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This study aims to understand the current production scenario emphasizing the significance of green manufacturing in achieving economic and environmental sustainability goals to fulfil future needs; to determine the viability of particular strategies and actions performed to increase the process efficiency of electrical discharge machining; and to uphold the values of sustainability in the nonconventional manufacturing sector and to identify future works in this regard.

A thorough analysis of numerous experimental studies and findings is conducted. This prominent nontraditional machining process’s potential machinability and sustainability challenges are discussed, along with the current research to alleviate them. The focus is placed on modifications to the dielectric fluid, choosing affordable substitutes and treating consumable tool electrodes.

Trans-esterified vegetable oils, which are biodegradable and can be used as a substitute for conventional dielectric fluids, provide pollution-free machining with enhanced surface finish and material removal rates. Modifying the dielectric fluid with specific nanomaterials could increase the machining rate and demonstrate a decrease in machining flaws such as micropores, globules and microcracks. Tool electrodes subjected to cryogenic treatment have shown reduced tool metal consumption and downtime for the setup.

The findings suggested eco-friendly machining techniques and optimized control settings that reduce energy consumption, lowering operating expenses and carbon footprints. Using eco-friendly dielectrics, including vegetable oils or biodegradable dielectric fluids, might lessen the adverse effects of the electrical discharge machine operations on the environment. Adopting sustainable practices might enhance a business’s reputation with the public, shareholders and clients because sustainability is becoming increasingly significant across various industries.

A detailed general review of green nontraditional electrical discharge machining process is provided, from high-quality indexed journals. The findings and results contemplated in this review paper can lead the research community to collectively apply it in sustainable techniques to enhance machinability and reduce environmental effects.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

In many of today’s manufacturing industries, such as automobile, aerospace, defence, die and mould making, medical and electrical discharge machining (EDM) has emerged as an effective material removal process. In this process, a series of discontinuous electric discharges is used for removing material from the workpiece in the form of craters generating a replica of the tool into the workpiece in a dielectric environment. Appropriate selection of the tool electrode material and combination of input parameters is an important requirement for performance enhancement of an EDM process. This paper aims to optimize an EDM process using single-valued neutrosophic grey relational analysis using Cu-multi-walled carbon nanotube (Cu-MWCNT) composite tool electrode.

This paper proposes the application of grey relational analysis (GRA) in a single-valued neutrosophic fuzzy environment to identify the optimal parametric intermix of an EDM process while considering Cu-MWCNT composite as the tool electrode material. Based on Taguchi’s L9 orthogonal array, nine experiments are conducted at varying combinations of four EDM parameters, i.e. pulse-on time, duty factor, discharge current and gap voltage, with subsequent measurement of two responses, i.e. material removal rate (MRR) and tool wear rate (TWR). The electrodeposition process is used to fabricate the Cu-MWCNT composite tool.

It is noticed that both the responses would be simultaneously optimized at higher levels of pulse-on time (38 µs) and duty factor (8), moderate level of discharge current (5 A) and lower level of gap voltage (30 V). During bi-objective optimization (maximization of MRR and minimization of TWR) of the said EDM process, the achieved values of MRR and TWR are 243.74 mm³/min and 0.001034 g/min, respectively.

Keeping in mind the type of response under consideration, their measured values for each of the EDM experiments are expressed in terms of linguistic variables which are subsequently converted into single-valued neutrosophic numbers. Integration of GRA with single-valued neutrosophic sets would help in optimizing the said EDM process with the Cu-MWCNT composite tool while simultaneously considering truth-membership, indeterminacy membership and falsity-membership degrees in a human-centric uncertain decision-making environment.

This study aims to investigate the optimal process parameters of the wire-cut electrical discharge machining (WCEDM) for the machining of the GZR-AA7475 hybrid metal matrix composite (HMMC). HMMCs are prepared with 2 Wt.% graphite and 4 Wt.% zirconium dioxide reinforced with aluminium alloy 7475 (GZR-AA7475) composite by using the stir casting method. The objective is to enhance the mechanical properties of the material while preserving its unique features. WCEDM with a 0.18 mm molybdenum wire electrode is used for machining the composite.

