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A special issue of Technologies (ISSN 2227-7080). This special issue belongs to the section "Manufacturing Technology".

Deadline for manuscript submissions: closed (31 August 2023) | Viewed by 27546

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Special Issue Editors

Prof. Dr. Sergey N. Grigoriev

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Guest Editor

Department of High-Efficiency Processing Technology, Moscow State University of Technology, 127055 Moscow, Russia
Interests: processing by concentrated energy flows; laser processing; electrophysical machining; heat and hardening treatment; surface finishing and coating; powder metallurgy; nanomaterials; nanocoatings and thin films; thermal spray technologies; process diagnostics and monitoring
Special Issues, Collections and Topics in MDPI journals

Dr. Marina A. Volosova

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Guest Editor

Department of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, 127055 Moscow, Russia
Interests: processing by concentrated energy flows; surface finishing and coating; processing of ceramics; nanocomposites; nanoceramics; nanocoatings and thin films; additive manufacturing; laser processing; electron beam processing; plasma processing; electrophysical and electrochemical processing; spark plasma sintering
Special Issues, Collections and Topics in MDPI journals

Dr. Anna A. Okunkova

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Guest Editor

Department of High-Efficiency Processing Technologies, Moscow State University of Technology STANKIN, Moscow, Russia
Interests: additive manufacturing; electrical discharge machining; high-energy fluxes; laser processing; monitoring; thermal and chemical processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Advanced processing technologies of innovative materials have become challenging in modern mechanical engineering development, where they have to deal with the issues of adapting the latest progressive technologies to production realities to move to the sixth technological order. Today, like never before, questions arise related to the quality of the product’s surface after its growth and repair via additive manufacturing methods, for which additional laser or plasma processing, cleaning, and technologies for applying new nano- and functional coatings can be proposed in the broad context. Fundamental issues of thermal decomposition and mechanical destruction of innovative multicomponent metal alloys, advanced ceramic composites and nanocomposites, multilayer materials and coatings, and other wear- and heat-resistant materials remain especially in demand in the scientific and industrial environment. In addition, issues of in situ monitoring and diagnostics and improvements to the performance of technologies deserve special attention.

The latest achievements in advanced processing technologies of innovative materials have become a relevant topic in the most authoritative scientific journals and conferences for the last half-century. In addition, progressive achievements have received multiple awards in the most prestigious competitions and exhibitions worldwide and at international scientific events.

The Special Issue is devoted to the most recent achievements in the field of innovative nano- and functionally gradient materials, industrial ceramics, and advanced technologies of its processing based on plasma and laser treatment, electrophysical processing using thermal dissociation of materials, and mechanical cutting of the actual metals and alloys.

Prof. Dr. Sergey N. Grigoriev
Dr. Marina A. Volosova
Dr. Anna A. Okunkova
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. Technologies 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 1600 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

additive manufacturing
ceramics
coatings
composites
electrical discharge machining
functionally gradient materials
laser and plasma processing
metals
post-processing
productivity of advanced technologies
properties
surface quality

Published Papers (14 papers)

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Research

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12 pages, 3139 KiB

Open AccessCommunication

Comparison of Shallow (−20 °C) and Deep Cryogenic Treatment (−196 °C) to Enhance the Properties of a Mg/2wt.%CeO₂ Nanocomposite

by Shwetabh Gupta, Gururaj Parande and Manoj Gupta

Technologies 2024, 12(2), 14; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies12020014 - 23 Jan 2024

Cited by 1 | Viewed by 1328

Abstract

Magnesium and its composites have been used in various applications owing to their high specific strength properties and low density. However, the application is limited to room-temperature conditions owing to the lack of research available on the ability of magnesium alloys to perform in sub-zero conditions. The present study attempted, for the first time, the effects of two cryogenic temperatures (−20 °C/253 K and −196 °C/77 K) on the physical, thermal, and mechanical properties of a Mg/2wt.%CeO₂ nanocomposite. The materials were synthesized using the disintegrated melt deposition method followed by hot extrusion. The results revealed that the shallow cryogenically treated (refrigerated at −20 °C) samples display a reduction in porosity, lower ignition resistance, similar microhardness, compressive yield, and ultimate strength and failure strain when compared to deep cryogenically treated samples in liquid nitrogen at −196 °C. Although deep cryogenically treated samples showed an overall edge, the extent of the increase in properties may not be justified, as samples exposed at −20 °C display very similar mechanical properties, thus reducing the overall cost of the cryogenic process. The results were compared with the data available in the open literature, and the mechanisms behind the improvement of the properties were evaluated. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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20 pages, 7644 KiB

