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This document is a special issue of the journal "Materials" that focuses on the recent progress in the structure transition, processing, characterization, and applications of metallic materials. The issue includes research papers on various topics such as the development of dispersion-strengthened copper alloys, the characterization of carbide precipitation in steel, the effect of magnetic fields on aluminum bronze, and the enhancement of impact toughness in cast iron through heat treatment. The issue aims to provide comprehensive and up-to-date information for researchers, engineers, and industry experts in the field of metallic materials. [Extracted from the article]

Sensitivity analysis of influencing factors on frost resistance is carried out in this paper, and a two-stage neural network model based on grey theory and Back Propagation Neural Networks (BPNNs) is established for the sake of predicting the frost resistance of active-admixture recycled concrete quickly and accurately. Firstly, the influence degree of cement, water, sand, natural aggregate, recycled aggregate, mineral powder, fly ash, fiber and air-entraining agent on the frost resistance of active-admixture recycled-aggregate concrete was analyzed based on the grey system theory, and the primary and secondary relationships of various factors were effectively distinguished. Then, the input layer of the model was determined as cement, water, sand, recycled aggregate and air-entraining agent, and the output layer was the relative dynamic elastic modulus. A total of 120 datasets were collected from the experimental data of another author, and the relative dynamic elastic modulus was predicted using the two-stage BPNN prediction model proposed in this paper and compared with the BPNN prediction results. The results show that the proposed two-stage BPNN model, after removing less-sensitive parameters from the input layer, has better prediction accuracy and shorter run time than the BPNN model. [ABSTRACT FROM AUTHOR]

Giga-casting, a revolutionary approach for manufacturing large, single-piece car body components from aluminium, has emerged as a potential game-changer in the automotive industry. However, these large, thin-walled castings are prone to distortions during solidification and heat treatment processes. Straightening these distortions is crucial to ensure structural integrity, facilitate downstream assembly, and maintain aesthetic qualities. This paper proposes a novel method for straightening giga-cast components using a multi-pin straightening machine. The machine's versatility stems from its ability to adapt to various geometries through multiple strategically controlled straightening pins. This paper introduces the concept of a "straightening stroke decision algorithm" to achieve precise straightening and overcome the challenges of complex shapes. This algorithm determines the stroke length for each pin, combining a polynomial model representing the global stiffness of the component with a machine learning model that captures the stiffness changes arising from the current geometry. The effectiveness of the proposed approach is evaluated through comprehensive numerical experiments using finite element analyses. The straightening performance is assessed for the straightening algorithm with different machine learning models (deep neural network and XGBoost) and compared to a traditional optimisation method. The proposed surrogate models decided the straightening strokes so that the maximum remaining distortion became 0.02% of the largest dimension of each target geometry. The results of the numerical experiment showed that the proposed straightening method is suitable for straightening distortion in large thin-walled components. [ABSTRACT FROM AUTHOR]

Existing research in metasurface design was based on trial-and-error high-intensity iterations and requires deep acoustic expertise from the researcher, which severely hampered the development of the metasurface field. Using deep learning enabled the fast and accurate design of hypersurfaces. Based on this, in this paper, an integrated learning approach was first utilized to construct a model of the forward mapping relationship between the hypersurface physical structure parameters and the acoustic field, which was intended to be used for data enhancement. Then a dual-feature fusion model (DFCNN) based on a convolutional neural network was proposed, in which the first feature was the high-dimensional nonlinear features extracted using a data-driven approach, and the second feature was the physical feature information of the acoustic field mined using the model. A convolutional neural network was used for feature fusion. A genetic algorithm was used for network parameter optimization. Finally, generalization ability verification was performed to prove the validity of the network model. The results showed that 90% of the integrated learning models had an error of less than 3 dB between the real and predicted sound field data, and 93% of the DFCNN models could achieve an error of less than 5 dB in the local sound field intensity. [ABSTRACT FROM AUTHOR]

