Advanced Manufacturing Research: Table of Contents

Vibrator with two impacting pairs, one of them in the position of equilibrium

Ragulskis, K. — 2023-06-25T00:00:00Z

Advanced Manufacturing Research, Vol. 1, Issue 1, 2023, p. 1-15.
K. Ragulskis, L. Ragulskis
In the dynamic processes taking place in manipulators and robots, impact interactions play an important role. Among them two sided impacts are important. In this paper investigation of dynamic regimes of a system with two impacting surfaces, one of which is in the position of equilibrium is performed. Dynamics in steady state regime for typical parameters of the investigated system having one degree of freedom is investigated. Displacements as functions of time as well as velocities as functions of time for various positions of the impacting surface are presented. Non symmetric impacts enable to reduce the dimensions of the vibrator and to achieve increase of effectiveness of useful impacts of a manipulator. Investigations of the conservative system as well as of the system with forced harmonic excitation are performed.

Capillary force method to improve the green density of binder jet additive manufacturing

Soylemez, Emrecan — 2023-06-25T00:00:00Z

Advanced Manufacturing Research, Vol. 1, Issue 1, 2023, p. 16-21.
Emrecan Soylemez
This study investigates the impact of capillary adhesion force on the green part density in metal powder binder jetting 3D printing. Gas atomized Co-Cr-Mo, SS316L, and pure Cu powders were used to print various samples. The printed samples were then treated with water, 1-Hexanol, and n-Amyl alcohol vapor for 24 hours to nucleate capillary bridges between particles and shrink samples uniformly. The volume change was calculated for each sample, and up to –3.1 % volume change was observed. The proposed method can be used to improve green part densities directly on printed parts before sintering.

Multi-indicator optimization of riveting joint forming quality of aluminum alloy sheets based on response surface test

Liu, Shi — 2023-11-04T00:00:00Z

Advanced Manufacturing Research, Vol. 1, Issue 2, 2023, p. 22-37.
Shi Liu, Yong Qiang Zhao, Da Hai Wang, Miao Yuan Mei, Tao Huang
In this paper, the effects of the interaction between punch diameter, die depth and punch speed on the quality of riveted joints are investigated using the BBD response surface test method. The results show that the mold depth has the greatest influence on the key dimensional parameters of riveted joints, followed by the punching speed, and then the punch diameter, while the punch diameter and the mold depth are the two factors with the most obvious interaction. The optimum riveted joint process parameters determined are punch diameter of 5.24 mm, die depth of 1.44 mm, and stamping speed of 5.00 mm/s. The corresponding relative errors predicted by numerical simulation and response surface optimization objective are 5.96 % for neck thickness, 3.29 % for interlocking value, and 1.37 % for bottom thickness; and the relative errors predicted by experimental results and optimization objective are 13.42 % for neck thickness, 13.42 % for interlocking value, and 1.37 % for bottom thickness. 13.42 %, interlock value is 4.23 %, and bottom thickness is 2.23 %, the model accuracy is high, and the optimization method of response surface test can effectively improve the quality of riveted joints. Through numerical simulation, the metal flow law and stress distribution during the riveting and forming process of aluminum alloy plate were analyzed, and the strength test of riveted joint was carried out, and the maximum destructive shear load of the joint was 1.8 KN, and the strength of the joint was improved, which verified the validity of the response surface optimization method.

1D manipulator with vibration impact drive, based on which it is possible to create orthogonal manipulators and robots of any dimension

Ragulskis, K. — 2024-03-17T00:00:00Z

Advanced Manufacturing Research, Vol. 2, Issue 1, 2024, p. 24-36.
K. Ragulskis, L. Ragulskis
Manipulator of the investigated type may move according to a straight line. It has an advantage in the fact that by choosing geometrical parameters of the manipulator it is possible to achieve its effective operation. This is presented by using analytical and graphical methods. The performed research shows that manipulators with vibration impact drives have some positive qualities. In their structure it is not necessary to include the self-stopping mechanism. In the conservative case of the system static position of equilibrium of the impact pair can be with negative, zero or positive tightening. In the case of zero tightening eigenfrequency and period of the system does not depend on the quantity of motion of impact excitation. In the case of harmonic forced excitation resonant motions take place in the vicinity of the eigenfrequency of the conservative system with zero tightening. Analytical – numerical calculations contribute to the creation of manipulators and robots with vibration impact drives.