Open AccessArticle

Information-Analytical Software for Developing Digital Models of Porous Structures’ Materials Using a Cellular Automata Approach

by Igor Lebedev, Anastasia Uvarova and Natalia Menshutina

Technologies 2024, 12(1), 1; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies12010001 - 20 Dec 2023

Viewed by 1543

Abstract

An information-analytical software has been developed for creating digital models of structures of porous materials. The information-analytical software allows you to select a model that accurately reproduces structures of porous materials—aerogels—creating a digital model by which you can predict their properties. In addition, the software contains models for calculating various properties of aerogels based on their structure, such as pore size distribution and mechanical properties. Models have been implemented that allow the description of various processes in porous structures—hydrodynamics of multicomponent systems, heat and mass transfer processes, dissolution, sorption and desorption. With the models implemented in this software, various digital models for different types of aerogels can be developed. As a comparison parameter, pore size distribution is chosen. Deviation of the calculated pore size distribution curves from the experimental ones does not exceed 15%, which indicates that the obtained digital model corresponds to the experimental sample. The software contains both the existing models that are used for porous structures modeling and the original models that were developed for different studied aerogels and processes, such as the dissolution of active pharmaceutical ingredients and mass transportation in porous media. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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17 pages, 4003 KiB

Open AccessArticle

Improvement of β-SiC Synthesis Technology on Silicon Substrate

by Yana Suchikova, Sergii Kovachov, Ihor Bohdanov, Artem L. Kozlovskiy, Maxim V. Zdorovets and Anatoli I. Popov

Technologies 2023, 11(6), 152; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11060152 - 27 Oct 2023

Cited by 2 | Viewed by 2197

Abstract

This article presents an enhanced method for synthesizing β-SiC on a silicon substrate, utilizing porous silicon as a buffer layer, followed by thermal carbide formation. This approach ensured strong adhesion of the SiC film to the substrate, facilitating the creation of a hybrid hetero-structure of SiC/por-Si/mono-Si. The surface morphology of the SiC film revealed islands measuring 2–6 μm in diameter, with detected micropores that were 70–80 nm in size. An XRD analysis confirmed the presence of spectra from crystalline silicon and crystalline silicon carbide in cubic symmetry. The observed shift in spectra to the low-frequency zone indicated the formation of nanostructures, correlating with our SEM analysis results. These research outcomes present prospects for the further utilization and optimization of β-SiC synthesis technology for electronic device development. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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15 pages, 3248 KiB

Open AccessArticle

Regenerating Iron-Based Adsorptive Media Used for Removing Arsenic from Water

by Ilaria Ceccarelli, Luca Filoni, Massimiliano Poli, Ciro Apollonio and Andrea Petroselli

Technologies 2023, 11(4), 94; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11040094 - 12 Jul 2023

Viewed by 1174

Abstract

Of all the substances that can be present in water intended for human consumption, arsenic (As) is one of the most toxic. Many treatment technologies can be used for removing As from water, for instance, adsorption onto iron media, where commercially available adsorbents are removed and replaced with new media when they are exhausted. Since this is an expensive operation, in this work, a novel and portable plant for regenerating iron media has been developed and tested in four real case studies in Central Italy. The obtained results highlight the good efficiency of the system, which was able, from 2019 to 2023, to regenerate the iron media and to restore its capability to adsorb the As from water almost entirely. Indeed, when the legal threshold value of 10 μg/L is exceeded, the regeneration process is performed and, after that, the As concentration in the water effluent is at the minimum level in all the investigated case studies. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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13 pages, 1160 KiB

Open AccessArticle

Optical Properties of AgInS₂ Quantum Dots Synthesized in a 3D-Printed Microfluidic Chip

by Konstantin Baranov, Ivan Reznik, Sofia Karamysheva, Jacobus W. Swart, Stanislav Moshkalev and Anna Orlova

Technologies 2023, 11(4), 93; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11040093 - 12 Jul 2023

Cited by 1 | Viewed by 2099

Abstract

Colloidal nanoparticles, and quantum dots in particular, are a new class of materials that can significantly improve the functionality of photonics, electronics, sensor devices, etc. The main challenge addressed in the article is modification of the syntheses of colloidal NP to launch them into mass production. It is proposed to use an additive printing method of chips for microfluidic synthesis, and it is shown that our approach allows to offer a cheap, easily scalable and automated synthesis method which allows to increase the product yield up to 60% with improved optical properties of

