mg for the first time. Hereby, high solidification rates are realisable, which introduces a microstructure that is about four times finer than in the sand casting process. In particular, it is shown that a fine microstructure close to the modification with Na or Sr is achieved by the high solidification rate in the TRC process without using these elements. Based on this, the mechanical properties increase, and especially the ductility is enhanced. Subsequent joining investigations validate the positive influence of a high solidification rate since cracks in joints can be avoided. Finally, a microstructure-property-joint suitability correlation is presented. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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10 pages, 2686 KiB

Open AccessArticle

Contact Temperature Measurements on Hybrid Aluminum–Steel Workpieces in a Cross-Wedge Rolling Process

by Paulina Merkel, Jens Kruse, Mareile Kriwall, Bernd-Arno Behrens and Malte Stonis

J. Manuf. Mater. Process. 2023, 7(4), 130; https://doi.org/10.3390/jmmp7040130 - 13 Jul 2023

Viewed by 1861

Abstract

The Collaborative Research Center 1153 is investigating a novel process chain for manufacturing high-performance hybrid components. The combination of aluminum and steel can reduce the weight of components and lead to lower fuel consumption. During the welding of aluminum and steel, a brittle intermetallic phase is formed that reduces the service life of the component. After welding, the workpiece is heated inhomogeneously and hot-formed in a cross-wedge rolling process. Since the intermetallic phase grows depending on the temperature during hot forming, temperature control is of great importance. In this paper, the possibility of process-integrated contact temperature measurement with thin-film sensors is investigated. For this purpose, the initial temperature distribution after induction heating of the workpiece is determined. Subsequently, cross-wedge rolling is carried out, and the data of the thin-film sensors are compared to the temperature measurements after heating. It is shown that thin-film sensors inserted into the tool are capable of measuring surface temperatures even at a contact time of 0.041 s. The new process monitoring of the temperature makes it possible to develop a better understanding of the process as well as to further optimize the temperature distribution. In the long term, knowledge of the temperatures in the different materials also makes it possible to derive quality characteristics as well as insights into the causes of possible process errors (e.g., fracture of the joining zone). Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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10 pages, 2749 KiB

Open AccessCommunication

Investigation of the Formability of Cryogenic Rolled AA6061 and Its Improvement Using Artificial Aging Treatment

by Abbas Sadeghi, Ernst Kozeschnik and Farid R. Biglari

J. Manuf. Mater. Process. 2023, 7(2), 54; https://doi.org/10.3390/jmmp7020054 - 27 Feb 2023

Cited by 2 | Viewed by 1855

Abstract

Cryogenic rolling is one of the essential severe plastic deformation processes to manufacture high-strength aluminum sheets with excellent formability limits. The present work characterizes the formability of AA6061 for cryogenic rolling before and after artificial aging. Nakajima method based on ISO standard is used to measure formability. Samples are aged in the range of 100 °C to 150 °C. Artificial aging at 150 °C is found to be the optimum temperature for achieving a good combination of strength and formability. Over the course of artificial aging, strength improved up to 40%, where the original value of 250 MPa for cryo-rolled condition increased to 350 MPa after 50 h of aging at 150 °C, and the formability of the cryo-rolled sample improved especially for multi-axial forming condition. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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28 pages, 6516 KiB

Open AccessArticle

Influence of ECAP Parameters on the Structural, Electrochemical and Mechanical Behavior of ZK30: A Combination of Experimental and Machine Learning Approaches

by Mahmoud Shaban, Abdulrahman I. Alateyah, Mohammed F. Alsharekh, Majed O. Alawad, Amal BaQais, Mokhtar Kamel, Fahad Nasser Alsunaydih, Waleed H. El-Garaihy and Hanadi G. Salem

