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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 October 2024) | Viewed by 16360

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Dr. Maojun Li

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College of Mechanical and Vehicle Engineering, State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha 410082, China
Interests: superalloys; metal cutting; composites; additive manufacturing; laser processing/cutting
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Prof. Dr. Pan Gong

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School of Materials Science and Engineering, State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China
Interests: bulk metallics glasses; high-entropy alloys; titanium alloys; metallic composites; precision metal plastic forming; powder metallurgy
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Dr. Xin Wang

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Key Laboratory for New Type of Functional Materials of Hebei Province, School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300400, China
Interests: solidification behavior of light alloys; bulk metallic glass composites; strengthening and toughening of metals and their fatigue behavior; functional metal materials for water treatment
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Dr. Guangchao Han

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Guest Editor

School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Interests: microforming; ultrasonic forming; ultrasonic machining; additive manufacturing
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Special Issue Information

Dear Colleagues,

The use of advanced alloys and composites is steadily increasing as an alternative to traditional metallic materials in various industry sectors. Within the aerospace sector, components in the latest generation of airplanes have already incorporated greater levels of advanced materials in order to provide benefits in terms of strength-to-weight ratios or high-temperature resistance, leading to enhanced aircraft operational performance/efficiency and associated fuel cost savings. Although there is knowledge and research already present in the literature on the manufacturing of alloys/composites, developing new precision and ultraprecision manufacturing strategies/techniques is still important to significantly improve component performance, productivity and machinability; hence, the motivation for organizing this Special Issue.

This special Issue aims to bring together leading academic scientists, researchers and research scholars to exchange and share their research experiences and experimental results on all aspects of “Precision Manufacturing of Advanced Alloys and Composites”. It also provides a premier interdisciplinary platform for researchers, practitioners and educators to present the most recent innovations, trends and practical challenges encountered, as well as solutions adopted in the field of precision manufacturing.

It is our pleasure to invite you to submit original research papers, short communications or reviews within the scope of this Special Issue, which covers the topics/research areas mainly related to precision/ultraprecision manufacturing technologies and their use in advanced alloys and composites, precision machinery, surface integrity, microstructure evolution, and mechanics and modeling during precision forming and machining processes.

Dr. Maojun Li
Prof. Dr. Pan Gong
Dr. Xin Wang
Dr. Guangchao Han
Guest Editors

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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. Materials 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 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

forming technologies
conventional machining technologies
non-conventional machining technologies
precision manufacturing process
precision machinery
intelligent manufacturing
precision engineering
advanced aerospace alloys/composites

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Published Papers (10 papers)

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Research

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17 pages, 36804 KiB

Open AccessArticle

Using the Radial-Shear Rolling Method for Casted Zirconium Alloy Ingot Structure Improvement

by Alexandr Arbuz, Fedor Popov, Alexandr Panichkin, Anna Kawałek, Nikita Lutchenko and Kirill Ozhmegov

Materials 2024, 17(20), 5078; https://doi.org/10.3390/ma17205078 - 18 Oct 2024

Viewed by 543

Abstract

In developing materials for the nuclear industry, it is crucial to enhance both alloy composition and processing methods. This study focuses on investigations of applying radial-shear rolling (RSR) to a Zr-1%Nb alloy ingot, aiming to refine its microstructure and improve its properties for nuclear applications. This method, with complex vortex metal flow inside of a casted workpiece, has not been previously tested for processing zirconium ingots, so experimental verification of its applicability is of scientific interest. The 30 mm diameter ingot, produced by vacuum induction melting, was initially rolled to 20 mm at 800 °C to eliminate defects and refine the cast structure. A second rolling stage reduced the diameter to 13 mm at 530 °C, resulting in an ultrafine-grained structure. The RSR method effectively combines structural refinement and defect healing within fewer cycles, making it suitable for producing components for nuclear reactors. This approach demonstrates a potential reduction in traditional processing steps, providing a more efficient route for preparing high-quality materials for nuclear applications. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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13 pages, 4034 KiB

Open AccessArticle

Investigations on the Effects of Bonding and Forming Conditions on the Deformation Behavior of Copper–Steel Bimetallic Rods during the Cold Drawing Processes