In this work, we focus on the prediction of the influence of CO2 laser parameters on the kerf properties of cut spruce wood. Laser kerf cutting is mainly characterized by the width of kerf and the width of the heat-affected zone, which depend on the laser power, cutting speed, and structure of the cut wood, represented by the number of cut annual rings. According to the measurement results and ANN prediction results, for lower values of the laser power (P) and cutting speed (v), the effect of annual rings (ARs) is non-negligible. The results of the sensitivity analysis show that the effect of v increases at higher energy density (E) values. With P in the range between 100 and 500 W, v values between 3 and 50 mm·s−1, and AR numbers between 3 and 11, the combination of P = 200 W and v = 50 mm·s−1, regardless of the AR value, leads to the best cut quality for spruce wood. In this paper, the main goal is to show how changes in the input parameters affect the characteristics of the cutting kerf and heat-affected zones for all possible input parameter values. [ABSTRACT FROM AUTHOR]

Warm mix flame retardant asphalt mixture can reduce the energy dissipation and harmful gas emissions during asphalt pavement construction, as well as mitigate the adverse effects of road fires. For this, this paper studies the design and performance of a mixture modified with a combination of warm mix agent and flame retardant, and the pavement performance and flame retardancy of the modified mixture are evaluated. Additionally, a flame retardancy prediction model based on the radial basis function (RBF) neural network model is established. On this basis, the principal components analysis (PCA) model is used to analyze the most significant evaluation indicators affecting flame retardancy, and finally, a three-dimensional finite element model is developed to analyze the effects of loading on the pavement structure. The results show that compared to virgin asphalt mixture, the modified mixture shows a reduction in mixing and compaction temperatures by approximately 12 °C. The high-temperature performance of the mixture is improved, while the low-temperature performance and moisture stability slightly decrease, but its flame retardancy is significantly enhanced. The RBF neural network model revealed that the established flame retardancy prediction model has a high accuracy, allowing for precise evaluation of the flame retardancy. Finally, the PCA model identified that the combustion time has a significant effect on the flame retardancy of the asphalt mixture, and the finite element model revealed that the displacements of the warm mix fire retardant asphalt mixture were lower than virgin asphalt mixture in all directions under the loading. [ABSTRACT FROM AUTHOR]

The quality of Ti alloy casing is crucial for the safe and stable operation of aero engines. However, the fluctuation of key process parameters during the investment casting process of titanium alloy casings has a significant influence on the volume and number of porosity defects, and this influence cannot be effectively suppressed at present. Therefore, this paper proposes a strategy to control the influence of process parameters on shrinkage volume and number. This study constructed multiple regression prediction models and neural network prediction models of porosity volume and number for a ZTC4 casing by simulating the gravity investment casting process. The results show that the multiple regression prediction model and neural network prediction model of shrinkage cavity total volume have an accuracy of over 99%. The accuracy of the neural network prediction model is higher than that of the multiple regression model, and the neural network model realizes the accurate prediction of shrinkage defect volume and defect number through pouring temperature, pouring time, and mold shell temperature. The sensitivity degree of casing defects to key process parameters, from high to low, is as follows: pouring temperature, pouring time, and mold temperature. Further optimizing the key process parameter window reduces the influence of process parameter fluctuation on the volume and number of porosity defects in casing castings. This study provides a reference for actual production control process parameters to reduce shrinkage cavity and loose defects. [ABSTRACT FROM AUTHOR]

This paper tackles the issue of moisture variation in wood-based materials, explicitly focusing on melamine-coated particleboard (hereafter referred to as melamine) and medium-density fiberboard (MDF) used in the third phase of wood industry transformation. The approach involves a comprehensive strategy for predicting moisture content variation, incorporating numerical simulation, experimental testing, and the application of artificial neural network (ANN) technology to enhance accuracy in furniture manufacturing. The developed ANN models are tailored to predict moisture content changes under specific thermal comfort conditions. Remarkably, these models demonstrate high precision, with an average error margin of only 1.40% for 8% moisture content (MC) and 2.85% for 12% MC in melamine, as well as 1.42% for 8% MC and 2.25% for 12% MC in MDF. These levels of precision surpass traditional models, emphasizing this study's novelty and practical relevance to the industrial context. The findings indicate that ANN models adapt to diverse environmental conditions, presenting a robust tool for optimizing moisture management in wood-based materials. This research contributes valuable insights for improving the reliability and efficiency of moisture content predictions in the wood industry. [ABSTRACT FROM AUTHOR]