J. Manuf. Mater. Process. 2023, 7(2), 52; https://doi.org/10.3390/jmmp7020052 - 22 Feb 2023

Cited by 13 | Viewed by 2489

Abstract

Several physics-based models have been utilized in material design for the simulation and prediction of material properties. In this study, several machine-learning (ML) approaches were used to construct a prediction model to analyze the influence of equal-channel angular pressing (ECAP) parameters on the microstructural, corrosion and mechanical behavior of the biodegradable magnesium alloy ZK30. The ML approaches employed were linear regression, the Gaussian process, and support vector regression. For the optimization of the alloy’s performance, experiments were conducted on ZK30 billets using different ECAP routes, channel angles, and number of passes. The adopted ML model is an adequate predictive model which agreed with the experimental results. ECAP die angles had an insignificant effect on grain refinement, compared to the route type. ECAP via four passes of route Bc (rotating the sample 90° on its longitudinal axis after each pass in the same direction) was the most effective condition producing homogenous ultrafine grain distribution of 1.92 µm. Processing via 4-Bc and 90° die angle produced the highest hardness (97-HV) coupled with the highest tensile strength (344 MPa). The optimum corrosion rate of 0.140 mils penetration per year (mpy) and the optimum corrosion resistance of 1101 Ω·cm² resulted from processing through 1-pass using the 120°-die. Grain refinement resulted in reducing the corrosion rates and increased corrosion resistance, which agreed with the ML findings. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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15 pages, 8944 KiB

Open AccessArticle

Effect of Heat Treatment on the Mechanical and Tribological Properties of Dual-Reinforced Cold-Sprayed Al Coatings

by Kia Min Phua, Thomas Stapel and Troy Y. Ansell

J. Manuf. Mater. Process. 2023, 7(1), 32; https://doi.org/10.3390/jmmp7010032 - 28 Jan 2023

Cited by 1 | Viewed by 1813

Abstract

The aluminum cold spray feedstock powder was single- and dual-reinforced with no greater than 2 vol% boron nitride nanoplatelets (BNNP) and/or nanometric boron carbide (nB₄C). These powders were cold sprayed onto Al-6061 substrates and then heat-treated in an argon environment. In addition, micro- and nano-indentation hardness and wear testing were performed on the heat-treated samples. Further microscopy and optical profilometry were used to characterize the microstructure and wear track volumes. Minimal changes to the splat structure were observed after heat treatment. However, when compared to the pure Al coating, microhardness improved with reinforcement after treatment at 500 °C, while nanohardness improved only in the dual-reinforced coatings, again after treatment at 500 °C. The elastic modulus generally decreased for the reinforced coatings after treatment; however, indentation test results were mixed. The wear testing done on samples heat treated at 500 °C for one hour showed increases in the specific wear rate for single-reinforced coatings but decreases in the dual-reinforced coatings. These results indicate that both dual-reinforcement and heat treatment are required for improvements in the mechanical and tribological properties of Al nanocomposites. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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19 pages, 8075 KiB

Open AccessArticle

Fundamental Investigations to Evaluate the Influence of Notching Processes on a Subsequent Cyclic Bending Process for the Production of Wire Cores

by Alina Biallas, Sophia Ohmayer and Marion Merklein

J. Manuf. Mater. Process. 2023, 7(1), 24; https://doi.org/10.3390/jmmp7010024 - 17 Jan 2023

Cited by 1 | Viewed by 1865

Abstract

The production of wire cores by notch rolling and cyclic bending promises an ecologically and economically efficient manufacturing option for steel fibers. The paper at hand evaluates the influence of wire strips on cyclic bending by applying rolled wire strips of DP600 sheet metal (t₀ = 0.8 mm) and a new cyclic bending testing tool. Analysis of material separation with varying parameters, rolling gap d and bending angle β, proves the interdependency of both process step, but indicates reduced adjustability of the notch rolling process. To enable better adjustability of the wire strip’s characteristics and analysis of their effects, wire strip production in the laboratory by notch stamping instead of rolling is aspired. The prior interaction analysis states the web height b, the notch angle α, and the hardening distribution as relevant wire strip’s characteristics to be replicated. Based on experimental analysis, an equivalent of notch rolling by notch stamping is deduced by considering the web height b identical for stamping and rolling, by adjusting the tool’s notch angle α_t based on an equation considering geometric evaluations of α, and by taking advantage of the asymmetric hardening distribution of the outer notch which is comparable to rolled wire strip. Full article

(This article belongs to the Special Issue Advances in Metal Forming and Thermomechanical Processing)

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