by Yeong-Maw Hwang, Hiu Shan Rachel Tsui and Cheng-Yu Lu

Materials 2024, 17(16), 4015; https://doi.org/10.3390/ma17164015 - 12 Aug 2024

Viewed by 971

Abstract

Metal composite parts are widely used in different industries owing to their significant improvement in material properties, such as mechanical strength, electrical conductivity, and corrosion resistivity, compared to traditional single metals. Such composite parts can be manufactured and processed in different ways to achieve the desired geometry and quality. Among various metal forming techniques, drawing is the most commonly used process to produce long composite wires or rods from raw single materials. During the drawing process of composite wires or rods, not only does the core radius ratio change, but the core or sleeve layer may also undergo necking or fracture due to excessive tensile stresses in the softer layer. In this paper, bimetallic rods with AISI-1006 low-carbon steel cores and C10100 oxygen-free electronic copper sleeves are modeled using the finite element software DEFORM. The simulation models are verified by drawing experiments. The effects of initial bonding conditions, the initial core ratio, reduction ratio, semi-die angle, drawing speed, and friction on the plastic deformation behavior of the bimetallic rods are investigated. The results indicate that the initial bonding conditions have a great impact on the deformation behavior of the billets in terms of strain distribution, material flow, residual stress, and the final core ratio. The permissible forming parameters for obtaining a sound product are investigated as well. With the aid of these analyses, the drawing process and the quality of the products can be controlled steadily. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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13 pages, 10227 KiB

Open AccessArticle

Electrochemical Polishing of Ti and Ti₆Al₄V Alloy in Non-Aqueous Solution of Sulfuric Acid

by Agata Kołkowska, Joanna Michalska, Rafał Zieliński and Wojciech Simka

Materials 2024, 17(12), 2832; https://doi.org/10.3390/ma17122832 - 10 Jun 2024

Cited by 1 | Viewed by 1091

Abstract

This paper reports the results of our study on electrochemical polishing of titanium and a Ti-based alloy using non-aqueous electrolyte. It was shown that electropolishing ensured the removal of surface defects, thereby providing surface smoothing and decreasing surface roughness. The research was conducted using samples made of titanium and Ti₆Al₄V alloy, as well as implant system elements: implant analog, multiunit, and healing screw. Electropolishing was carried out under a constant voltage (10–15 V) with a specified current density. The electrolyte used contained methanol and sulfuric acid. The modified surface was subjected to a thorough analysis regarding its surface morphology, chemical composition, and physicochemical properties. Scanning electron microscope images and profilometer tests of roughness confirmed significantly smoother surfaces after electropolishing. The surface profile analysis of processed samples also yielded satisfactory results, showing less imperfections than before modification. The EDX spectra showed that electropolishing does not have significant influence on the chemical composition of the samples. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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19 pages, 9237 KiB

Open AccessArticle

Improvements in Wear and Corrosion Resistance of Ti-W-Alloyed Gray Cast Iron by Tailoring Its Microstructural Properties

by Abdul Razaq, Peng Yu, Adnan Raza Khan, Xiao-Yuan Ji, Ya-Jun Yin, Jian-Xin Zhou and Taher A. Shehabeldeen

Materials 2024, 17(10), 2468; https://doi.org/10.3390/ma17102468 - 20 May 2024

Viewed by 1295

Abstract

The improved wear and corrosion resistance of gray cast iron (GCI) with enhanced mechanical properties is a proven stepping stone towards the longevity of its versatile industrial applications. In this article, we have tailored the microstructural properties of GCI by alloying it with titanium (Ti) and tungsten (W) additives, which resulted in improved mechanical, wear, and corrosion resistance. The results also show the nucleation of the B-, D-, and E-type graphite flakes with the A-type graphite flake in the alloyed GCI microstructure. Additionally, the alloyed microstructure demonstrated that the ratio of the pearlite volume percentage to the ferrite volume percentage was improved from 67/33 to 87/13, whereas a reduction in the maximum graphite length and average grain size from 356 ± 31 µm to 297 ± 16 µm and 378 ± 18 µm to 349 ± 19 µm was detected. Consequently, it improved the mechanical properties and wear and corrosion resistance of alloyed GCI. A significant improvement in Brinell hardness, yield strength, and tensile strength of the modified microstructure from 213 ± 7 BHN to 272 ± 8 BHN, 260 ± 3 MPa to 310 ± 2 MPa, and 346 ± 12 MPa to 375 ± 7 MPa was achieved, respectively. The substantial reduction in the wear rate of alloyed GCI from 8.49 × 10⁻³ mm³/N.m to 1.59 × 10⁻³ mm³/N.m resulted in the upgradation of the surface roughness quality from 297.625 nm to 192.553 nm. Due to the increase in the corrosion potential from −0.5832 V to −0.4813 V, the impedance of the alloyed GCI was increased from 1545 Ohm·cm² to 2290 Ohm·cm². On the basis of the achieved experimental results, it is suggested that the reliability of alloyed GCI based on experimentally validated microstructural compositions can be ensured during the operation of plants and components in a severe wear and corrosive environment. It can be predicted that the proposed alloyed GCI components are capable of preventing the premature failure of high-tech components susceptible to a wear and corrosion environment. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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19 pages, 4765 KiB