Adoption of metal additive manufacturing in nnpc limited: current state and challenges

Umar, Al-Amin Barambu — 2024-04-02T00:00:00Z

Advanced Manufacturing Research, Vol. 2, Issue 1, 2024, p. 1-14.
Al-Amin Barambu Umar, Muniru M. Mai, Devon Hagedorn-Hansen
Metal additive manufacturing has emerged as a promising technology with vast potential in the oil and gas industry. The Nigerian National Petroleum Company (NNPC) Limited recognizes the significance of this technology and has initiated efforts to adopt metal additive manufacturing within its operations. This paper aims to provide an overview of the current state of metal additive manufacturing in the NNPC and highlight the challenges faced during its adoption process. The study goes on further to suggest strategies and future directions to ensure successful company-wide and industry-wide adoption and acceptance.

Numerical modelling of the warping behaviour at the first layer-build plate interface in 3D-printed models produced via the fused deposition modelling process

Ramful, Raviduth — 2024-04-14T00:00:00Z

Advanced Manufacturing Research, Vol. 2, Issue 1, 2024, p. 15-23.
Raviduth Ramful
The material structure of 3D-models printed via the fused deposition modelling (FDM) technique is mainly affected in the z-direction of the 3D-print as a result of the layer-by-layer approach which tend to exhibit a deformation behavior corresponding to a type of transversely orthotropic material. Moreover, uncontrolled parameters such as printing temperature and printing speed have been reported to adversely affect 3D-print quality leading to undesired effects such as distortion and warpage. The additive manufacturing process is a relatively new field in advanced manufacturing where further research and innovation are required to overcome the limited strength and structural performance observed in presently 3D-printed components. In line with the above, this study proposes the numerical investigation of the warping behavior in PLA (Polylactic acid) - based 3D printed models by considering the finite element method (FEM) software of LS-DYNA. The warping investigation was specifically centered on the cooling cycle prevailing between the layer-by-layer structures. The findings of this study showed that warpage would most likely occur in the thermal process model corresponding to abrupt change in temperature due to a buildup of strain between the bottom most layers of the 3D model and the build plate. The findings of this study, which shed light on the warping behaviour in 3D-models, has direct implications on the final quality of 3D-printed components.

Determination of solid particle erosion wear behaviour of aircraft turbine blades specific to additive manufacturing orientation effects

Aydın, Mehmet Esat — 2025-04-07T00:00:00Z

Advanced Manufacturing Research, Vol. 3, Issue 1, 2025, p. 29-41.
Mehmet Esat Aydın, Musa Demirci, Mehmet Bağcı
In many areas of the industry, especially in the aviation sector, mechanical components have to work under harsh environmental conditions. In addition to being exposed to extreme environmental conditions due to the environment in which they operate, the basic components of aircraft have to take into account many engineering details such as high strength expectations, speed and impact problems under the influence of hard particles. In addition, the geometries of parts in aircraft can be quite complex and detailed shapes. For this reason, it makes sense to utilize different manufacturing processes to create the final shapes of the components. In this study, a research was carried out to determine the solid particle erosion wear behaviour of In718 test specimens representing the material properties of jet engine turbine blades in aircraft by alternative manufacturing methods and to interpret the results obtained by performing experiments. In718 alloys with horizontal (0°), vertical (90°) and angular (45°) orientation were produced by selective laser melting, a layered powder-based additive manufacturing method, and test specimens were produced by casting, a conventional method. These specimens were subjected to solid particle erosion tests using three different sizes (500 g, 1000 g and 1500 g) of Al2O3 abrasive particles at 30° impact angle. Surface topography and macroscope images were used to interpret the results of the surface differences obtained at the end of the experiments. Consequently, the layer orientation in additive manufacturing and the additive manufacturing method were compared with parts produced by a conventional method in terms of erosion rate. In addition, it was concluded whether the surface damage that occurs in erosive wear depending on the impact angle has a ductile, semi-ductile or brittle character.

