Manufacturing and Processing of Materials for Transport Industry

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Topic Information

Dear Colleagues,

Logistics is an important source of greenhouse gas emissions. The global aim to reduce greenhouse gas emissions determines the need to reduce energy consumption, e.g., in all means of transport. In addition to the development of new forms of propulsion, it is necessary to develop means of reducing the overall weight of transport vehicles. New types of materials, especially composite materials, cermetals, new types of alloys, etc., ensure high strength, fatigue life and stiffness. The possibility of using new types of light materials requires developing and adapting the technology of shaping and joining to new production conditions. Therefore, we launched this Topic initiative, which will bring together journals publishing articles focused on advances in plastic-forming and thin-walled-structure-bonding technologies. The main goal of this Topic is the publication of high-quality manuscripts dealing with research on new joining technologies and broad research on the properties of these joints: for example, shaping composites, metals and cermetals create structures that are rigid and light at the same time. Our ambition is for this Topic to become a kind of platform for the exchange of views on research achievements and to review the latest technologies that have been, or in the near future will be, used in aviation, automotive, shipbuilding and other industries where weight reduction is required. We encourage authors to submit manuscripts related to a wide range of topics described by the keywords below.

Prof. Dr. Dariusz Fydrych
Prof. Dr. Andrzej Kubit
Dr. Ankur Gupta
Dr. Agnieszka Kowalczyk
Dr. Jan Klett
Prof. Dr. Ján Slota
Dr. Wojciech Suder
Dr. Balázs Varbai
Dr. Abbas Tamadon
Topic Editors

Keywords

Participating Journals

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Lubricants lubricants	3.5	4.1	2013	14.8 Days	CHF 2600
Materials materials	3.4	5.2	2008	13.9 Days	CHF 2600
Metals metals	2.9	4.4	2011	15 Days	CHF 2600
Processes processes	3.5	4.7	2013	13.7 Days	CHF 2400
Sustainability sustainability	3.9	5.8	2009	18.8 Days	CHF 2400

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Published Papers (7 papers)

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All Lubricants Materials Metals Processes Sustainability

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16 pages, 776 KiB  

Open AccessArticle

Optimizing Manufacturing Cycles to Improve Production: Application in the Traditional Shipyard Industry

by Ikhlef Jebbor, Zoubida Benmamoun and Hanaa Hachimi

Processes 2023, 11(11), 3136; https://0-doi-org.brum.beds.ac.uk/10.3390/pr11113136 - 02 Nov 2023

Viewed by 1487

Abstract

This article explores the important role of traditional shipyards in the global maritime industry, covering aspects of construction, repair, and maintenance. With the advent of faster manufacturing techniques, traditional shipyards face important challenges, such as planning errors, coordination problems, delivery delays, and underutilization [...] Read more.

This article explores the important role of traditional shipyards in the global maritime industry, covering aspects of construction, repair, and maintenance. With the advent of faster manufacturing techniques, traditional shipyards face important challenges, such as planning errors, coordination problems, delivery delays, and underutilization of technology, which results in high costs, reduced productivity, and prolonged projects. The application of Manufacturing Cycle Efficiency (MCE) emerged as an important solution to significantly increase production efficiency. MCE empowers shipyards to deal effectively with waste, bottlenecks, and disruptions, thereby increasing performance, competitiveness, and profitability. Using a comprehensive approach that uses both qualitative and quantitative methods, including field surveys, and in-depth interviews in the traditional shipyard industry, this research identifies Nonvalue-Added (NVA) processes, conducts process mapping, and calculates MCE. The findings reported in this article underscore the significant wastage in the production process, indicating an urgent need for improvement, given the current average MCE value of 67.08%, indicating considerable room for improvement. This article provides innovative perspectives on optimizing the traditional shipyard industry through production cycle efficiencies while offering actionable recommendations. Key focus areas include integrating management systems, adopting advanced technologies, and implementing sustainable strategies to improve MCE, especially by reducing nonvalue-added time wastage, such as inspection and storage. By implementing strategies that optimize production, minimize waste, and overcome the challenges of global competition, this research contributes to improving MCE. In conclusion, this study is an invaluable guide for industry stakeholders, enabling them to enhance their competitiveness and adapt effectively to a dynamic business environment. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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23 pages, 16571 KiB  

Open AccessArticle

Numerical Calculation of High-Strength-Steel Saddle Plate Forming Suitable for Lightweight Construction of Ships

by Shun Wang, Jinliang Dai, Ji Wang, Rui Li, Jiayan Wang and Zhikang Xu

Materials 2023, 16(10), 3848; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16103848 - 19 May 2023

Cited by 2 | Viewed by 1123

Abstract

With the demand for construction of lightweight ships and polar ships, high-strength steel is increasingly applied in shipbuilding. There are a large number of complex curved plates to be processed in ship construction. The main method for forming a complex curved plate is [...] Read more.