{AgInS}_{2}

quantum dots. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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11 pages, 2121 KiB

Open AccessArticle

Features of Metalorganic Chemical Vapor Deposition Selective Area Epitaxy of Al_zGa_1−zAs (0 ≤ z ≤ 0.3) Layers in Arrays of Ultrawide Windows

by Viktor Shamakhov, Sergey Slipchenko, Dmitriy Nikolaev, Ilya Soshnikov, Alexander Smirnov, Ilya Eliseyev, Artyom Grishin, Matvei Kondratov, Artem Rizaev, Nikita Pikhtin and Peter Kop’ev

Technologies 2023, 11(4), 89; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11040089 - 07 Jul 2023

Cited by 1 | Viewed by 1103

Abstract

Al_zGa_1−zAs layers of various compositions were grown using metalorganic chemical vapor deposition on a GaAs substrate with a pattern of alternating SiO₂ mask/window stripes, each 100 µm wide. Microphotoluminescence maps and thickness profiles of Al_zGa_1−zAs layers that demonstrated the distribution of the growth rate and z in the window were experimentally studied. It was shown that the layer growth rate and the AlAs mole fraction increased continuously from the center to the edge of the window. It was experimentally shown that for a fixed growth time of 10 min, as z increased from 0 to 0.3, the layer thickness difference between the center of the window and the edge increased from 700 Å to 1100 Å, and the maximum change in z between the center of the window and the edge reached Δz 0.016, respectively. Within the framework of the vapor -phase diffusion model, simulations of the spatial distribution of the layer thickness and z across the window were carried out. It was shown that the simulation results were in good agreement with the experimental results for the effective diffusion length D/k: Ga—85 µm, Al—50 µm. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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13 pages, 2828 KiB

Open AccessEditor’s ChoiceArticle

Two Fe-Zr-B-Cu Nanocrystalline Magnetic Alloys Produced by Mechanical Alloying Technique

by Jason Daza, Wael Ben Mbarek, Lluisa Escoda, Joan Saurina and Joan-Josep Suñol

Technologies 2023, 11(3), 78; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11030078 - 16 Jun 2023

Viewed by 2479

Abstract

Fe-rich soft magnetic alloys are candidates for applications as magnetic sensors and actuators. Spring magnets can be obtained when these alloys are added to hard magnetic compounds. In this work, two nanocrystalline Fe-Zr-B-Cu alloys are produced by mechanical alloying, MA. The increase in boron content favours the reduction of the crystalline size. Thermal analysis (by differential scanning calorimetry) shows that, in the temperature range compressed between 450 and 650 K, wide exothermic processes take place, which are associated with the relaxation of the tensions of the alloys produced by MA. At high temperatures, a main crystallisation peak is found. A Kissinger and an isoconversional method were used to determine the apparent activation of the exothermic processes. The values are compared with those found in the scientific literature. Likewise, adapted thermogravimetry allowed for the determination of the Curie temperature. The functional response has been analysed by hysteresis loop cycles. According to the composition, the decrease of the Fe/B ratio diminishes the soft magnetic behaviour. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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10 pages, 4431 KiB

Open AccessCommunication

Anisotropy Analysis of the Permeation Behavior in Carbon Dioxide-Assisted Polymer Compression Porous Products

by Takafumi Aizawa

Technologies 2023, 11(2), 52; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11020052 - 03 Apr 2023

Viewed by 1249

Abstract

The carbon dioxide-assisted polymer compression method is used to create porous polymer products with laminated fiber sheets that are crimped in the presence of carbon dioxide. In this method, fibers are oriented in the sheet-spread direction, and the intersections of the upper and lower fibers are crimped, leading to several intersections within the porous product. This type of orientation in a porous material is anisotropic. A dye solution was injected via a syringe into a compression product made of poly(ethylene terephthalate) nonwoven fabric with an average fiber diameter of 8 μm. The anisotropy of permeation was evaluated using the aspect ratio of the vertical and horizontal permeation distances of a permeation area. The aspect ratio decreased monotonically with decreasing porosity; it was 2.73 for the 80-ply laminated product with a porosity of 0.63 and 2.33 for the 160-ply laminated product with a porosity of 0.25. A three-dimensional structural analysis using X-ray computed tomography revealed that as the compression ratio increased, the fiber-to-fiber connection increased due to the increase in adhesion points, resulting in decreased anisotropy of permeation. The anisotropy of permeation is essential data for analyzing the sustained release behavior of drug-loaded tablets for future fabrication. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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10 pages, 1723 KiB

