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This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

Material extrusion-based additive manufacturing is a prominent manufacturing technique to fabricate complex geometrical three-dimensional (3D) parts. Despite the indisputable advantages of material extrusion-based technique, the poor surface and subsurface integrity hinder the industrial application of this technology. The purpose of this study is introducing the hot air jet treatment (HAJ) technique for surface treatment of additive manufactured parts.

In the presented research, novel theoretical formulation and finite element models are developed to study and model the polishing mechanism of printed parts surface through the HAJ technique. The model correlates reflow material volume, layer width and layer height. The reflow material volume is a function of treatment temperature, treatment velocity and HAJ velocity. The values of reflow material volume are obtained through the finite element modeling model due to the complexity of the interactions between thermal and mechanical phenomena. The theoretical model presumptions are validated through experiments, and the results show that the treatment parameters have a significant impact on the surface characteristics, hardness and dimensional variations of the treated surface.

The results demonstrate that the average value of error between the calculated theoretical results and experimental results is 14.3%. Meanwhile, the 3D plots of Ra and Rq revealed that the maximum values of Ra and Rq reduction percentages at 255°C, 270°C, 285°C and 300°C treatment temperatures are (35.9%, 33.9%), (77.6%,76.4%), (94%, 93.8%) and (85.1%, 84%), respectively. The scanning electron microscope results illustrate three different treatment zones and the treatment-induced and manufacturing-induced entrapped air relief phenomenon. The measured results of hardness variation percentages and dimensional deviation percentages at different regimes are (8.33%, 0.19%), (10.55%, 0.31%) and (−0.27%, 0.34%), respectively.

While some studies have investigated the effect of the HAJ process on the structural integrity of manufactured items, there is a dearth of research on the underlying treatment mechanism, the integrity of the treated surface and the subsurface characteristics of the treated surface.

Selective jet electrodeposition (SJED) is an emerging additive manufacturing (AM) technology for realizing metallic components of nano and micro sizes. The deposited parts on the substrate form metallurgical bonding, so separating them from the substrate is an unsolved issue. Therefore, this paper aims to propose a method for separating the deposited micro parts from a sacrificial substrate. Furthermore, single and multi-bead optimization is performed to fabricate microparts with varying density.

A typical SJED process consists of a nozzle (to establish a column of electrolytes) retrofitted on a machine tool (to provide relative motion between substrate and nozzle) that deposits material atom-by-atom on a conductive substrate.

A comprehensive study of process parameters affecting the layer height, layer width and morphology of the deposited micro-parts has been provided. The uniformity in the deposited parts can be achieved with the help of low applied voltage and high scanning speed. Multi-bead analysis for the flat surface condition is experimentally performed, and the flat surface condition is achieved when the centre distance between two adjacent beads is kept at half of the width of a single bead.

Although several literatures have demonstrated that the SJED process can be used for the fabrication of parts; however, part fabrication through multi-bead optimization is limited. Moreover, the removal of the fabricated part from the substrate is the novelty of the current work.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process.

To overcome the lack of certainty associated with correlations and relationships in quality functional deployment, fuzzy numbers have been integrated with the quality functional deployment framework. Twenty performance measures have been identified from the literature under five groups, namely, mechanical properties, physical properties, geometrical properties, cost and material properties. Using house of quality weights are allocated to performance measures and groups, relationships are established between performance measures and strategies, and correlations are assigned between strategies. Finally, for each strategy, relative importance, score and crisp values are calculated.

Inter pass cold rolling process strategy is computed with the highest crisp value of 15.80 which is followed by peening process, heat treatment process, friction stir processing, inter pass cooling process,] and oscillation process strategy.

To the best of the authors’ knowledge, there has been no research in the literature that analyzes the strategies to improve the quality and productivity of the wire arc additive manufacturing process.

This paper aims to compare the wear behavior, surface roughness, friction coefficient and volume loss of high-velocity oxy-fuel (HVOF) sprayed WC–Co and WC–Cr₃C₂–Ni coatings on AISI 1095 steel with spraying times of 10 and 15 s.

In this study, the pin-on-disc testing technique was used to evaluate the wear characteristics at a speed of 0.24 m/s, load of 40 N and test time of 60 min under dry conditions at room temperature. The wear characteristics were examined and analyzed by scanning electron microscopy and energy dispersive X-ray spectroscopy. The surface roughness of a coated surface was measured, and microhardness measurements were performed on the cross-sectioned and polished surfaces of the coating.

Spraying time and powder material affected the hardness of HVOF coatings due to differences in the porosity of the coated layers. The average hardness of the WC–Cr₃C₂–Ni coating with a spaying time of 15 s was approximately 14% higher than that of the WC–Cr₃C₂–Ni coating with a spraying time of 10 s. Under an applied load of 40 N, the WC–Co coating with a spraying time of 15 s had the lowest variation in the friction coefficient compared with the other coatings. The WC–Co coating with a spraying time of 10 s had the lowest average and variation in volume loss compared to the other coatings. The WC–Cr₃C₂–Ni coating with a spraying time of 10 s exhibited the highest average volume loss. The wear features changed slightly with the spraying time owing to variations in the hardness and friction coefficient.

This study investigated tribological performance of WC–Co; WC-Cr₃C₂-Ni coatings with spraying times of 10 and 15 s using pin-on-disc tribometer by rotating the relatively soft pin (C45 steel) against hard coated substrate (disc).

This study aims to investigate the performance of filament-based material extrusion additive manufacturing (MEX), combined with debinding and sintering, as a novel approach to manufacturing ceramic components.

