Manufacturing Technology Journal - Latest articles
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Strategy for Fabricating Tree-Like Branched Al-Al₂Cu Heterogeneous Nanostructures for Future Application in Battery Anodes
Elena Chochoľaková, Lucia Bajtošová, Nikoleta Štaffenová, Jan Hanuš, Peter Minárik, Miroslav Cieslar
Manufacturing Technology 2025, 25(5):589-596 | DOI: 10.21062/mft.2025.067 
Tree-like branched Al-Al₂Cu heterogeneous nanostructures with a high surface area ratio were successfully fabricated using magnetron sputtering of Al matrix and Cu nanoparticles, followed by in situ annealing. The method enables precise control over the composition and morphology of the nanosized columnar Al₂Cu phase grown on the substrate and embedded in the Al matrix. The formation of Al₂Cu begins at the initial locations of sputtered Cu nanoparticles. Further annealing promotes their coalescence and coarsening. Orientation relationships examined in several Al₂Cu particles revealed a semi-coherency with the Al matrix. The...
Research on Optimization Design and Processing Technology of Engine Intake System Based on NX and Fluent
Jun Zhang, Ruqian Gao, Yangfang Wu
Manufacturing Technology 2025, 25(5):711-719 | DOI: 10.21062/mft.2025.066
To design an engine intake system that complies with FSC racing regulations while achieving enhanced operational stability, this study conducts a comprehensive review of domestic and international research advancements in racing engine intake systems. Through computational fluid dynamics simulations performed in Workbench Fluent, critical structural parameters of the restrictor valve were optimized, resulting in a 12.06% improvement in outlet mass flow rate compared to the baseline design. A three-dimensional parametric model of the racing intake system was developed using Siemens NX platform. Taking the intake plenum chamber as a representative component,...
The Influence of Solidification Route on As-cast Microstructures of Al-Cu-Li-Mg-Zr-Sc Alloy
Rostislav Králík, Lucia Bajtošová, Barbora Kihoulou, Tomáš Krajňák, Miroslav Cieslar
Manufacturing Technology 2025, 25(5):626-644 | DOI: 10.21062/mft.2025.065
The influence of the casting method on the microstructures of Al-Cu-Li-Mg-Zr-Sc was examined. The techniques include mold casting, twin-roll casting, and melt spinning. Estimated solidification rates up to 107 K·s−1 produce dendritic solidification with eutectic cells ranging from 500 nm to 50 μm, decorated by primary phase particles with thicknesses from 200 nm to 3 μm. Exceeding this solidification rate results in near-diffusionless solidification, which traps more solutes in the matrix. This type of solidification yields a more supersaturated material with nearly 90% of the total Cu content in the matrix and a fine dispersion...
Hydrogen Embrittlement of Ferritic-Perlitic and Martenzitic Pipe Steels
Anna Knaislová, Jan Zmeko, Matěj Reiser, Nikola Macháčková, Dalibor Vojtěch
Manufacturing Technology 2025, 25(5):618-625 | DOI: 10.21062/mft.2025.064
This study investigates the susceptibility of two pipeline steels, ferritic–pearlitic CSN 12022 and martensitic L80, to hydrogen embrittlement. Electrolytic hydrogen charging increased the absorbed hydrogen content approximately fivefold in both steels, with the martensitic grade showing higher uptake due to its dense dislocation network and carbide distribution. Tensile tests demonstrated that hydrogen had little influence on yield or ultimate tensile strength but caused a severe reduction in ductility. Elongation dropped from 39 % to 13 % in CSN 12022 and from 25 % to 11 % in L80. Fractographic analysis confirmed a transition from ductile dimple...
Temperature Matters: Annealing Effects on Silver Protection and Tungsten Oxidation in W@Ag Core-Shell Powder
Angelina Strakošová, Pavel Lejček, Ilona Voňavková, Vojtěch Dalibor
Manufacturing Technology 2025, 25(5):689-697 | DOI: 10.21062/mft.2025.063
Core-shell powders have been extensively studied due to their complex structure and wide range of applications. W@Ag core-shell powders are particularly interesting due to the synergy between the tungsten and silver, which can be beneficial in the electronics industry. However, knowledge of their thermal stability is limited, particularly concerning the impact of annealing temperatures on structural integrity and oxidation resistance. In this work, W@Ag core-shell powder was heat-treated in the temperature range 100–700 °C for 1 h in air. Investigation of the microstructural changes using scanning electron microscopy equipped with energy-dispersive...