The manufacturing processes and design of metal and alloy products can be performed over a wide range of strain rates and temperatures. To design and optimize these processes using computational mechanics tools, the selection and calibration of the constitutive models is critical. In the case of hazardous and explosive impact loads, it is not always possible to test material properties. For this purpose, this paper assesses the efficiency and the accuracy of different architectures of ANNs for the identification of the Johnson–Cook material model parameters. The implemented computational tool of an ANN-based parameter identification strategy provides adequate results in a range of strain rates required for general manufacturing and product design applications. Four ANN architectures are studied to find the most suitable configuration for a reduced amount of experimental data, particularly for cases where high-impact testing is constrained. The different ANN structures are evaluated based on the model's predictive capability, revealing that the perceptron-based network of 66 inputs and one hidden layer of 30 neurons provides the highest prediction accuracy of the effective flow stress–strain behavior of Ti64 alloy and three virtual materials. [ABSTRACT FROM AUTHOR]

Structures made of heterogeneous materials, such as composites, often require a multiscale approach when their behavior is simulated using the finite element method. By solving the boundary value problem of the macroscale model, for previously homogenized material properties, the resulting stress maps can be obtained. However, such stress results do not describe the actual behavior of the material and are often significantly different from the actual stresses in the heterogeneous microstructure. Finding high-accuracy stress results for such materials leads to time-consuming analyses in both scales. This paper focuses on the application of machine learning to multiscale analysis of structures made of composite materials, to substantially decrease the time of computations of such localization problems. The presented methodology was validated by a numerical example where a structure made of resin epoxy with randomly distributed short glass fibers was analyzed using a computational multiscale approach. Carefully prepared training data allowed artificial neural networks to learn relationships between two scales and significantly increased the efficiency of the multiscale approach. [ABSTRACT FROM AUTHOR]

This article explores the possibility of predicting the compliance coefficients for composite shear keys of built-up timber beams using artificial neural networks. The compliance coefficients determine the stresses and deflections of built-up timber beams. The article analyzes current theoretical methods for designing wooden built-up timber beams with shear keys and possible ways of applying them in modern construction. One of the design methods, based on the use of the compliance coefficients, is also discussed in detail. The novelty of this research is that the authors of the article collected, analysed, and combined data on the experimental values of the compliance coefficient for composite shear keys of built-up timber beams obtained by different researchers and published in other studies. For the first time, the authors of this article generated a table of input and output data for predicting compliance coefficients based on the analysis of the literature and collected data by the authors. As a result of this research, the article's authors proposed an artificial neural network (ANN) architecture and determined the mean absolute percentage error for the compliance coefficients kw and ki, which are equal to 0.054% and 0.052%, respectively. The proposed architecture can be used for practical application in designing built-up timber beams using various composite shear keys. [ABSTRACT FROM AUTHOR]

Buried pipelines are widely used, so it is necessary to analyze and study their fracture characteristics. The locations of corrosion defects on the pipe are more susceptible to fracture under the influence of internal pressure generated during material transportation. In the open literature, a large number of studies have been conducted on the failure pressure or residual strength of corroded pipelines. On this basis, this study conducts a fracture analysis on buried pipelines with corrosion areas under seismic loads. The extended finite element method was used to model and analyze the buried pipeline under seismic load, and it was found that the stress value at the crack tip was maximum when the circumferential angle of the crack was near 5° in the corrosion area. The changes in the stress field at the crack tip in the corrosion zone of the pipeline under different loads were compared. Based on the BP algorithm, a neural network model that can predict the stress field at the pipe crack tip is established. The neural network is trained using numerical model data, and a prediction model with a prediction error of less than 10% is constructed. The crack tip characteristics were further studied using the BP neural network model, and it was determined that the tip stress fluctuation range is between 450 MPa and 500 MPa. The neural network model is optimized based on the GA algorithm, which solves the problem of convergence difficulties and improves the prediction accuracy. According to the prediction results, it is found that when the internal pressure increases, the corrosion depth will significantly affect the crack tip stress field. The maximum error of the optimized neural network is 5.32%. The calculation data of the optimized neural network model were compared with the calculation data of other models, and it was determined that GA-BPNN has better adaptability in this research problem. [ABSTRACT FROM AUTHOR]