High-entropy alloys in wire arc additive manufacturing: a review

Gürkan, Doruk — 2025-05-06T00:00:00Z

Advanced Manufacturing Research, Vol. 3, Issue 1, 2025, p. 14-28.
Doruk Gürkan, Savas Dilibal
High-entropy alloys (HEAs) have emerged as a promising class of materials due to their exceptional mechanical properties, thermal stability, and corrosion resistance. The application of HEAs in Wire Arc Additive Manufacturing (WAAM) presents new opportunities for large-scale component fabrication with customized material properties. This paper reviews recent developments in WAAM processing of HEAs, focusing on the influence of process parameters on microstructure evolution, mechanical performance, and potential industrial applications. Challenges such as segregation, porosity, and residual stresses are also discussed, along with strategies for optimizing HEA properties through alloy design and process control. Furthermore, the potential industrial applications of WAAM-fabricated HEAs in aerospace, marine, and energy sectors are highlighted, demonstrating their relevance in high-performance environments. The insights presented in this review contribute to a deeper understanding of WAAM-based HEAs, guiding future research toward process optimization and industrial adoption.

Numerical-experimental single point incremental forming of thin circular plate

Hasanlu, M. — 2025-06-29T00:00:00Z

Advanced Manufacturing Research, Vol. 3, Issue 1, 2025, p. 1-13.
M. Hasanlu, S. Mokari
Single Point Incremental Forming (SPIF) represents a transformative shift in sheet metal manufacturing, offering unparalleled flexibility, reduced tooling costs, and adaptability for low-volume and customized production. This study presents a hybrid numerical-experimental investigation of SPIF applied to thin circular galvanized plates, integrating finite element simulations via FormingSuite software with experimental validation. A key innovation of this work lies in its detailed analysis of coupled deformation modes, tensile-tensile and tensile-compressive, governing failure and thinning mechanisms under high forming angles, particularly around 90°, which are typically fracture-prone. The research introduces a novel use of the Fracture Forming Line (FFL) over traditional Forming Limit Curves (FLCs) to better predict failure in SPIF. Results reveal improved strain capacity and process stability, supported by deformation mapping, safe zone identification, and stress-strain simulations. This comprehensive approach not only enhances the predictive capabilities of SPIF modeling but also supports smarter and more sustainable manufacturing processes.

Potential of handheld laser beam welding

Jahna, Simon — 2025-08-28T00:00:00Z

Advanced Manufacturing Research, Vol. 3, Issue 2, 2025, p. 62-71.
Simon Jahna, Martin Schmitz, Matthias Pieper, Robert Prowaznik, Johannes Lange
Since 2023 at the latest, handheld laser beam welding systems (HLBW) gained interest by many companies. This is mainly due to two factors. Firstly, the cost of such a system has fallen considerably in recent years. Secondly, there is an economic pressure for the manufactures of welded products, partly due to the shortage of skilled workers. This publication addresses various aspects of HLBW, in particular the current state of the art and the potential applications. The higher throughput, less straightening work due to the lower heat input, and the use of less experienced personnel has to be mentioned here. However, welders still need to be qualified, especially to get informed about the hazards of laser radiation. In addition to welding, many systems for HLBW also include a cleaning function, some even a cutting function. The risks to be considered for both last mentioned are significantly greater, since on one hand, a touchdown or contact control is often omitted and on the other, the laser beam is conditioned for a longer working distance. For HLBW, the requirements of the process must be taken into account during the design phase already. This continues with edge preparation, e.g. pre-weld cleaning. HLBW is a supplement to traditional arc welding processes. Arc processes will be still used in the future as well, e.g. for small, complex geometries or in terms of accessibility. However, for longer welds, e.g. 1.5 m long 2 mm thick stainless steel sheets, HLBW sets currently the standard, especially with regard to the welding speed for manual welding.