A commercial ZrO₂ filament was selected and analysed by infra-red (IR) spectroscopy, rheology and thermo-gravimetry. The influence of the print parameters (layer thickness, flow rate multiplier, printing speed) and sintering cycle were investigated to define a suitable printing and sintering strategy. Biaxial flexure tests were applied on sintered discs realised with optimised printing strategies, and the results were analysed via Weibull statistics to evaluate the mechanical properties of printed components. The hardness and thermal conductivity of sintered components were also tested.

Layer thickness and flow rate multiplier of the printing process were proved to have significant effect on the density of as-printed parts. Optimised samples display a sintered density >99% of the theoretical density, 20% linear sintering shrinkage, a characteristic flexural strength of 871 MPa with a Weibull modulus of 4.9, a Vickers hardness of 12.90 ± 0.3 GPa and a thermal conductivity of 3.62 W/mK. Gyroids were printed for demonstration purposes.

To the best of the authors’ knowledge, this work is the first to apply biaxial flexure tests and Weibull statistics to additively manufactured MEX zirconia components, hence providing comparable results to other additive technologies. Moreover, fractography analysis builds the connection between printing defects and the fracture mechanism of bending. This study also provides guidelines for fabricating high-density zirconia components with MEX.

The purpose of this paper is to investigate the effect of laser peening (LP) on mechanical and wear properties of 304 stainless steel sheet.

Three-dimensional morphology, micro-hardness and micro-structure of shocked samples were tested. The wear amount, wear track morphology and wear mechanism were also characterized under dry sliding wear using Al₂O₃ ceramics ball.

The LP treatment generates deformation twins that contribute to the grain refinement and hardness increase. The wear test displays that the wear mechanism of samples is mainly abrasive wear and oxidation wear at 10 N load. While at 30 N, the delamination and adhesion areas of treated sample are reduced visibly compared to untreated ones.

This study specifically investigates the mechanical and wear properties of 304 stainless steel after the direct action of LP on its surface, which shows an effective improvement on the wear resistance. For example, the wear loss of processed sample is reduced by 19% at 30 N, the friction coefficient decreases from 0.4714 to 0.4308 and the groove depth is reduced from 78.1 to 74.4 µm under same condition.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0007/

This study aims to investigate the corrosion behavior of cold-rolled Fe₃₅Ni₂₀C_r12Mn_(28-x)Al_x high-entropy alloys (HEAs) using the potentiodynamic polarization technique in 1 M H₂SO₄ acid. Additionally, the influence of molybdenum (Mo) additions as inhibitors and the effect of variations in cold rolling reduction ratios and Al content on corrosion behavior are examined.

Two cold rolling reduction ratios, namely, 50% (R50) and 90% (R90), were examined for the cold-rolled Fe₃₅Ni₂₀Cr₁₂Mn₂₈Al₅ (Al₅) and Fe₃₅Ni₂₀Cr₁₂Mn₂₃Al₁₀ (Al₁₀) HEAs. Mo inhibitor additions were introduced at varying concentrations of 0.3, 0.6 and 0.9 Wt.%. The potentiodynamic polarization technique was used to evaluate the corrosion rates (CRs) under different experimental conditions.

The results indicate that the addition of 0.3 Wt.% Mo in 1 M H₂SO₄ yielded the lowest CR for both R50 and R90, irrespective of the Al content in the HEAs. However, the highest CR was observed at 0.6 Wt.% Mo addition. Furthermore, increasing the concentration of Al resulted in a corresponding rise in the CR. Comparatively, the CR decreased significantly when the cold rolling reduction ratio increased from R50 to R90.

This research provides valuable insights into the intricate relationship between Mo inhibitors, cold rolling reduction ratio, Al content and the resulting corrosion behavior of Fe₃₅Ni₂₀Cr₁₂Mn_(28-x)Al_x HEAs. The comprehensive analysis of corroded HEAs, including surface morphology, compositions and elemental distribution mapping, contributes to the understanding of the corrosion mechanisms and offers potential strategies for enhancing the corrosion behavior of HEAs.

This study aims to synthesize two different benzoxazines (Bz) monomers using bio-based and petroleum-based primary amines, respectively, and they have been compared to study their thermal and mechanical performances.

A bio-based bisphenol, Divanillin (DiVa), was formed by reacting two moles of vanillin with one mole of ethylenediamine (EDA) which was then reacted firstly with paraformaldehyde and EDA to form the benzoxazine DiVa-EDA-Bz, and secondly with paraformaldehyde and furfuryl amine (FFA) to form the benzoxazine DiVa-FFA-Bz. The molecular structure and thermal properties of the benzoxazines were characterized by fourier transform infrared spectroscopy and nuclear magnetic resonance (1H,13C) spectroscopies, differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA), respectively. The benzoxazines were further coated on mild steel panels to evaluate their mechanical properties and chemical resistance.

The DSC results of DiVa-FFA-Bz showed two exothermic peaks related to crosslinking compared to the one in DiVa-EDA-Bz. The DiVa-FFA-Bz also showed a higher heat of polymerization than DiVa-EDA-Bz. The TGA results showed that DiVa-FFA-Bz exhibited higher thermal stability with a residual char of 54.10% than 43.24% for DiVa-EDA-Bz. The chemical resistance test results showed that DiVa-FFA-Bz showed better chemical resistance and mechanical properties due to its higher crosslinking density.

This study shows the use of bio-based materials, vanillin and FFA, for synthesizing a benzoxazine resin and its application at high temperatures.