The automobile industry relies primarily on spot welding operations, particularly resistance spot welding (RSW). The performance and durability of the resistance spot-welded joints are significantly impacted by the welding quality outputs, such as the shear force, nugget diameter, failure mode, and the hardness of the welded joints. In light of this, the present study sought to determine how the aforementioned welding quality outputs of 0.5 and 1 mm thick austenitic stainless steel AISI 304 were affected by RSW parameters, such as welding current, welding time, pressure, holding time, squeezing time, and pulse welding. In order to guarantee precise evaluation and experimental analysis, it is essential that they are supported by a numerical model using an intelligent model. The primary objective of this research is to develop and enhance an intelligent model employing artificial neural network (ANN) models. This model aims to provide deeper knowledge of how the RSW parameters affect the quality of optimum joint behavior. The proposed neural network (NN) models were executed using different ANN structures with various training and transfer functions based on the feedforward backpropagation approach to find the optimal model. The performance of the ANN models was evaluated in accordance with validation metrics, like the mean squared error (MSE) and correlation coefficient (R2). Assessing the experimental findings revealed the maximum shear force and nugget diameter emerged to be 8.6 kN and 5.4 mm for the case of 1–1 mm, 3.298 kN and 4.1 mm for the case of 0.5–0.5 mm, and 4.031 kN and 4.9 mm for the case of 0.5–1 mm. Based on the results of the Pareto charts generated by the Minitab program, the most important parameter for the 1–1 mm case was the welding current; for the 0.5–0.5 mm case, it was pulse welding; and for the 0.5–1 mm case, it was holding time. When looking at the hardness results, it is clear that the nugget zone is much higher than the heat-affected zone (HZ) and base metal (BM) in all three cases. The ANN models showed that the one-output shear force model gave the best prediction, relating to the highest R and the lowest MSE compared to the one-output nugget diameter model and two-output structure. However, the Levenberg–Marquardt backpropagation (Trainlm) training function with the log sigmoid transfer function recorded the best prediction results of both ANN structures. [ABSTRACT FROM AUTHOR]

This study explores the prediction of concrete compressive strength using machine learning models, aiming to overcome the time-consuming and complex nature of conventional methods. Four models—an artificial neural network (ANN), a multiple linear regression, a support vector machine, and a regression tree—are employed and compared for performance, using evaluation metrics such as mean absolute deviation, root mean square error, coefficient of correlation, and mean absolute percentage error. After preprocessing 1030 samples, the dataset is split into two subsets: 70% for training and 30% for testing. The ANN model, further divided into training, validation (15%), and testing (15%), outperforms others in accuracy and efficiency. This outcome streamlines compressive strength determination in the construction industry, saving time and simplifying the process. [ABSTRACT FROM AUTHOR]

The accurate online detection of laser welding penetration depth has been a critical problem to which the industry has paid the most attention. Aiming at the laser welding process of TC4 titanium alloy, a multi-sensor monitoring system that obtained the keyhole/molten pool images and laser-induced plasma spectrum was built. The influences of laser power on the keyhole/molten pool morphologies and plasma thermo-mechanical characteristics were investigated. The results showed that there were significant correlations among the variations of the keyhole–molten pool, plasma spectrum, and penetration depth. The image features and spectral features were extracted by image processing and dimension-reduction methods, respectively. Moreover, several penetration depth prediction models based on single-sensor features and multi-sensor features were established. The mean square error of the neural network model built by multi-sensor features was 0.0162, which was smaller than that of the model built by single-sensor features. The established high-precision model provided a theoretical basis for real-time feedback control of the penetration depth in the laser welding process. [ABSTRACT FROM AUTHOR]