To conduct experimental studies, a Taguchi L27 orthogonal array was adopted. Input variables such as peak current (I_p), pulse-on-time (T_ON) and flushing pressure (P_F) were used. The effect of process parameters on the output responses, such as material removal rate (MRR), surface roughness rate (SRR) and wire wear ratio (WWR), were investigated. The grey relational analysis (GRA) is used to obtain the optimal combination of the process parameters. Analysis of variance (ANOVA) was also used to identify the significant process parameters affecting the output responses.

Results from the current study concluded that the optimal condition for grey relational grade is obtained at T_ON = 105 µs, I_p = 100 A and P_F = 90 kg/cm². Peak current is the most prominent parameter influencing the MRR, whereas SRR and WRR are highly influenced by flushing pressure.

Identifying the optimal process parameters in WCEDM for machining of GZR-AA7475 HMMC. ANOVA and GRA are used to obtain the optimal combination of the process parameters.

The purpose of this study is analysis of deformation and vibrations of turbine blades produced by high electrolyte pressure during electrochemical machining.

An experimental setup was designed, experiments were conducted and the obtained results were compared with the finite element results. The deformations were measured according to various flow rates of electrolyte. In finite element calculations, the pressure distribution created by the electrolyte on the blade surface was obtained in the ANSYS® (A finite element analysis software) Fluent software and transferred to the static structural where the deformation analysis was carried out. Three different parameters were examined, namely blade thickness, blade material and electrolyte pressure on blade disk caused by mass flow rate. The deformation results were compared with the gap distances between cathode and anode.

Large deformations were obtained at the free end of the blade and the most curved part of it. The appropriate pressure values for the electrolyte to be used in the production of blisk blades were proposed numerically. It has been determined that high pressure applications are not suitable for gap distance lower than 0.5 mm.

When the literature is examined, it is required that the high speed flow of the electrolyte is desired in order to remove the parts that are separated from the anode from the machining area during electrochemical machining. However, the electrolyte flowing at high speeds causes high pressure in the blisk blades, excessive deformation and vibration of the machined part, and as a result, contact of the anode with the cathode. This study provides important findings for smooth electro chemical machining at high electrolyte flows.

This study aims to investigate the morphology and physicochemical properties of BiOBr/Polyvinylidene fluoride (PVDF) composite membranes and the differences in the properties of BiOBr/PVDF composite membranes made by adding different precursor ratios during the casting process.

In this paper, sodium bromide and Bi(NO3)3 were used as precursors for the preparation of BiOBr photocatalysts, and PVDF membranes were modified by using the phase conversion method in conjunction with the in situ deposition method to produce BiOBr/PVDF hydrophilic composite membranes with both membrane separation and photocatalytic capabilities.

The characterization results confirmed that the composites were successfully and homogeneously co-mingled in the PVDF membranes. The related performance of the composite membrane was tested, and it was found that the composite membrane with the optimal precursor incorporation ratio had good photocatalytic efficiency and antipollution ability; the removal efficiencies of methyl orange, rhodamine B and methylene blue were 80.43%, 85.02% and 86.94%, respectively, in 2.5 h. The photocatalytic efficiency of composite membranes with different precursor ratios increased and then decreased with the increase of the precursor addition ratio.

The composite membrane is prepared by phase conversion method with in situ deposition method, and the BiOBr material has unique advantages for the degradation of organic dyes. The comprehensive experimental data can be known that the composite membrane prepared in this paper has high degradation efficiency and good durability for organic dyes.

This study’s aim is to introduce a high-performance sorbent for the removal of both anionic (Congo red; CR) and cationic (methylene blue; MB) dyes from aqueous solutions.

Sodium silicate is adopted as a substrate for GO and AgNPs with positive charge are used as modifiers. The synthesized nanocomposite is characterized by FTIR, FESEM, EDS, BET and XRD techniques. Then, some of the most effective parameters on the removal of CR and MB dyes such as solution pH, sorbent dose, adsorption equilibrium time, primary dye concentration and salt effect are optimized using the spectrophotometry technique.

