There is, I think, something ethereal about i —the square root of minus one. I remember first hearing about it at school. It seemed an odd beast at that time—an intruder hovering on the edge of reality.

Usually familiarity dulls this sense of the bizarre, but in the case of i it was the reverse: over the years the sense of its surreal nature intensified. It seemed that it was impossible to write mathematics that described the real world in …

I and i

Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is no specific consensus on the definition of the term ‘hybrid processes’, researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors’ classification, followed by discussion of their developments, limitations and future research needs.

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A review of hybrid manufacturing processes – state of the art and future perspectives

A review on forming techniques for manufacturing lightweight complex—shaped aluminium panel components

Low- and high-cycle fatigue resistance of Ti-6Al-4V ELI additively manufactured via selective laser melting: Mean stress and defect sensitivity

Superplasticity in Ti-6Al-4V: Characterisation, modelling and applications

Comparison of the hardening behaviour of different steel families: From mild and stainless steel to advanced high strength steels

Influence of the pressure dependent coefficient of friction on deep drawing springback predictions

The elastic behaviour of TRIP 700 steel under plastic deformation is analysed. The analysis is carried out by means of classical tensile test and loading–unloading cyclic tests. These tests have been performed using high deformation strain gages, which enable an accurate and continuous measurement of strain. An elastic modulus reduction of 20% is observed for 12% plastic deformation. Furthermore, non-linear unloading and loading paths have been found in this work. This is an important difference with respect to other authors and opens new possibilities for the development of new material models to improve the prediction of the post-forming springback of industrial parts, which is an important issue for the automotive industry.

Elastic behaviour characterisation of TRIP 700 steel by means of loading–unloading tests

Industrial application of magnesium alloys is increasing in the last decade due to the very high mechanical strength to weight ratio they present. Typical applications are aeronautic parts but their use in the automotive industry is also growing. The bigger the reduction of the vehicle weight is, which can be obtain using these alloys, the bigger the energy saving will be in the near future. However, the formability of these alloys is poor and they are very difficult to be formed at room temperature. Several works have been presented by different authors on the positive influence the temperature increase has to form magnesium alloys. Normal process temperature is about 200-250°C. In this paper warm incremental forming of magnesium alloys is investigated. The work focuses in the formability limits of the alloys and the identification of the optimal process parameters. Aiming to obtain a homogeneous temperature in the forming areas, hot fluid is used as heating media. Experimental results for different temperatures are presented and final microstructures are related to the possible deformation mechanism.

Warm Incremental Forming of Magnesium Alloys Using Hot Fluid as Heating Media

As important light-weight structure material, aluminum alloys have been widely used in automotive and aerospace industries. In the last years, the manufacturing of parts with high strength and good dimensional accuracy has become the main objective in industrial applications. Within the available aluminum alloys, the 7xxx series has attract the interest of the industrial designers due to the high yield strength and ultimate tensile strength they present. However, the formability of these alloys in as-received industrial condition is very poor at room temperature and various studies are being carried out to develop efficient warm and hot forming processes to form them industrially using heated tools. In the present paper, the W-Temper forming is studied as an alternative to the warm and hot forming processes. Heat treatment temperatures and critical times are presented and an industrial B-Pillar is formed to validate the new process. In the last chapter, the final mechanical properties of the part are reported, before and after a virtual e-coat process where the W-Temper forming is compared with a hot stamping process.

Lander Galdos

Papers

Comparison of the hardening behaviour of different steel families: From mild and stainless steel to advanced high strength steels

Influence of the pressure dependent coefficient of friction on deep drawing springback predictions

Elastic behaviour characterisation of TRIP 700 steel by means of loading–unloading tests

Warm Incremental Forming of Magnesium Alloys Using Hot Fluid as Heating Media

Room Temperature Forming of AA7075 Aluminum Alloys: W-Temper Process