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Metals
Special Issues
Manufacturing Processes of Metallic Materials
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Manufacturing Processes of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 25 March 2025 | Viewed by 3978

Special Issue Editors

Prof. Dr. Hong Xiao

E-Mail Website
Guest Editor
National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, China
Interests: metals forming; rolling processes; finite element analysis; joining processes; bonding processes
Dr. Chao Yu

E-Mail Website
Guest Editor
National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, China
Interests: advanced composite material forming technology; electromagnetic induction heating process and technology

Special Issue Information

Dear Colleagues,

This Special Issue aims to provide the most recent advances in the manufacturing processes of metallic materials and to identify directions both in experimental and numerical research, including the requirements for sustainable technologies and processes. A key aspect is proper process design in order to guarantee the compliance of the final product with the intended functionality, while at the same time minimizing resource usage.

The Special Issue will cover, but will not be limited to, the following topics:

  • Formability in metal forming processes;
  • Modeling and designing of forming and joining processes;
  • Additive, subtractive and hybrid manufacturing;
  • Emerging manufacturing processes;
  • Intelligent metal processing technologies;
  • Forming processes of lightweight metals;
  • Product design and process optimization;
  • Mechanical performance of products;
  • Mechanical joining processes;
  • Bonding and special rolling processes.

Prof. Dr. Hong Xiao
Dr. Chao Yu
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. Metals 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

  • metals forming
  • manufacturing processes
  • rolling processes
  • finite element analysis
  • additive manufacturing
  • joining processes
  • bonding processes
  • simulation of manufacturing processes

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (6 papers)

