Additive manufacturing (AM) techniques have transformed the production of parts and components with intricate geometries and customized designs, driving innovation in sustainable manufacturing practices. The additive manufacturing technology used in this work was selective laser melting (SLM), a process that uses laser energy to sinter powdered metals into solid structures. Among the various materials utilized in AM, Ti6Al4V titanium alloys are of particular interest due to their favorable mechanical properties, corrosion resistance, biocompatibility, and potential for reducing material waste. However, the machining of additively manufactured titanium parts presents challenges due to the material’s low conductivity, elastic modulus, and chemical affinity with cutting tools, which impact tool wear and surface finish quality. Milling, a commonly employed process for finishing titanium parts, often involves significant energy use and tool wear, highlighting the need for optimized and eco-conscious machining strategies. This study aims to establish correlations among four key aspects: (1) surface finish of machined Ti6Al4V AM parts, (2) cutting tool damage, (3) dry milling parameters including different cutting tools, and (4) variation of temperature at the contact surface of AM parts and tools using infrared thermography. By examining parameters such as feed per tooth (Fz), axial depth of cut (Ap), spindle trajectories (trochoidal, helicoidal, and linear), and cutting tool diameters, this work identifies conditions that enhance process efficiency while reducing environmental impact. Infrared thermography provides insights into temperature variations during milling, correlating these changes to surface roughness and critical machining parameters, thus contributing to the development of sustainable and high-performance manufacturing practices.

The high-pressure die-casting process is growing since it is a cost-effective solution in the production of lightweight parts for a variety of industries. Nevertheless, the harsh working conditions of the die lead to premature failing and poor quality of the produced parts. Lubricants are applied to cooling the die surface and create a protective film to minimize die wear. However, the high temperature of the die during the casting production makes it difficult for the lubricant to reach the die surface due to the Leidenfrost effect. In this study, the effectiveness of newly developed ester-based lubricants designed to address Leidenfrost phenomenon in high-pressure die-casting is evaluated at laboratory and pilot plant scale. The new lubricants are based on the same ester solution; however, one of them includes a specially formulated anti-Leidenfrost additive to optimize performance at the temperature ranges typically encountered in industrial aluminum high-pressure die-casting processes. The results show a correlation between lubricant heat-transfer capability and aluminum adhesion. Additionally, a pilot plant methodology for testing newly formulated lubricants has been established while the experimental methodology developed for assessing heat-transfer capability is validated as a rapid and cost-effective approach for evaluating lubrication alternatives for high-pressure die-casting applications. Finally, the efficiency of environmentally friendly ester-based lubricants for high-temperature applications has been demonstrated.

Computational approaches are increasingly used to study the relationship between form and function in extinct and living organisms. However, one major challenge remains: assumptions about bone material properties, especially when studying fossils. In this work, direct mechanical testing and computer-based modelling are combined to assess cranial bone stiffness in the lizard genus Gallotia , endemic to the Canary Islands (Spain), including extinct species. Using linear mixed models, bone stiffness was found to be uniform across skull regions, with a trend towards lower stiffness in larger species. Simulations of biting loads showed that differences in bone properties had a limited influence on mechanical performance, supporting the use of average values in functional models. Using this framework, bone stiffness in extinct Gallotia giants was estimated, and its significance was explored. The results suggest a link between skull flexibility, body size, and diet, offering a practical approach to reconstructing biomechanical traits in extinct vertebrates across evolutionary timescales.