With the demand for construction of lightweight ships and polar ships, high-strength steel is increasingly applied in shipbuilding. There are a large number of complex curved plates to be processed in ship construction. The main method for forming a complex curved plate is line heating. A saddle plate is an important type of double-curved plate, which affects the resistance performance of the ship. The existing research on high-strength-steel saddle plates is lacking. To solve the problem of forming for high-strength-steel saddle plates, the numerical calculation of line heating for a EH36 steel saddle plate was studied. By combining it with a line heating experiment of low-carbon-steel saddle plates, the feasibility of numerical calculation based on the thermal elastic–plastic theory for high-strength-steel saddle plates was verified. Under the premise that the processing conditions such as the material parameters, heat transfer parameters, and the constraint mode of the plate were correctly designed, the effects of the influencing factors on deformation of the saddle plate could be studied by the numerical calculation method. The numerical calculation model of line heating for high-strength-steel saddle plates was established, and the effects of geometric parameters and forming parameters on shrinkage and deflection were studied. This research can provide ideas for the lightweight construction of ships and provide data support for automatic processing of curved plates. It can also provide inspiration for curved plate forming in fields such as aerospace manufacturing, the automotive industry, and architecture. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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15 pages, 4833 KiB  

Open AccessArticle

Effects of Contact Conditions at Wire–Die Interface on Temperature Distribution during Wire Drawing

by Joong-Ki Hwang and Young-Chul Chang

Processes 2023, 11(2), 513; https://0-doi-org.brum.beds.ac.uk/10.3390/pr11020513 - 08 Feb 2023

Cited by 1 | Viewed by 2772

Abstract

The effects of contact conditions at the wire–die interface on the temperature distribution of the specimen and die are investigated to understand the wire drawing process. Finite element analysis and experiments are performed to analyze the temperature distribution of a drawn wire and [...] Read more.

The effects of contact conditions at the wire–die interface on the temperature distribution of the specimen and die are investigated to understand the wire drawing process. Finite element analysis and experiments are performed to analyze the temperature distribution of a drawn wire and die based on different contact conditions using a low-carbon steel wire. The maximum temperature (T_max) of the die decreases as the contact heat transfer coefficient at the wire–die interface increases, whereas that of the wire increases with the contact heat transfer coefficient. The T_max of the die and wire decreases with the thermal conductivity of the die. As the thermal conductivity of the die increases, the heat generated by friction is rapidly absorbed into the die, and the T_max of the die decreases, thus resulting in a decrease in the surface temperature of the wire. The T_max of both the die and wire linearly increases with the friction factor. In particular, the T_max of the die more sensitively changes with the friction factor compared with that of the wire. The T_max of the die linearly increases with the drawing velocity, whereas that of the wire parabolically increases with the drawing velocity. The influence of bearing length on the temperature increase in both the wire and die is insignificant. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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22 pages, 2647 KiB  

Open AccessReview

A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0

by Jose E. Naranjo, Gustavo Caiza, Rommel Velastegui, Maritza Castro, Andrea Alarcon-Ortiz and Marcelo V. Garcia

Sustainability 2022, 14(24), 16723; https://0-doi-org.brum.beds.ac.uk/10.3390/su142416723 - 13 Dec 2022

Cited by 1 | Viewed by 2619

Abstract

The fourth industrial revolution was a milestone at the industrial level. It forced most industries to evolve technically and for their collaborators to prepare and advance together with technology; the oil industry was no exception. It develops its activities in dangerous and dynamic [...] Read more.

The fourth industrial revolution was a milestone at the industrial level. It forced most industries to evolve technically and for their collaborators to prepare and advance together with technology; the oil industry was no exception. It develops its activities in dangerous and dynamic environments and needs to protect its human resources, equipment, and infrastructure. This article presents a scoping review, based on the PRISMA guidelines, of pipeline maintenance methodologies based on Industry 4.0. From the first collection of 123 articles from prestigious databases such as SpringerLink, MDPI, Scopus, IEEEXplore and ACM, a final sample of 31 articles was obtained. Here, technologies that enhance preventive and predictive maintenance systems are discussed. The results show that predictive maintenance compared to preventive maintenance has a percentage difference in upkeep time optimization of 38% in the last five years. This difference was corroborated with a Student’s t-test for independent samples, with a significance of 0.023. Likewise, the most used technologies were analyzed, with artificial intelligence standing out with 45.16%. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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15 pages, 5259 KiB  

Open AccessArticle

The Effect of Shot Peening on Residual Stress and Surface Roughness of AMS 5504 Stainless Steel Joints Welded Using the TIG Method

by Magdalena Bucior, Rafał Kluz, Tomasz Trzepieciński, Kamil Jurczak, Andrzej Kubit and Kamil Ochał

Materials 2022, 15(24), 8835; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15248835 - 10 Dec 2022

Cited by 3 | Viewed by 1320

Abstract

This article presents the influence of the Shot Peening (SP) process on residual stress and surface roughness of AMS 5504 joints welded using the Tungsten Inert Gas (TIG) method. Thin-walled steel structures are widely used in the aviation and automotive industries, among others. [...] Read more.