The authors successfully achieved notable maximum adsorption capacities (Qmax) of CR and MB, which were 41.15 and 37.04 mg g⁻¹, respectively. The required equilibrium times for maximum efficiency of the developed sorbent were 10 and 15 min for CR and MB dyes, respectively. Adsorption equilibrium data present a good correlation with Langmuir isotherm, with a correlation coefficient of R2 = 0.9924 for CR and R2 = 0.9904 for MB, and kinetic studies prove that the dye adsorption process follows pseudo second-order models (CR R2 = 0.9986 and MB R2 = 0.9967).

The results showed that the proposed mechanism for the function of the developed sorbent in dye adsorption was based on physical and multilayer adsorption for both dyes onto the active sites of non-homogeneous sorbent.

The as-prepared nano-adsorbent has a high ability to remove both cationic and anionic dyes; moreover, to the high efficiency of the adsorbent, it has been tried to make its synthesis steps as simple as possible using inexpensive and available materials.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

This study aims to evaluate the efficiency of various techniques for enhancing indoor air quality (IAQ) in construction. It analyzed the alterations in the concentration of indoor air pollutants over time for each product employed in controlling pollution sources and removing it, which included eco-friendly substances and adsorbents. The study will provide more precise and dependable data on the effectiveness of these control methods, ultimately supporting the creation of more efficient and sustainable approaches for managing indoor air pollution in buildings.

The research investigates the impact of eco-friendly materials and adsorbents on improving indoor air quality (IAQ) in Dubai's tall apartment buildings. Field experiments were conducted in six units of The Gate Tower, comparing the IAQ of three units built with “excellent” grade eco-friendly materials with three built with “good” grade materials. Another experiment evaluated two adsorbent products (H and Z) in the Majestic Tower over six months. Results indicate that “excellent” grade materials significantly reduced toluene emissions. Adsorbent product Z showed promising results in pollutant reduction, but there is concern about the long-term behavior of adsorbed chemicals. The study emphasizes further research on household pollutant management.

The research studied the effects of eco-friendly materials and adsorbents on indoor air quality in Dubai's new apartments. It found that apartments using “excellent” eco-friendly materials had significantly better air quality, particularly reduced toluene concentrations, compared to those using “good” materials. However, high formaldehyde (HCHO) emissions were observed from wood products. While certain construction materials led to increased ethylbenzene and xylene levels, adsorbent product Z showed promise in reducing pollutants. Yet, there is a potential concern about the long-term rerelease of these trapped chemicals. The study emphasizes the need for ongoing research in indoor pollutant management.

The research, while extensive, faced limitations in assessing the long-term behavior of adsorbed chemicals, particularly the potential for rereleasing trapped pollutants over time. Despite the study spanning a considerable period, indoor air pollutant concentrations in target households did not stabilize, making it challenging to determine definitive improvement effects and reduction rates among products. Comparisons were primarily relative between target units, and the rapid rise in pollutants during furniture introduction warrants further examination. Consequently, while the research provides essential insights, it underscores the need for more prolonged and comprehensive evaluations to fully understand the materials' and adsorbents' impacts on indoor air quality.

The research underscores the importance of choosing eco-friendly materials in new apartment constructions for better IAQ. Specifically, using “excellent” graded materials can significantly reduce harmful pollutants like toluene. However, the study also highlights that certain construction activities, such as introducing furniture, can rapidly elevate pollutant levels. Moreover, while adsorbents like product Z showed promise in reducing pollutants, there is potential for adsorbed chemicals to be rereleased over time. For practical implementation, prioritizing higher-grade eco-friendly materials and further investigation into furniture emissions and long-term behavior of adsorbents can lead to healthier indoor environments in newly built apartments.

The research offers a unique empirical assessment of eco-friendly materials' impact on indoor air quality within Dubai's rapidly constructed apartment buildings. Through field experiments, it directly compares different material grades, providing concrete data on pollutant levels in newly built environments. Additionally, it explores the efficacy of specific adsorbents, which is of high value to the construction and public health sectors. The findings shed light on how construction choices can influence indoor air pollution, offering valuable insights to builders, policymakers and residents aiming to promote public health and safety in urban living spaces.

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.