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Research

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18 pages, 8392 KiB  
Article
Analysis of Temperature and Stress Fields in the Process of Hot-Rolled Strip Coiling
by Meng Dai, Yuting Hu, Yanchao Hao, Ping Qiu and Hong Xiao
Metals 2025, 15(2), 111; https://doi.org/10.3390/met15020111 - 24 Jan 2025
Viewed by 356
Abstract
During the coiling process of a hot-rolled strip, with the increasing layers the temperature and stress distribution inside the coil constantly change and interact with each other. Due to the contact with the sleeve and the transition of the heat exchange state, it [...] Read more.
During the coiling process of a hot-rolled strip, with the increasing layers the temperature and stress distribution inside the coil constantly change and interact with each other. Due to the contact with the sleeve and the transition of the heat exchange state, it is inaccurate to consider the temperature of the whole coil as the coiling temperature set by the process requirement. Meanwhile, due to the periodic interlayer contact in the radial direction, the relation between stress and deformation is nonlinear. For the coiling process, it is difficult to consider the above factors using conventional methods. Therefore, an incremental model has been established to couple the temperature and stress of the coil. In order to obtain the mechanical properties of the strip and radial elastic modulus of the coil, tensile tests and laminated compression experiments are conducted at different temperatures. The effects of changes in strip thickness, coiling tension, and initial temperature of the sleeve on the stress and the temperature inside the coil are studied. Finally, by comparing the model results with measurements and analytical solutions, the effectiveness of the incremental coupled model is verified and the errors caused by the analytical method are analyzed. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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13 pages, 3460 KiB  
Article
Direct In Situ Fabrication of Strong Bonding ZIF-8 Film on Zinc Substrate and Its Formation Mechanism
by Haidong Wang, Jie Liu, Baosheng Liu, Zhechao Zhang, Xiaoxia Ren, Xitao Wang, Pengpeng Wu and Yuezhong Zhang
Metals 2024, 14(12), 1403; https://doi.org/10.3390/met14121403 - 9 Dec 2024
Viewed by 649
Abstract
There is much promise for creating metal organic framework (MOF) films on metal substrates in fields including sensing and electrical conduction. For these applications, direct production of MOF films with strong bonding on metal substrates is extremely desirable. In this study, a simple [...] Read more.
There is much promise for creating metal organic framework (MOF) films on metal substrates in fields including sensing and electrical conduction. For these applications, direct production of MOF films with strong bonding on metal substrates is extremely desirable. In this study, a simple one-step method without the need for additives or pre-modification is used to directly create zeolitic imidazolate framework-8 (ZIF-8) films with strong bonding on zinc substrate. The formation mechanisms of ZIF-8 film are analyzed. The strong bonding ZIF-8 film can be attributed to an in-situ grown ZnO interlayer between the ZIF-8 and substrate. The growth process shows the formation time of zinc oxide on the substrate, which is subsequently covered by ZIF-8 crystals. The ZnO interlayer results from a combination of decomposition products of the solvent and the zinc ions. Furthermore, the ZnO interlayer serves as a sacrificial precursor for the in-situ nucleation and continuous growth of ZIF-8 film. It serves as an anchoring site between ZIF-8 film and substrate, resulting in strong adhesion. This paper describes a simple and straightforward production process that is expected to provide a theoretical basis for the laboratory preparation of ZIF films. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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19 pages, 5129 KiB  
Article
Computational Thermochemistry for Modelling Oxidation During the Conveyance Tube Manufacturing Process
by Megan Kendall, Mark Coleman, Hollie Cockings, Elizabeth Sackett, Chris Owen and Michael Auinger
Metals 2024, 14(12), 1402; https://doi.org/10.3390/met14121402 - 7 Dec 2024
Viewed by 673
Abstract
Conveyance tube manufacturing via a hot-finished, welded route is an energy-intensive process which promotes rapid surface oxidation. During normalisation at approximately 950 °C to homogenise the post-weld microstructure, an oxide mill scale layer grows on tube outer surfaces. Following further thermomechanical processing, there [...] Read more.
Conveyance tube manufacturing via a hot-finished, welded route is an energy-intensive process which promotes rapid surface oxidation. During normalisation at approximately 950 °C to homogenise the post-weld microstructure, an oxide mill scale layer grows on tube outer surfaces. Following further thermomechanical processing, there is significant yield loss of up to 3% of total feedstock due to scale products, and surface degradation due to inconsistent scale delamination. Delaminated scale is also liable to contaminate and damage plant tooling. The computational thermochemistry software, Thermo-Calc 2023b, with its diffusion module, DICTRA, was explored for its potential to investigate oxidation kinetics on curved geometries representative of those in conveyance tube applications. A suitable model was developed using the Stefan problem, bespoke thermochemical databases, and a numerical solution to the diffusion equation. Oxide thickness predictions for representative curved surfaces revealed the significance of the radial term in the diffusion equation for tubes of less than a 200 mm inner radius. This critical value places the conveyance tubes’ dimensions well within the range where the effects of a cylindrical coordinate system on oxidation, owing to continuous surface area changes and superimposed diffusion pathways, cannot be neglected if oxidation on curved surfaces is to be fully understood. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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16 pages, 55876 KiB  
Article
Influence of Post-Weld Heat Treatment on S960QL High-Strength Structural Steel Electron-Beam-Welded Joint
by Raghawendra Pratap Singh Sisodia, Piotr Sliwinski, Dániel Koncz-Horváth and Marek St. Węglowski
Metals 2024, 14(12), 1393; https://doi.org/10.3390/met14121393 - 5 Dec 2024
Viewed by 681
Abstract
Electron beam welding (EBW) is one of the most highly precise methods that is gaining more importance in high-strength structural steel (HSSS) thicker plate application in various vehicles, construction industries, etc. Since it offers particular advantages over arc welding processes like narrow welds, [...] Read more.
Electron beam welding (EBW) is one of the most highly precise methods that is gaining more importance in high-strength structural steel (HSSS) thicker plate application in various vehicles, construction industries, etc. Since it offers particular advantages over arc welding processes like narrow welds, reduced heat-affected zone (HAZ), and low distortion, it inherits lower linear heat input characteristics. The main purpose of this study is to analyze and compare the effect of localized electron beam–post-weld heat treatment (LEB-PWHT) with that of an as-welded EB-welded S960QL joint of a thickness of 12 mm for various joint and HAZ properties. LEB-PWHT can be beneficial in terms of time saving, more local treatment, higher flexibility, energy saving, greater efficiency, increased productivity, etc. In this study, LEB-PWHT was applied to an autogenous EB-welded S960QL joint using a defocused beam. Microstructural characteristics were observed through light optical and scanning electron microscopy (SEM) while mechanical properties, including microhardness, tensile strength, bending, and Charpy V-notch (CVN) impact test, are compared in as-welded and LEB-PWHT joints. The microstructural results showed that the EBW coarse-grain heat-affected zone (CGHAZ) consists of martensite, while the PWHT weld metal contains tempered martensite with carbide precipitates. The fine-grain heat-affected zone (FGHAZ) of EBW exhibits a martensitic and bainitic microstructure, whereas the FGHAZ of the PWHT joint exhibits equiaxed grain with finely dispersed carbides. The hardness decrease after LEB-PWHT in the weld metal and HAZ was approximately 23% and 21%, respectively. An increase in tensile strength (3%) was observed in the LEB-PWHT joints (1082 MPa) compared to the EBW joint (1051 MPa). Both tensile and bending tests demonstrated improved ductility behavior after PWHT. However, the impact test at −40 °C indicated a reduction in toughness in the weld metal of LEB-PWHT (27 J) compared to EBW (63 J). Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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23 pages, 10308 KiB  
Article
High-Cycle Fatigue Characteristics of Aluminum/Steel Clinched and Resistance-Spot-Welded Joints Based on Failure Modes
by Ákos Meilinger, Péter Zoltán Kovács and János Lukács
Metals 2024, 14(12), 1375; https://doi.org/10.3390/met14121375 - 1 Dec 2024
Viewed by 717
Abstract
Materials for lightweight vehicle structures play an increasingly important role in both economic and environmental terms; high-strength steels and aluminum alloys are suitable for this role. Resistance spot welding (RSW) and conventional clinching (CCL) methods can be used for joining vehicle bodies and [...] Read more.
Materials for lightweight vehicle structures play an increasingly important role in both economic and environmental terms; high-strength steels and aluminum alloys are suitable for this role. Resistance spot welding (RSW) and conventional clinching (CCL) methods can be used for joining vehicle bodies and can also be applied for aluminum/steel hybrid joints. Whereas vehicle structures are subjected to cyclic loading, damages can occur due to high-cycle fatigue (HCF) during long-term operation. Systematic HCF test results are rarely found in the literature, while HCF loading basically determines the lifetime of the hybrid joints. The base materials 5754-H22, 6082-T6, and DP600 were used for similar and hybrid RSW and CCL joints, and HCF tests were performed. The number of cycles-to-failure values and failure modes were studied and analyzed. Based on the experimental results, HCF design curves belonging to a 50% failure probability were calculated for all cases, and the curves were compared. Clear relationships were found between the failure modes and fatigue cycle numbers for both joining methods. Considering the steel/steel joints as a base, the load-bearing capacity of the hybrid joints is lower (48.7% and 73.0% for RSW, 35.0% and 38.7% for CCL) and it is even lower for the aluminum/aluminum joints (39.9% and 50.4% for RSW, 31.7% and 35.0% for CCL). With one exception, the load-bearing capacity of the CCL joints is higher than that of the RSW joints (156.1–108.3%). Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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Review