Open AccessArticle

Comparative Effect of the Type of a Pulsed Discharge on the Ionic Speciation of Plasma-Activated Water

by Victor Panarin, Eduard Sosnin, Andrey Ryabov, Victor Skakun, Sergey Kudryashov and Dmitry Sorokin

Technologies 2023, 11(2), 41; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11020041 - 14 Mar 2023

Cited by 1 | Viewed by 1347

Abstract

The comparison of ion concentrations, pH index, and conductivity in distilled and ground water after exposure to low-temperature plasma formed by barrier and bubble discharges is performed. It has been found that in the case of groundwater, the best performance for the production of NO₃⁻ anions is provided by the discharge inside the gas bubbles. For distilled water, the barrier discharge in air, followed by saturation of water with plasma products, is the most suitable from this point of view. In both treatments, the maximum energy input into the stock solution is ensured. After 10 min treatment of ground water, the pH index increases and then it decreases. The obtained numerical indicators make it possible to understand in which tasks the indicated treatment modes should be used, their comparative advantages, and disadvantages. From the point of view of energy consumption for obtaining approximately equal (in order of magnitude) amounts of NO₃⁻ anions, both types of discharge treatment are suitable. The research results point to a fairly simple way to convert salts (calcium carbonates) from an insoluble form to soluble one. Namely, when interacting with NO₃⁻ anions, insoluble carbonates pass into soluble nitrates. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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7 pages, 3313 KiB

Open AccessCommunication

Moisture Condensation on Epitaxial Graphene upon Cooling

by Muhammad Farooq Saleem, Niaz Ali Khan, Muhammad Javid, Ghulam Abbas Ashraf, Yasir A. Haleem, Muhammad Faisal Iqbal, Muhammad Bilal, Peijie Wang and Lei Ma

Technologies 2023, 11(1), 30; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11010030 - 13 Feb 2023

Viewed by 1739

Abstract

Condensation of moisture on the epitaxial graphene on 6H-SiC was observed below room temperature despite continuous nitrogen flow on the graphene surface. Raman peaks associated with ice were observed. A combination of peaks in the frequency range of 500–750 cm⁻¹, along with a broad peak centered at ~1327 cm⁻¹, were also observed and were assigned to airborne contaminants. The latter is more important since its position is in the frequency range where the defect-associated D band of graphene appears. This band can be easily misunderstood to be the D band of graphene, particularly when the Raman spectrum is taken below room temperature. This peak was even observed after the sample was brought back to room temperature due to water stains. This work highlights the importance of careful Raman investigation of graphene below room temperature and its proper insulation against moisture. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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22 pages, 6361 KiB

Open AccessEditor’s ChoiceArticle

Investigation of Surface Layer Condition of SiAlON Ceramic Inserts and Its Influence on Tool Durability When Turning Nickel-Based Superalloy

by Sergey N. Grigoriev, Marina A. Volosova and Anna A. Okunkova

Technologies 2023, 11(1), 11; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11010011 - 12 Jan 2023

Cited by 3 | Viewed by 2004

Abstract

SiAlON is one of the problematic and least previously studied but prospective cutting ceramics suitable for most responsible machining tasks, such as cutting sophisticated shapes of aircraft gas turbine engine parts made of chrome–nickel alloys (Inconel 718 type) with increased mechanical and thermal loads (semi-finishing). Industrially produced SiAlON cutting inserts are replete with numerous defects (stress concentrators). When external loads are applied, the wear pattern is difficult to predict. The destruction of the cutting edge, such as the tearing out of entire conglomerates, can occur at any time. The complex approach of additional diamond grinding, lapping, and polishing combined with an advanced double-layer (CrAlSi)N/DLC coating was proposed here for the first time to minimize it. The criterion of failure was chosen to be 0.4 mm. The developed tri-nitride coating sub-layer plays a role of improving the main DLC coating adhesion. The microhardness of the DLC coating was 28 ± 2 GPa, and the average coefficient of friction during high-temperature heating (up to 800 °C) was ~0.4. The average durability of the insert after additional diamond grinding, lapping, polishing, and coating was 12.5 min. That is superior to industrial cutting inserts and those subjected to (CrAlSi)N/DLC coating by 1.8 and 1.25 times, respectively. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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21 pages, 7053 KiB