Fast and Cost-effective Calibration Method of Assembly Errors on Rotary Axes of Five-axis Machine Tools
Yongqiang Pan, Yue Tang
Manufacturing Technology 2025, 25(5):670-677 | DOI: 10.21062/mft.2025.062
Five-axis machine tools are key equipment to process impellers, blades, and other precision mechanical parts. However, the accuracy of the machine tools is significantly influenced by assembly errors, and over time, these errors may change, further impacting the machining accuracy. Traditional laser interferometry technology can identify such assembly errors. The development of on-machine measurement technology has enabled methods that utilize on-machine measurement for assembly error calibration, improving calibration efficiency. The study introduces an efficient method to calibrate the assembly errors of machine tool rotary axes. First, the kinematic...
Push-Type Rotary Steering Mandrel Mechanical Analysis and Life Prediction
Wenzhe Li, Ye Chen, Jichuan Zhang, Xudong Wang, Pengcheng Wu, Chengyu Ma, Xiumei Wan, Xing Chen
Manufacturing Technology 2025, 25(5):645-654 | DOI: 10.21062/mft.2025.061
The push-type rotary steerable core bearing has high load capacity and high precision, and has been widely used in oil and gas drilling field. Its service life is difficult to predict due to various complex working conditions. Based on the finite element method, this paper establishes a three-dimensional rotating guide mandrel model to calculate and analyze the mechanical simulation of the guide mandrel under different working conditions, and establishes the corresponding life prediction model to predict its life. The results show that reducing the torque and speed in the range of drilling requirements is conducive to improving the overall life of...
Strain Field Determination for Additively Manufactured Thermoplastics Using Computer Vision
Jaroslav Majko, Ondrej Piroh, Ján Minárik, Milan Vaško, Marián Handrik, Milan Sága, Zbigniew Saternus
Manufacturing Technology 2025, 25(4):511-520 | DOI: 10.21062/mft.2025.060
The effective application of additively manufactured materials requires accurate identification of their mechanical properties as well as damage mechanisms. Computer vision offers a novel approach for non-contact measurements, enabling the identification of selected mechanical properties. This paper presents a new method based on image analysis and the detection of circular markers for non-contact displacement measurements. The core principle involves detecting the centers of gravity of the circular markers formed on the sample under investigation. The centers of gravity are evaluated on each image created during the tensile test, representing nodal...
Improving Strength and Ductility in Mg–Y–Zn alloy via Pre-deformation Prior to Extrusion
Drahomír Dvorský, Yoshihito Kawamura, Shin-Ichi Inoue, Jiří Kubásek, David Nečas, Luděk Heller, Esther De Prado, Jan Duchoň, Petr Svora, Miroslav Čavojský, Dalibor Vojtěch
Manufacturing Technology 2025, 25(4):455-459 | DOI: 10.21062/mft.2025.059
The Mg-Y-Zn alloy system is well known for its outstanding combination of high strength and ductility, even at relatively low concentrations of alloying elements. This exceptional performance is primarily at-tributed to its characteristic microstructure, which features Long-Period Stacking Ordered (LPSO) phas-es and the distinctive Mille-Feuille Structure (MFS). Kink-induced strengthening, developed during thermomechanical processing, has emerged as a promising strategy to simultaneously enhance strength and ductility. In this study, the beneficial effect of pre-deformation aimed at introducing additional kinks into the microstructure prior to extrusion...
Geometric Accuracy of Elements Made Using the FFF Method from Selected Polymers with Different Internal Structure Densities
Małgorzata Gontarz-Kulisiewicz, Jacek Bernaczek, Mariusz Dębski
Manufacturing Technology 2025, 25(4):489-499 | DOI: 10.21062/mft.2025.058
Due to their availability and ease of use, additive techniques are experiencing dynamic development. This applies to both the industrial sector and individual recipients. The authors of numerous publications address in their research the subject of the influence of selected printing process parameters on the strength of models, usually made using selected MEX (Material Extrusion) methods. Among the MEX methods, the most frequently chosen are the FFF (Fused Filament Fabrication) and FDM (Fused Deposition Modeling) methods. This is due to the high availability and low cost of devices using the methods mentioned above and the high availability of polymer...