Open AccessArticle

Design and Optimization of Heat Treatment Process Parameters for High-Molybdenum-Vanadium High-Speed Steel for Rolls

by Jibing Chen, Yanfeng Liu, Yujie Wang, Rong Xu, Qianyu Shi, Junsheng Chen and Yiping Wu

Materials 2023, 16(22), 7103; https://doi.org/10.3390/ma16227103 - 9 Nov 2023

Cited by 3 | Viewed by 1489

Abstract

High-molybdenum-vanadium high-speed steel is a new type of high-hardenability tool steel with excellent wear resistance, castability, and high-temperature red hardness. This paper proposes a composition design of high-molybdenum-vanadium high-speed steel for rolls, and its specific chemical composition is as follows (wt.%): C2%, Mo7.0%, V7.0%, Si0.3%, Mn0.3%, Ni0.4%, Cr3.0%, and the rest of the iron. This design is characterized by the increase in molybdenum and vanadium in high-speed steel to replace traditional high-speed steel rolls with the tungsten element in order to reduce the heavy elements’ tungsten-specific gravity segregation caused by centrifugal casting so that the roll performance is uniform and the stability of use is improved. JMatPro (version 7.0) simulation software is used for the composition design of high-molybdenum-vanadium high-speed steel. The phase composition diagram is analyzed under different temperatures. The content of different phases of the organization in different temperatures is also studied. The martensitic transformation temperature and different tempering temperatures with the different types of compounds and grain sizes are calculated. The process parameters of heat treatment of high-molybdenum-vanadium high-speed steel are optimized. The selection of carbon content and the temperature of M50 are calculated and optimized, and the results show that the range of pouring temperatures, quenching temperatures, annealing temperatures, and tempering temperatures are 1360~1410 °C, 1190~1200 °C, 818~838 °C, and 550~600 °C, respectively. Scanning electron microscope (SEM) analysis of the samples obtained by using the above heat treatment parameters is consistent with the simulation results, which indicates that the simulation has important reference significance for guiding the actual production. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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16 pages, 6428 KiB

Open AccessArticle

Simulation and Experiment on the Low-Velocity Impact Response of Flax Fabric Reinforced Composites

by Xiaoshuang Xiong, Zisheng Wang, Zihao Zhang, Qiaomin Li, Chen Shen, Fei Fan, Xiang Li and Mingzhang Chen

Materials 2023, 16(9), 3489; https://doi.org/10.3390/ma16093489 - 30 Apr 2023

Cited by 1 | Viewed by 1981

Abstract

Natural fiber reinforced composites are increasingly used to fabricate structural components prone to suffering low-velocity impacts. The low-velocity impact response of flax fabric reinforced composites under different impact energies is experimentally studied and numerically simulated. A multi-scale finite element analysis strategy for the progressive damage prediction of flax fabric reinforced composites is developed. Micro- and meso-scale analyses are conducted to predict the effective properties of the woven unit cell. Macro-scale analysis is carried out subsequently to predict the impact response of composite laminates using the results of micro- and meso-scale analyses as inputs. Simulation results and experimental results both show that most of the impact energy is absorbed by the specimens when the impact energy is lower than 4 J, and the absorption ratio of impact energy slightly increases with the increase in impact energy. On the contrary, a dramatic decrease occurs in the absorption ratio when the impact energy is 6 J, due to the severe damage to the specimen. In addition, simulation results indicate that matrix shear damage and interlaminar damage are the primary failure modes of composites under high impact energy. The numerical results of impact force, absorbed energy, and damage morphologies on both sides for all specimens show good agreement with the experimental results. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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14 pages, 6811 KiB

Open AccessArticle

Grinding Force and Surface Formation Mechanisms of 17CrNi2MoVNb Alloy When Grinding with CBN and Alumina Wheels

by Xiaoyang Jiang, Ke Liu, Mingda Si, Maojun Li and Pan Gong

Materials 2023, 16(4), 1720; https://doi.org/10.3390/ma16041720 - 19 Feb 2023

Cited by 2 | Viewed by 1606

Abstract

The 17CrNi2MoVNb alloy is widely used for manufacturing heavy-duty gears in vehicles’ transmission systems, where grinding is a significant process affecting gears’ working performance and service life. This work comprehensively analyzed the grinding force, surface morphology, and surface roughness when grinding 17CrNi2MoVNb alloy using alumina and CBN grinding wheels. Results showed that the maximum normal grinding force from the CBN wheel was only ~67% of the one from the alumina wheel. Due to the small size and limited cutting depth of CBN grains, the grinding force increased by about 20% when the grinding depth increased from 0.02 to 0.03 mm for CBN grinding wheels. Surface defects, including cavities and material tearing, were mainly found on the ground surface when using an alumina grinding wheel. The surface roughness Ra recorded from the CBN grinding wheel mainly ranged from 0.263 to 0.410 μm, accounting for less than 40% of the one from the alumina grinding wheel. The information from this work could provide benchmark data and references for optimizing grinding tools and parameters when manufacturing gears in the vehicle industry. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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13 pages, 11786 KiB