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30 pages, 9979 KiB  
Review
Fatigue Behaviour of Mechanical Joints: A Review
by Animesh Kumar Basak, Dharamvir Singh Bajwa and Alokesh Pramanik
Metals 2025, 15(1), 25; https://doi.org/10.3390/met15010025 - 31 Dec 2024
Viewed by 545
Abstract
Mechanical joints, regardless of materials, are useful when joining multiple components, though there are certain limits when applying them in engineering applications such as fatigue loading. The purpose of this research is to provide a comprehensive review of the trend of fatigue properties [...] Read more.
Mechanical joints, regardless of materials, are useful when joining multiple components, though there are certain limits when applying them in engineering applications such as fatigue loading. The purpose of this research is to provide a comprehensive review of the trend of fatigue properties of common non-thermal mechanical connections such as adhesive, bolted, clinched and riveted joints. Towards that, a narrative approach was taken. In modern engineering applications, most of the joints contain both metallic and non-metallic components. The relevant experimental studies have proven many factors that can affect each type of joint and how they can be implemented in real-time appliances. For instance, the fatigue behaviour of adhesive joints is affected by the bond length, thickness and the use of different materials. Increasing the bond length can enhance its fatigue resistance up to a certain length, whilst increasing the thickness of laminate or adhesive decreases the fatigue life unless the surface roughness increases. On the other hand, different laminate materials can affect the fatigue performance depending on their mechanical properties. These findings will allow readers to have an overall concept of the fatigue behaviour of mechanical joints and the influence of various internal and external parameters on that. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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