Surface Morphology and Ablation Efficiency in DUV Ultrafast Laser Micromachining of Fused Silica
Jan Novotný, Libor Mrňa, Josef Sedlák, Štěpán Kolomý
Manufacturing Technology 2025, 25(4):521-530 | DOI: 10.21062/mft.2025.057
Fused silica is a key material for high-precision applications such as micro-optics and microfluidics. One route to improving direct laser writing (DLW) of fused silica is the use of shorter laser wavelengths, which enable tighter focusing and enhanced absorption. In this study, the influence of process parameters on surface quality and material removal during DLW using a deep ultraviolet (DUV) ultrafast laser (257 nm, 1 ps) was investigated. A full-factorial design of the experiment was used to identify conditions that optimise both surface quality and ablation efficiency. Surface roughness as low as Sa ≈ 200 nm and material removal...
Experimental Evaluation of Vibration Responses to Progressive Gear Damage in Planetary Gear
Tomáš Gajdošík, Matúš Vereš, Igor Gajdáč, Ronald Bašťovanský
Manufacturing Technology 2025, 25(4):469-481 | DOI: 10.21062/mft.2025.056
This study presents a systematic experimental analysis of vibration responses in a planetary gearbox (type A2000) under both undamaged and artificially induced fault conditions. The primary aim was to identify specific frequency-domain signatures of various types and severities of gear defects—such as pitting on the flanks of gear teeth, missing teeth, unbalance of the carrier, and damage to the ring gear—through spectral analysis of vibration signals. Measurements were conducted in both loaded and unloaded states using non-contact torque sensors and a multi-channel diagnostic system (SKF IMx-S) with tri-axial accelerometers. The results...
Study on Material Performance Calculation and Rolling Process Simulation of 35W210X Advanced High Strength Silicon Containing Steel
Tie Ye, Boran Chen, Zetian Li, Zhenyu Gao, Kuibo Liu, Zheng Ren
Manufacturing Technology 2025, 25(4):549-558 | DOI: 10.21062/mft.2025.055
This study used JMatPro software to comprehensively analyze the new low-iron-loss cold-rolled non-oriented high-grade electrical steel 35W210X, calculating phase composition, Gibbs free energy, stress-strain relationships, and yield strength changes. Results showed its ferritic structure and consistent calculated room-temperature yield strength with experiments. To study production cracks, JMatPro data was used in Deform-3D to simulate the five-pass reciprocating cold rolling on a Sendzimir 20-roll mill, successfully replicating the cracks. Aiming at the problems of frequent cracking and low yield rate (<50%), the study found the original single...
Influence of Selected Heat Treatment on Alloy Properties of Ti–6Al–4V Alloy
Roman Horký, Sylvia Kuśmierczak, Tomáš Vlach
Manufacturing Technology 2025, 25(4):482-488 | DOI: 10.21062/mft.2025.054
Titanium is the polymorphic metal whose recrystallization temperature significantly affects its final properties. The area between 850 °C and 995 °C is a very important area from the point of view of heat treatment of titanium alloys. It is a transition area just below the β transition limit. This article deals with the analysis of the influence of thermal loading on the change in tensile strength and fracture behavior of titanium alloys in comparison with thermally unloaded samples. Monitoring of fracture surfaces and description of the internal structure of the material.
AI-Integrated Thermal Prediction and Multi-Criteria Optimization in Cylindrical Grinding Using Machine Learning and Genetic Algorithms
Maya M. Charde, Yogesh J. Bhalerao, Lenka Cepova, Sharadchandra N. Rashinkar, B. Swarna
Manufacturing Technology 2025, 25(4):432-447 | DOI: 10.21062/mft.2025.053
The paper focuses on the application of machine learning techniques and optimization algorithms in predictions and controls of grinding temperature variations. The major thrust of investigation has been on how the different input conditions such as feed, depth of cut, and cooling conditions influence grinding temperatures and the effectiveness of these conditions on the control of their thermal effects. Three machine learning models: Random Forest (RF), Gradient Boosting (GB), and Artificial Neural Networks (ANN) were then used to develop prediction models for the grinding temperature on both face and shoulder of the workpiece. Out of all the models,...