Manufacturing processes in industry applications are often controlled by the evaluation of surface topography. Topography, in its overall performance, includes form, waviness, and roughness. Methods of measurement of surface roughness can be roughly divided into tactile and contactless techniques. The latter ones are much faster but sensitive to external disturbances from the environment. One type of external source error, while the measurement of surface topography occurs, is a high-frequency noise. This noise originates from the vibration of the measuring system. In this study, the methods for reducing high-frequency errors from the results of contactless roughness measurements of turned surfaces were supported by machine learning methods. This research delves into optimizing filtration methods for surface topography measurements through the application of machine learning models, focusing on enhancing the accuracy of surface roughness assessments. By examining turned surfaces under specific machining conditions and employing a variety of digital filters, the study identifies the Gaussian regression filter and spline filter as the most effective methods at a 22.5 µm cut-off. Utilizing neural networks, support vector machines, and decision trees, the research demonstrates the superior performance of SVMs, achieving remarkable accuracy and sensitivity in predicting optimal filtration methods. [ABSTRACT FROM AUTHOR]

Friction is one of the main phenomena accompanying sheet metal forming methods, affecting the surface quality of products and the formability of the sheet metal. The most basic and cheapest way to reduce friction is to use lubricants, which should ensure the highest lubrication efficiency and at the same time be environmentally friendly. Due to the trend towards sustainable production, vegetable oils have been used in research as an alternative to petroleum-based lubricants. The analysis of friction in sheet metal forming requires an appropriate tribotester simulating the friction conditions in a specific area of the sheet metal being formed. Research has used a special strip drawing tribometer, enabling the determination the value of the coefficient of friction in the blankholder zone in the deep drawing process. Quantitative analysis of the friction phenomenon is necessary at the stage of designing the technological process and selecting technological parameters, including blankholder pressure. This article presents the results of friction testing of 1.0338 (DC04) steel sheets using a strip drawing test. The experimental tests involved pulling a strip of sheet metal between two countersamples with a rounded surface. The tests were carried out on countersamples with different levels of roughness for the range of contact pressures occurring in the blankholder zone in the deep drawing process (1.7–5 MPa). The values of the coefficient of friction determined under dry friction conditions were compared with the results for edible (corn, sunflower and rapeseed) and non-edible (Moringa, Karanja) vegetable lubricants. The tested oils are the most commonly used vegetable-based biolubricants in metal forming operations. Multi-layer artificial neural networks were used to determine the relationship between the value of the contact pressure, the roughness of the countersamples, the oil viscosity and density, and the value of the coefficient of friction. Rapeseed oil provided the best lubrication efficiency during friction testing for all of the tested samples, with an average surface roughness of Sa 0.44–1.34 μm. At the same time, as the roughness of the countersamples increased, a decrease in lubrication efficiency was observed. The lowest root mean squared error value was observed for the MLP-4-8-1 network trained with the quasi-Newton algorithm. Most of the analysed networks with different architectures trained using the various algorithms showed that the kinematic viscosity of the oil was the most important aspect in assessing the friction of the sheets tested. The influence of kinematic viscosity on the value of the coefficient of friction is strongly dependent on the surface roughness of the countersamples. [ABSTRACT FROM AUTHOR]

Fatigue life testing is a complex and costly matter, especially in the case of fibre-reinforced thermoplastics, where other parameters in addition to force alone must be taken into account. The number of tests required therefore increases significantly, especially if the influence of different fibre orientations is to be taken into account. It is therefore important to gain the greatest possible amount of knowledge from the limited number of available tests. In order to achieve this, this study aims to utilise adaptive sampling, which is used in numerous areas of computational engineering, for the design of experiments on fatigue life testing. Artificial neural networks (ANNs) are therefore trained on data for the short-fibre-reinforced material PBT GF30, and their areas of greatest model uncertainty are queried. This was undertaken with ANNs from various numbers of hidden layers, which were analysed for their performance. The ideal case turned out to be four hidden layers, for which a squared error as small as 1 × 10−3 was recorded. Locally resolved, the ANN was used to identify the region of greatest uncertainty for samples of vertical orientation and small numbers of cycles. With information such as this, additional data can be obtained in such uncertain regions in order to improve the model prediction—almost halving the recorded error to only 0.55 × 10−3. In this way, a model of comparable value can be found with less experimental effort, or a model of better quality can be set up with the same experimental effort. [ABSTRACT FROM AUTHOR]