This article presents the influence of the Shot Peening (SP) process on residual stress and surface roughness of AMS 5504 joints welded using the Tungsten Inert Gas (TIG) method. Thin-walled steel structures are widely used in the aviation and automotive industries, among others. Unfortunately, the fatigue properties become worse during the welding process. Samples of 1 mm-thick AMS 5504 steel plates were first prepared using TIG welding and then strengthened by the Shot Peening (SP) process. The technological parameters of the SP process were changed in the range of time t from 2 min to 4 min and of pressure p from 0.4 MPa to 0.6 Mpa. The residual stresses were measured by X-ray diffraction in three zones: fusion zone (FZ), heat-affected zone (HAZ) and base metal (BM). The results showed that SP introduced compressive residual stresses in all of the zones measured, especially in the FZ. The greatest value of compressive residual stresses σ = −609 MPa in the FZ was observed for the maximum parameters of SP (p = 0.6 MPa, t = 4 min). The increase in value of residual stress is about 580% when compared to welding specimens without treatment. As a result of shot peening in the FZ, the mean roughness value Ra decreased in range 63.07% to 77.67% in the FZ, while in the BM increased in range 236.87% to 352.78% in comparison to specimen without treatment. Selected surface roughness parameters in FZ and BM were analyzed using neural networks. In FZ, it was demonstrated that the most correlated parameters with residual stresses are Rt and Rsk. On the other hand, in the BM zone, the most correlated parameters were Rv, Rt and Rq. This enables the estimation of stresses in the welded joint after SP on the basis of selected roughness parameters. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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13 pages, 6907 KiB  

Open AccessArticle

Investigations into Flux-Free Plasma Brazing of Aluminum in a Local XHV-Atmosphere

by Jan Klett, Benedict Bongartz, Vincent Fabian Viebranz, David Kramer, Chentong Hao, Hans Jürgen Maier and Thomas Hassel

Materials 2022, 15(23), 8292; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15238292 - 22 Nov 2022

Cited by 2 | Viewed by 986

Abstract

As a lightweight construction material, aluminum plays a key role in weight reduction and, thus, sustainability in the transport industry. The brazing of aluminum and its alloys is impeded by the natural passivating oxide layer, which interferes with the brazing process. The presented [...] Read more.

As a lightweight construction material, aluminum plays a key role in weight reduction and, thus, sustainability in the transport industry. The brazing of aluminum and its alloys is impeded by the natural passivating oxide layer, which interferes with the brazing process. The presented study investigates the possibility of using a thermal silane-doped argon plasma to reduce this oxide layer in situ and thus eliminating the need to use hazardous chemical fluxes to enable high-quality brazing. Using plasma spectroscopy and an oxygen partial pressure probe, it was shown that a silane-doped argon plasma could significantly reduce the oxygen concentration around the plasma in a thermal plasma brazing process. Oxygen concentrations below 10⁻¹⁶ vol.-% were achieved. Additionally, metallographic analyses showed that the thickness of an artificially produced Al₂O₃-Layer on top of AlMg1 samples could be substantially reduced by more than 50%. With the oxide layer removed and inhibition of re-oxidation, silane-doped plasma brazing has the potential to become an economically efficient new joining method. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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14 pages, 5213 KiB  

Open AccessArticle

Investigating Residual Stresses in Metal-Plastic Composites Stiffening Ribs Formed Using the Single Point Incremental Forming Method

by Andrzej Kubit, Raheem Al-Sabur, Andrzej Gradzik, Kamil Ochał, Ján Slota and Marcin Korzeniowski

Materials 2022, 15(22), 8252; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15228252 - 21 Nov 2022

Cited by 8 | Viewed by 1891

Abstract

Low weight and high strength are significant factors in the current decade’s spread of composite sandwich materials. Previous studies have proven that forming stiffening ribs in these materials through the Single Point Incremental Forming (SPIF) process is possible and gives encouraging results. On [...] Read more.

Low weight and high strength are significant factors in the current decade’s spread of composite sandwich materials. Previous studies have proven that forming stiffening ribs in these materials through the Single Point Incremental Forming (SPIF) process is possible and gives encouraging results. On the other hand, knowledge of residual stress (RS) values that form during the manufacturing process is essential, as they may affect the structural integrity of manufactured elements, whether in compression or tension. The investigation of the RS in the composite materials formed by the SPIF process using the XRD method was very limited in the previous studies, so this research aims to apply the X-ray diffraction (XRD) method to determine RS on the part of the LITECOR^® sandwich material formed using SPIF. LITECOR^® consists of a plastic core between two layers of steel. In this study, three types of LITECOR^® were used with differing plastic core thicknesses of 0.8, 1.25, and 1.6 mm, while the steel layers’ thickness remained the same at 0.3 mm. The axial and traverse RSs were measured in five positions on both sides of the formed part. It was found that the achieved RSs varied from tensile to compressive along the formed regions. It was found that the residual stress values in both directions were inversely proportional to the thickness of the plastic core. It was noted that the highest RS values were in the unformed base metal, after which the RS was reduced on both sides of the SPIF-formed region, followed by a rise in the RS at the concave of the SPIF-formed region. The maximum measured RS for X-axes was 1041 MPa, whereas, for Y-axes, it was 1260 MPa, both of which were recorded on the back side at a thickness of t = 0.8 mm. Full article

(This article belongs to the Topic Manufacturing and Processing of Materials for Transport Industry)

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