Analytic Solution of the Motion Equations of the Rolling Stock Chassis Incorporating the Effect of Asymmetry and Kinematics Excitation
Blanka Skocilasova, Frantisek Klimenda, Jan Skocilas, Tereza Jarosova
Manufacturing Technology 2025, 25(4):531-539 | DOI: 10.21062/mft.2025.052
The article provides an analytical solution for the dynamics of a vehicle chassis designed for both road and rail operation, featuring either single or multiple primary linear suspensions using coil springs. It derives the equations of motion for a simplified two-axle chassis model that includes both a basic primary suspension and a simplified chassis suspension. The study focuses on the simplest calculation model to analyze suspension behavior, taking into account the asymmetry in spring stiffness and geometric positioning. There is an unequal distribution of weight across the vehicle body. An analysis is conducted on a comprehensive vehicle model...
Research on Stator Thermal Fault Detection of Steam Turbine Generator Based on Improved Transformer and Gaussian Mixture Model
Fengqin Cheng, Weinan Zheng
Manufacturing Technology 2025, 25(4):448-454 | DOI: 10.21062/mft.2025.051
This study proposes a multi-stage intelligent diagnostic approach integrating Physics-Guided Normalization (LPGN), enhanced Transformer networks, and Gaussian Mixture Models (GMM) for thermal fault detection in turbine generator stators. The methodology sequentially performs the following steps: (1) enhances localized anomaly features in temperature data through LPGN, (2) efficiently extracts temporal patterns via the optimized Transformer architecture, and (3) achieves unsupervised fault classification using GMM. Experimental results demonstrate the proposed method's superiority over conventional ARIMA and LSTM models across multiple evaluation metrics,...
Overcoming Rotary Mechanism Limitations in CNC Machines: A 3-PRS Approach
Rudolf Madaj, Matúš Vereš, Róbert Kohár, Peter Weis, Filip Šulek
Manufacturing Technology 2025, 25(4):500-510 | DOI: 10.21062/mft.2025.050
This paper presents the design and analysis of a 3-PRS mechanism for positioning cutting heads in CNC machines, addressing limitations of traditional rotary mechanisms such as hose twisting, wear, and limited modularity. Kinematic and dynamic analyses guided actuator selection and confirmed bearing durability. The mechanism achieves a favourable load-to-weight ratio and integrated Z-axis movement, making it suitable for simpler gantry CNC machines. Though programming is complex due to multiaxis synchronization, the modular design supports easy adaptation to different tools. Future research will focus on reducing the eccentric torch offset and refining...
Novel Multi Levels Tool Based on Rotating Ballizing Technique to Manufacturing the Externally Toothed Components an Experimental Study
Eman S. M. Abd-Elhalim, Emad A. Fahmy, Mohamed N. El-Sheikh, Ahmed M.I. Abu-Oqail, Hammad T. Elmetwally, Ayman Ali Abd-Eltwab
Manufacturing Technology 2025, 25(4):460-468 | DOI: 10.21062/mft.2025.049
Externally toothed components have a very crucial and essential role in all areas of production and manufacturing because they function as away of transmitting motion, energy, and power in all indus-trial applications, such asmodes of transportation, aviation, aerospace, equipment, and operating machines like lathes and milling. All machines have a gear box. Therefore, it is receiving increasing attention. This research presents a new multi-stage rotary ballizing technology for producing toothed parts in one stroke. This process has been investigated experimentally. The parameters that were ex-amined experimentally was at the optimal conditions for...
Fault Diagnosis of Electric Motor Rotor Systems Based on Feature Extraction and CNN-BiGRU-Attention
Mei Zhang, Zilong Sun, Wenchao Zheng
Manufacturing Technology 2025, 25(4):559-568 | DOI: 10.21062/mft.2025.048
To enhance the accuracy of fault diagnosis (FD) in motor rotor systems, this study introduces a novel method that leverages feature extraction (FE) combined with a CNN-BiGRU-Attention deep learning model. Initially, the time-domain features of the vibration signals are extracted using Variational Mode Decomposition (VMD), which also effectively denoises the data. Subsequently, the frequency-domain features of the vibration signals are extracted via Fast Fourier Transform (FFT). The aggregated features are then fed into the CNN-BiGRU-Attention model to perform fault classification. In this model, the Convolutional Neural Network (CNN) module extracts...