The article describes machine learning using artificial neural networks (ANNs) to develop the parameters of the friction stir welding (FSW) process for three types of aluminum joints (EN AW 7075). The ANNs were built using a total of 608 experimental data. Two types of networks were built. The first one was used to classify good/bad joints with MLP 7-19-2 topology (one input layer with 7 neurons, one hidden layer with 19 neurons, and one output layer with 2 neurons), and the second one was used to regress the tensile load-bearing capacity with MLP 7-19-1 topology (one input layer with 7 neurons, one hidden layer with 19 neurons, and one output layer with 1 neuron). FSW parameters, such as rotational speed, welding speed, and joint and tool geometry, were used as input data for ANN training. The quality of the FSW joint was assessed in terms of microstructure and mechanical properties based on a case study. The usefulness of both trained neural networks has been demonstrated. The quality of the validation set for the regression network was approximately 93.6%, while the errors for the confusion matrix of the test set never exceeded 6%. Only 184 epochs were needed to train the regression network. The quality of the validation set was approximately 87.1%. Predictive maps were developed and presented in the work, allowing for the selection of optimal parameters of the FSW process for three types of joints. [ABSTRACT FROM AUTHOR]

This research presents a comprehensive analysis of deep neural network models (DNNs) for the precise prediction of Vickers hardness (HV) in nitrided and carburized M50NiL steel samples, with hardness values spanning from 400 to 1000 HV. By conducting rigorous experimentation and obtaining corresponding nanoindentation data, we evaluated the performance of four distinct neural network architectures: Multilayer Perceptron (MLP), Convolutional Neural Network (CNN), Long Short-Term Memory network (LSTM), and Transformer. Our findings reveal that MLP and LSTM models excel in predictive accuracy and efficiency, with MLP showing exceptional iteration efficiency and predictive precision. The study validates models for broad application in various steel types and confirms nanoindentation as an effective direct measure for HV hardness in thin films and gradient-variable regions. This work contributes a validated and versatile approach to the hardness assessment of thin-film materials and those with intricate microstructures, enhancing material characterization and potential application in advanced material engineering. [ABSTRACT FROM AUTHOR]

Stainless steel is a cold-work-hardened material. The degree and mechanism of hardening depend on the grade and family of the steel. This characteristic has a direct effect on the mechanical behaviour of stainless steel when it is cold-formed. Since cold rolling is one of the most widespread processes for manufacturing flat stainless steel products, the prediction of their strain-hardening mechanical properties is of great importance to materials engineering. This work uses artificial neural networks (ANNs) to forecast the mechanical properties of the stainless steel as a function of the chemical composition and the applied cold thickness reduction. Multiple linear regression (MLR) is also used as a benchmark model. To achieve this, both traditional and new-generation austenitic, ferritic, and duplex stainless steel sheets are cold-rolled at a laboratory scale with different thickness reductions after the industrial intermediate annealing stage. Subsequently, the mechanical properties of the cold-rolled sheets are determined by tensile tests, and the experimental cold-rolling curves are drawn based on those results. A database is created from these curves to generate a model applying machine learning techniques to predict the values of the tensile strength (Rm), yield strength (Rp), hardness (H), and elongation (A) based on the chemical composition and the applied cold thickness reduction. These models can be used as supporting tools for designing and developing new stainless steel grades and/or adjusting cold-forming processes. [ABSTRACT FROM AUTHOR]

The article presents a hybrid method for calculating the chemical composition of steel with the required hardness after cooling from the austenitizing temperature. Artificial neural networks (ANNs) and genetic algorithms (GAs) were used to develop the model. Based on 550 diagrams of continuous cooling transformation (CCT) of structural steels available in the literature, a dataset of experimental data was created. Artificial neural networks were used to develop a hardness model describing the relationship between the chemical composition of the steel, the austenitizing temperature, and the hardness of the steel after cooling. A genetic algorithm was used to identify the chemical composition of the steel with the required hardness. The value of the objective function was calculated using the neural network model. The developed method for identifying the chemical composition was implemented in a computer application. Examples of calculations of mass concentrations of steel elements with the required hardness after cooling from the austenitizing temperature are presented. The model proposed in this study can be a valuable tool to support chemical composition design by reducing the number of experiments and minimizing research costs. [ABSTRACT FROM AUTHOR]