Open AccessArticle

Surface Morphology and Subsurface Microstructure Evolution When Form Grinding 20Cr2Ni4A Alloys

by Xiaodong Zhang, Xiaoyang Jiang, Maojun Li and Pan Gong

Materials 2023, 16(1), 425; https://doi.org/10.3390/ma16010425 - 2 Jan 2023

Cited by 4 | Viewed by 1865

Abstract

20Cr2Ni4A alloy is widely used in the manufacturing of heavy-duty gears, although limited information about its machinability during the form-grinding process has been reported. In this work, form-grinding trials on transmission gears of 20Cr2Ni4A alloy under various parameters were conducted. Surface morphology of the gear tooth, surface roughness distribution and microstructure evolution of the machined surface layer were comprehensively studied, and the influence of grinding parameters on grinding performance was investigated. The formation mechanisms of surface/subsurface defects during the form-grinding process, including plastic flow, deep grooves, successive crushing zone, adhesive chips and cavities, were analyzed. Results showed that the change in contact conditions between the grinding wheel and tooth surface led to the decrease in the surface roughness from tooth tip to root. Mechanical force and grinding heat promoted the deformation and refinement of the microstructure within the machined surface layer. With the increase in cutting depth and feed speed, the deformation ratio of the microstructure increased, which was also consistent with the variation trend in the form-grinding temperature. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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Review

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31 pages, 22578 KiB

Open AccessReview

A Review of an Investigation of the Ultrafast Laser Processing of Brittle and Hard Materials

by Jiecai Feng, Junzhe Wang, Hongfei Liu, Yanning Sun, Xuewen Fu, Shaozheng Ji, Yang Liao and Yingzhong Tian

Materials 2024, 17(15), 3657; https://doi.org/10.3390/ma17153657 - 24 Jul 2024

Cited by 2 | Viewed by 1482

Abstract

Ultrafast laser technology has moved from ultrafast to ultra-strong due to the development of chirped pulse amplification technology. Ultrafast laser technology, such as femtosecond lasers and picosecond lasers, has quickly become a flexible tool for processing brittle and hard materials and complex micro-components, which are widely used in and developed for medical, aerospace, semiconductor applications and so on. However, the mechanisms of the interaction between an ultrafast laser and brittle and hard materials are still unclear. Meanwhile, the ultrafast laser processing of these materials is still a challenge. Additionally, highly efficient and high-precision manufacturing using ultrafast lasers needs to be developed. This review is focused on the common challenges and current status of the ultrafast laser processing of brittle and hard materials, such as nickel-based superalloys, thermal barrier ceramics, diamond, silicon dioxide, and silicon carbide composites. Firstly, different materials are distinguished according to their bandgap width, thermal conductivity and other characteristics in order to reveal the absorption mechanism of the laser energy during the ultrafast laser processing of brittle and hard materials. Secondly, the mechanism of laser energy transfer and transformation is investigated by analyzing the interaction between the photons and the electrons and ions in laser-induced plasma, as well as the interaction with the continuum of the materials. Thirdly, the relationship between key parameters and ultrafast laser processing quality is discussed. Finally, the methods for achieving highly efficient and high-precision manufacturing of complex three-dimensional micro-components are explored in detail. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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17 pages, 1484 KiB

Open AccessReview

Carbon Fiber 3D Printing: Technologies and Performance—A Brief Review

by Gabriele Marabello, Chiara Borsellino and Guido Di Bella

Materials 2023, 16(23), 7311; https://doi.org/10.3390/ma16237311 - 24 Nov 2023

Cited by 10 | Viewed by 2966

Abstract

Additive manufacturing is evolving in the direction of carbon fiber 3D printing, a technology that combines the versatility of three-dimensional printing with the exceptional properties of carbon fiber. This work aims to provide a brief review of the main methodologies used in carbon fiber 3D printing, focusing particularly on the two most widespread types: continuous fiber printing and short fiber printing. In the context of continuous fiber printing, the process of embedding a continuous carbon fiber into a polymer matrix will be examined, resulting in the achievement of high-performance lightweight structural components. On the other hand, short fiber printing involves the use of short carbon fibers mixed in turn with polymeric materials, with the advantage of having greater ease of processing and obtaining highly performing components with large-scale economic investments that are lower in cost than additive manufacturing using continuous fiber printing. Furthermore, this work will conduct an evaluation of the mechanical properties of products printed using both technologies, focusing on key aspects, such as strength, stiffness, weight, and resistance to mechanical stress. The specific advantages and challenges associated with each printing technique will also be analyzed. Full article

(This article belongs to the Special Issue Precision Manufacturing of Advanced Alloys and Composites)

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