Optimizing Process Parameters during the Creation of Powder Laser Weld Cladding Coatings from a Nickel Alloy
Martin Švec, Libor Dvořák
Manufacturing Technology 2025, 25(4):540-548 | DOI: 10.21062/mft.2025.047
Nowadays, increasing emphasis is placed on the production of parts using additive technologies, particularly for alloys that are difficult to process. In addition to standard additive technologies, such as Selective Laser Melting (SLM), other additive technologies are increasingly being used, including Directed Energy Deposition (DED). DED offers several advantages and is utilized both for producing entire components and for repairing damaged parts through weld cladding. In this study, the possibility of weld cladding of nickel-based hard alloys using DED was tested using a laser as the energy source to melt the additive material. The tests performed...
Crack Detection and Monitoring of their Growth in Critical Parts of Steam Pipeline by Electric Potential Drop Method
Petr Živný, Jindřich Jansa, Marek Měkuta, Pavla Lukášová
Manufacturing Technology 2025, 25(4):569-574 | DOI: 10.21062/mft.2025.046
An innovative way of using DCPD (Direct Current Potential Drop) method for off-line and online monitoring of critical parts of energy equipment in operation is presented. There are only a few NDT methods that allow detection and monitoring of defect growth in components at high temperatures and pressures. Monitoring of steam pipes and critical pipeline components in operation has been carried out for several years with different results. a relatively new way of using the DCPD method outside the laboratory is described. The carried-out tests were intended to resemble operational loads as much as possible. Therefore, the tests were performed at a temperature...
Surface Treatment of Nylon Filters with Thin Layers of Ti, Cu, and Zr Metals and AgCu Alloys using PVD Magnetron Sputtering Technology
Anna Krobotová, Totka Bakalova, Michal Krafka, Magdalena Mrózek, Lucie Svobodová, Pavel Kejzlar, Blanka Tomková
Manufacturing Technology 2025, 25(3):348-356 | DOI: 10.21062/mft.2025.045
The development and characterizing of thin layers of AgCu, Cu, Ti, and Zr on nylon filters using PVD magnetron sputtering technology was conducted. The evaluation of these thin layers was mainly focused on characterizing specific parameters that may influence the expected functionality of the modified filter materials. The surface treatment of nylon filters with thin layers does not significantly affect the mechanical properties of the original nylon material. Thin layers deposited at a power of 0.9 kW exhibited greater thickness and lower static friction coefficient values than the layers deposited at 0.4 kW, except for a thin layer of the element...
Analysis of the Influence of Preparation Technology on the Structure and Properties of the CuZn10 Alloy
Anna Knaislová, Jakub Kabrle
Manufacturing Technology 2025, 25(3):318-330 | DOI: 10.21062/mft.2025.044
The CuZn10 alloy, a prominent brass variant known for its excellent cold formability, corrosion resistance, and suitability for various cold forming processes such as bending and stamping, finds widespread application across numerous industries. Optimizing its performance for specific industrial demands necessitates a thorough understanding of how different preparation technologies influence its intrinsic properties. This study provides a comprehensive examination into the impact of various processing routes on both the structural evolution and mechanical characteristics of deep-drawing CuZn10 brass. Utilizing advanced analytical techniques, including...
Frequency Dependence of Glass Transition Temperature of Thermoplastics in DMA Analysis
Marcel Kohutiar, Zbyněk Studený, Michal Krbata, Milan Jus, Pavol Mikuš, Ingrid Kovaříková
Manufacturing Technology 2025, 25(3):341-347 | DOI: 10.21062/mft.2025.043
The aim of this study is to investigate the effect of oscillatory loading frequency on the dynamic-mechanical properties of 3D printed thermoplastics, namely acrylonitrile-butadiene-styrene (ABS), glycol-modified polyethylene terephthalate (PETG), and polylactide, also known as polylactic acid (PLA). The investigated samples were manufactured using fused filament fabrication (FFF) technology and tested at different oscillation frequencies (1, 5, 10, 15 and 20 Hz). Dynamic mechanical analysis (DMA) demonstrated that an increase in the oscillation frequency causes an increase in the glass transition temperature (Tg) for all analyzed materials, while...