Open AccessEditor’s ChoiceArticle

Electrical Discharge Machining of Alumina Using Cu-Ag and Cu Mono- and Multi-Layer Coatings and ZnO Powder-Mixed Water Medium

by Anna A. Okunkova, Marina A. Volosova, Khaled Hamdy and Khasan I. Gkhashim

Technologies 2023, 11(1), 6; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies11010006 - 27 Dec 2022

Cited by 2 | Viewed by 1912

Abstract

The paper aims to extend the current knowledge on electrical discharge machining of insulating materials, such as cutting ceramics used to produce cutting inserts to machine nickel-based alloys in the aviation and aerospace industries. Aluminum-based ceramics such as Al₂O₃, AlN, and SiAlON are in the most demand in the industry but present a scientific and technical problem in obtaining sophisticated shapes. One of the existing solutions is electrical discharge machining using assisting techniques. Using assisting Cu-Ag and Cu mono- and multi-layer coatings of 40–120 µm and ZnO powder-mixed deionized water-based medium was proposed for the first time. The developed coatings were subjected to tempering and testing. It was noticed that Ag-adhesive reduced the performance when tempering had a slight effect. The unveiled relationship between the material removal rate, powder concentration, and pulse frequency showed that performance was significantly improved by adding assisting powder up to 0.0032–0.0053 mm³/s for a concentration of 14 g/L and pulse frequency of 2–7 kHz. Further increase in concentration leads to the opposite trend. The most remarkable results corresponded to the pulse duration of 1 µs. The obtained data enlarged the knowledge of texturing insulating cutting ceramics using various powder-mixed deionized water-based mediums. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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9 pages, 1928 KiB

Open AccessEditor’s ChoiceArticle

A Machine-Learning-Based Approach to Critical Geometrical Feature Identification and Segmentation in Additive Manufacturing

by Alexandre Staub, Lucas Brunner, Adriaan B. Spierings and Konrad Wegener

Technologies 2022, 10(5), 102; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies10050102 - 16 Sep 2022

Cited by 2 | Viewed by 1881

Abstract

Additive manufacturing (AM) processes offer a good opportunity to manufacture three- dimensional objects using various materials. However, many of the processes, notably laser Powder bed fusion, face limitations in manufacturing specific geometrical features due to their physical constraints, such as the thermal conductivity of the surrounding medium, the internal stresses, and the warpage or weight of the part being manufactured. This work investigates the opportunity to use machine learning algorithms in order to identify hard-to-manufacture geometrical features. The segmentation of these features from the main body of the part permits the application of different manufacturing strategies to improve the overall manufacturability. After selecting features that are particularly problematic during laser powder bed fusion using stainless steel, an algorithm is trained using simple geometries, which permits the identification of hard-to-manufacture features on new parts with a success rate of 88%, showing the potential of this approach. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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Review

Jump to: Research

25 pages, 5426 KiB

Open AccessEditor’s ChoiceReview

Surface Quality of Metal Parts Produced by Laser Powder Bed Fusion: Ion Polishing in Gas-Discharge Plasma Proposal

by Alexander S. Metel, Sergey N. Grigoriev, Tatiana V. Tarasova, Yury A. Melnik, Marina A. Volosova, Anna A. Okunkova, Pavel A. Podrabinnik and Enver S. Mustafaev

Technologies 2021, 9(2), 27; https://0-doi-org.brum.beds.ac.uk/10.3390/technologies9020027 - 09 Apr 2021

Cited by 5 | Viewed by 3368

Abstract

Additive manufacturing has evolved over the past decades into a technology that provides freedom of design through the ability to produce complex-shaped solid structures, reducing the operational time and material volumes in manufacturing significantly. However, the surface of parts manufactured by the additive method remains now extremely rough. The current trend of expanding the industrial application of additive manufacturing is researching surface roughness and finishing. Moreover, the limited choice of materials suitable for additive manufacturing does not satisfy the diverse design requirements, necessitating additional coatings deposition. Requirements for surface treatment and coating deposition technology depend on the intended use of the parts, their material, and technology. In most cases, they cannot be determined based on existing knowledge and experience. It determines the scientific relevance of the analytical research and development of scientific and technological principles of finishing parts obtained by laser additive manufacturing and functional coating deposition. There is a scientific novelty of analytical research that proposes gas-discharge plasma processing for finishing laser additive manufactured parts and technological principles development including three processing stages—explosive ablation, polishing with a concentrated beam of fast neutral argon atoms, and coating deposition—for the first time. Full article

(This article belongs to the Special Issue Advanced Processing Technologies of Innovative Materials)

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