Composite materials such as Fiber Metal Laminates (FMLs) have attracted the interest of the aerospace and automotive industries due to their high strength to weight ratio, but to use them as structures it is necessary to master the manufacturing and wiring techniques of these materials. Therefore, this paper aims to address and summarize the drilling and milling processes in FMLs based on a literature review of papers published from 2000 to 2023. Parameters used in multi-material manufacturing and machining such as drilling and milling, tool geometry, tool coating, lubricants and coolants published by researchers were analyzed, compared and discussed. Machining process parameters related to sustainability were also analyzed. A SWOT analysis was carried out and discussed to identify opportunities for improvement in the machining process. There are opportunities to develop the surface treatment of aluminum alloys, such as testing other combinations than those already used, testing non-traditional surface treatments and manufacturing modes, and developing sustainable techniques during the FML manufacturing process. In the area of tooling, the opportunities are mainly related to coatings for tools and changing machining parameters to achieve an optimum finished part. Finally, to improve the sustainability of the process, it is necessary to test coated drills under cryogenic conditions to reduce the use of lubricants during the machining process.

Due to Inconel 718’s high mechanical properties, even at higher temperatures, tendency to work-harden, and low thermal conductivity, this alloy is considered hard to machine. The machining of this alloy causes high amounts of tool wear, leading to its premature failure. There seems to be a gap in the literature, particularly regarding milling and finishing operations applied to Inconel 718 parts. In the present study, the wear behavior of multilayered PVD HiPIMS (High-power impulse magnetron sputtering)-coated TiN/TiAlN end-mills used for finishing operations on Inconel 718 is evaluated, aiming to establish/expand the understanding of the wear behavior of coated tools when machining these alloys. Different machining parameters, such as cutting speed, cutting length, and feed per tooth, are tested, evaluating the influence of these parameters’ variations on tool wear. The sustained wear was evaluated using SEM (Scanning electron microscope) analysis, characterizing the tools’ wear and identifying the predominant wear mechanisms. The machined surface was also evaluated after each machining test, establishing a relationship between the tools’ wear and production quality. It was noticed that the feed rate parameter exerted the most influence on the tools’ production quality, while the cutting speed mostly impacted the tools’ wear. The main wear mechanisms identified were abrasion, material adhesion, cratering, and adhesive wear. The findings of this study might prove useful for future research conducted on this topic, either optimization studies or studies on the simulation of the milling of Inconel alloys, such as the one presented here.

Inconel 718 is a Ni superalloy with superior mechanical properties, even at high temperatures. However, due to its high hardness and low thermal conductivity, it is considered a difficult-to-machine material. This material is widely used in applications that require good dimensional stability, making the milling process the most used in machining this alloy. The wear resulting from this process and the quality of the machined surface are still challenging factors when it comes to Inconel 718. TiAlN-based coating has been used on cutting tools with Yttrium as a doping element to improve the process performance. Based on this, this work evaluated the machined surface integrity and wear resistance of cutting tools coated using Physical Vapor Deposition (PVD) HiPIMS with TiAlYN in the end milling of Inconel 718, varying the process parameters such as cutting speed (v_c), feed per tooth (f_z), and cutting length (L_cut). It was verified that the L_cut is the parameter that exerts the most significant influence since, even at small distances, Inconel 718 already generates high tool wear (TW). Furthermore, the main wear mechanisms were abrasive and adhesive wear, with the development of a built-up edge (BUE) under a125 m/min feed rate (f) and a L_cut = 15 m. Chipping, cracking, and delamination of the coating were also observed, indicating a lack of adhesion between the coating and the substrate, suggesting the need for a good interlayer or the adjustment of the PVD parameters.

Injection moulds are crucial to produce plastic and lightweight metal components. One primary associated challenge is that these may suffer from different types of failures, such as wear and/or cracking, due to the extreme temperatures (T), thermal cycles, and pressures involved in the production process. According to the intended geometry and respective needs, mould manufacturing can be performed with conventional or non-conventional processes. This work focuses on three foremost alloys: AMPCO^® (CuBe alloy), INVAR-36^® (Fe-Ni alloys, Fe-Ni36), and heat-treated (HT) steels. An insight into the manufacturing processes’ limitations of these kinds of materials will be made, and solutions for more effective machining will be presented by reviewing other published works from the last decade. The main objective is to provide a concise and comprehensive review of the most recent investigations of these alloys’ manufacturing processes and present the machinability challenges from other authors, discovering the prospects for future work and contributing to the endeavours of the injection mould industry. This review highlighted the imperative for more extensive research and development in targeted domains.

Many municipal facilities, such as pools and drinking water treatment facilities, are subject to ongoing maintenance due to the corrosion of their metallic materials caused by chlorine, leading to high costs and a possible risk to public health. A proper study of the employed product’s effect could lead to the use of better materials, which significantly increase the lifetime of metallic equipment more attacked by corrosion, through studies evaluating their cost-effectiveness. This paper was carried out with the objective of studying the degradation of some metallic materials (AISI 316L, AISI 321 and Duplex 14462) used in the referred facilities in order to select the one that possessed a better behavior. It was observed that the introduction of some more adequate materials can drastically reduce maintenance operations, with Duplex 14462 showing the best results, ideal for greater chlorine concentrations, followed by AISI 321, which may be employed for components in less contact with chlorine, since it is more easily affordable.

Due to the automotive industry’s strict demands, customers submit constant production pressure, leading to the adoption of new methodologies, techniques, and management ideas. The goal is always to minimise losses and waste. These demands also affect the maintenance department, which has to keep the balance between machines’ availability for production and ensuring that the machines’ proper running conditions translate into excellent-quality products. Thus, continuous improvement and correct management of maintenance activities are crucial for a company to maintain effective production, without defects, breakdowns, and accidents. Nevertheless, some maintenance activities should also prevent the degradation of equipment conditions in order to produce high-quality products. This paper presents an improvement of maintenance activities conducted on equipment that produces large tires. The main problems and technical difficulties of Machine Tolerance Check (MTC) activities are explored by analysing existing documents, internal knowledge, and changes to working methods. We discuss the implementation of the SMED (Single-Minute Exchange of Die) methodology in calibration procedures, as this method is commonly applied to machines’ setups to reduce downtime. At the end of the study, a 31% decrease in the duration of machine tolerance check activities was achieved, which led to a significant increase in the equipment’s availability.