Advancing product and process innovation through knowledge-sharing networks among European industrial SMEs

Feyzioglu, Ahmet — 2025-12-31T00:00:00Z

Advanced Manufacturing Research, Vol. 3, Issue 2, 2025, p. 42-61.
Ahmet Feyzioglu, Eyyup Kuşak, Abdulkerim Kar, Donatella Santoro, Leonardo Piccinetti, Trevor Uyi Omoruyi
A methodical approach is created in this study to aid SMEs across Europe (Turkiye, UK, Belgium, Italy) in their product and process development endeavors. Methods and processes that must be followed are examined and streamlined, starting from the point of client contact, and ending with establishment of a pilot production line. This study provides strategies to help technicians and engineers create excellent product designs. Though most of the concepts and methods it will produce are anticipated to be applicable to the design of all types of goods, its primary focus is on the engineering-related aspects of product design. The formulation of problems and the conceptual and embodiment phases of design are the main topics of this work. It will support designers in SMEs with problem identification, explanation, and generation and assessment of solutions. To understand their approach and issues, a thorough search in this field is conducted, along with interviews with multiple SMEs. Additionally, to ascertain the SMEs’ network architecture and how their technical employees interact inside these organizations in a way that supports the creation of new products. This will demonstrate these SMEs' advantages or strengthen their creative positions in the face of global competition.

Integrating Industry 4.0 and 5.0 technologies for sustainable, resilient oil and gas production operations

Okirie, Ahiamadu Jonathan — 2026-02-20T00:00:00Z

Advanced Manufacturing Research, (in Press).
Ahiamadu Jonathan Okirie, Eleba Frank Lawson, Nyekachi Olumati Ozuru
In response to escalating environmental concerns, fluctuating markets, and swift technological advancement, the oil and gas industry is increasingly challenged to improve operational resilience while pursuing sustainability. Meeting these concurrent demands requires forward-thinking strategies that embrace cleaner technologies, enhance resource efficiency, and strengthen adaptability to external pressures, without compromising profitability or regulatory obligations. By employing qualitative content analysis and triangulation techniques, this study investigates 20 leading oil and gas firms to examine how the implementation of Industry 4.0 and 5.0 technologies is reshaping their approaches to resilience and sustainable operations. Industry 4.0 is characterized by advanced data analytics, artificial intelligence (AI), and the Internet of Things (IoT), while Industry 5.0 emphasizes human-machine collaboration and environmental stewardship. This study demonstrates that integrating these technologies enhances operational efficiency, reduces environmental impact, and improves safety within the industry, thereby supporting the objectives of key sections of the United Nations (UN) Sustainable Development Goals (SDGs) 7, 8, 9, 12, and 13. Organizations that adopt these innovations are better prepared to manage market fluctuations and regulatory pressures, which promotes sustainability. However, they face challenges such as high implementation costs, skill gaps, cybersecurity threats, and regulatory complexities. Notably, these challenges exist in both global and developing contexts, with variations primarily in their scale, access to resources, institutional support, and overall preparedness. The research underscores the importance of workforce upskilling, flexible strategies, and partnerships with technology providers for successful digital transformation. Additionally, it provides a strategic framework to guide oil and gas companies through this process.

In-depth insights into industrial turbo-compressors for smarter maintenance and repair

Hasanlu, Mojtaba — 2026-02-21T00:00:00Z

Advanced Manufacturing Research, (in Press).
Mojtaba Hasanlu, Siavash Mahdian, Mahdiyeh Shirvani
This article originally integrates an approach to turbo-compressor analysis, combining performance evaluation with modern diagnostic tools, and offers a fresh perspective that distinguishes your work from more conventional studies. Significantly, the research topic of turbo-compressor maintenance is of paramount importance to industrial efficiency and reliability and its exploration of this area contributes valuable knowledge to the field. Overall, the current organization is very easy to understand and logically structured. The paper proposes a comprehensive framework for intelligent maintenance and performance optimization of industrial turbo-compressors. The core contributions include, firstly, establishing a graphical framework linking mechanical analysis of key compressor components (impeller/rotor/seals/bearings) with real-time condition monitoring; secondly, integrating vibration analysis, oil analysis, temperature/pressure monitoring, and machine learning algorithms for fault prediction; and finally, specifying test procedures such as hydrostatic testing, over-speed testing, and mechanical run testing.