Effect of Brass Solder Composition on Quality in Laser Welding of Solar Panel Busbar
Wei Xiaohua, Zheng Mingliang
Manufacturing Technology 2025, 25(3):424-430 | DOI: 10.21062/mft.2025.042
In order to reveal the action mechanism of different brass solder compositions on the microstructure of weld joints in unleaded-tin-coated coppers brazing-stitch welding, the laser welding process of solar panel busbar was studied by using three different coated brass solders: Sn-37Bi-3Ag, Sn-42Bi-3Ag and Sn-47Bi-3Ag. Scanning electron microscope, energy spectrometer, X-ray diffractometer, tensile testing machine and Vickers microhardness tester were used to test and analyze the influence of Bi element content on the microstructure and mechanical properties of weld joints in solar panel busbar brazing-stitch welding. The results show that: (1) With...
Process Prediction and Force Measurement of Hot Rolling Process for 6061 Aluminum Alloy Wire
Jinn-Jong Sheu, En-Hsuan Chien
Manufacturing Technology 2025, 25(3):383-395 | DOI: 10.21062/mft.2025.041
This study examines the two-pass hot rolling process of 6061 aluminum alloy wire, focusing on forming load measurement to evaluate process stability and its effects on dimensional accuracy and mechanical property uniformity. Using response surface methodology (RSM), process parameters and forming loads were analyzed to assess their influence on mechanical property distribution and verify the applicability of load measurement in process quality evaluation. A full-factorial finite element simulation was conducted to investigate the effects of pre-forming section reduction rate, material temperature, roll speed, and friction coefficient. Experimental...
Features of Locomotive Adhesive Mass Utilization in a Braking Mode
Stanislav Semenov, Evgeny Mikhailov, Oleksandr Spivak, Ján Dižo, Miroslav Blatnický, Martin Bučko
Manufacturing Technology 2025, 25(3):374-382 | DOI: 10.21062/mft.2025.040
The magnitude of a locomotive's traction and braking forces is directly related to its adhesive mass, which largely determines its tractive and braking characteristics. Therefore, an important task is to maximize the utilization of the locomotive's adhesive mass. The degree of adhesive mass utilization is determined by more factors and is quantitatively characterized by the Adhesive Mass Utilization Coeffi-cient (AMUC). One of the ways to increase the AMUC is to improve the locomotive's lever-type brake transmission. In braking mode, it interacts with the wheelsets and the bogie frame and may block the operation of the first stage of the suspension...
Thermal Analysis of Micro Plasma Wire Arc Additive Manufacturing Deposition Process
Siti Khairiyah Sulaiman, Mohd Rizal Alkahari, Mohd Juzaila Abd Latif, Yupiter Harangan Prasada Manurung, Keval Priapratama Prajadhiana
Manufacturing Technology 2025, 25(3):396-404 | DOI: 10.21062/mft.2025.039
Additive manufacturing (AM) is rapidly developing with emerging technology of wire arc additive manufacturing (WAAM) process due to its ability to manufacture large components and high deposition rate. However, WAAM faces mechanical properties problems like porosity, distortion, and strength due to the large heat affected zone (HAZ) from commonly used heat sources such as metal inert gas (MIG) and tungsten inert gas (TIG). Utilization of micro plasma as the heat source should reduce this problem since it has a smaller heat source diameter. Therefore, this study investigates the thermal distribution of micro plasma wire arc additive manufacturing (MPWAAM)...
Effect of Thermal Ageing on Changes in Modulus of Elasticity E Measured by Ultrasound, Bending Test and EBSD
Jana Vesela, Petr Beneš, David Bricín
Manufacturing Technology 2025, 25(3):405-412 | DOI: 10.21062/mft.2025.038
The materials used in VVER nuclear power plants are subject to thermal ageing in operation, among other degradation mechanisms. The aim of the experiment was to verify the effect of thermal ageing on the change of ultrasound velocity on the extracted parts of main circulation piping and pressurizer surge line made of austenitic steels. Two steel conditions were evaluated, as received and thermally aged. The research was carried out on samples made from non-operated pipelines and samples from pipelines after 28 years of operation. The samples were subjected to thermal ageing at 450 °C in an atmospheric furnace with a specified exposure time to simulate...