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Selective laser melting (SLM) is one of the most well-known additive manufacturing methods available for the fabrication of functional parts from metal powders. Although SLM is now an established metal additive manufacturing technique, its widespread application in industry is still hindered by inherent phenomena, one of which is high residual stresses. Some of the effects of residual stresses–such as warping and thermal stress-related cracking–cannot be corrected by post processing. Therefore, establishing input process parameter combinations that result in the least residual stress magnitudes and related distortions and/or cracking is critical. This paper presents the influence of laser power, scanning speed, and layer thickness on residual stresses, distortions and achievable density for maraging steel 300 steel parts in order to establish the most optimum input parameter combinations. An analysis of the interdependence between process outcomes shows that high residual stress magnitudes lead to high dimensional distortions in the finished parts, whilst porous parts suffer relatively lower residual stresses and associated distortions.

The ball bearing market is mature where there is a massive range of products available with new ones being developed all the time due to technological advancements. Additive Manufacturing (AM) provides a promising approach for developing oil-impregnated ball bearings. Oil impregnated bearings are critical for applications requiring smooth and low-friction motion. This study explores the feasibility of utilizing laser powder bed fusion (LPBF) technology to fabricate 304 stainless steel (304SS) samples with open pores, which can then be impregnated with a lubricant. To achieve this, 304SS powder was used, and optimum selective laser melting (SLM) printing parameters were altered to induce intentional pores. Initial screening of samples involved Archimedes density measurements and computed tomography (CT) scanning was conducted on a selected samples to assess their porosity levels. CT scan foam analysis results indicated a correlation between hatch spacing and porosity. Results revealed trends in cell volume and solidified scanning tracks thickness, indicating greater connectedness with larger pores. Synthesis of these findings could help in the development of efficient and reliable open pores that may find use in oil-impregnated self-lubricating ball bearings.

The use of computer simulation to imitate physical processes has proven to be a time-efficient and cost-effective way of performing scenario testing for process optimisation in different applications. The finite element analysis (FEA) is the dominant numerical simulation method for analysing sheet metal forming processes. It uses mathematical tools and computer-aided engineering software programmes to predict forming processes. To improve the quality of output from the simulation, accurate material characterisation data that correctly model the behaviour of the material when it undergoes deformation must be provided. This paper outlines the stages of conducting material characterisation experiments, such as tensile, hardness, and formability tests, using the aluminium alloy AA1050-O. Sample preparation, the machine setup, and testing procedures for the material characterisation tests are given. Subsequent data preparation methods for input into an FEA software programme are also outlined. Implications of the testing results to a deep drawing process are examined while considering the formation of a rectangular monolithic component measuring 2300 mm by 1400 mm with a drawing depth of approximately 150 mm. The results from the characterisation tests indicate that the forming process for the product can be achieved using cold forming at room temperatures as a 25% strain was recorded before necking against an anticipated uniaxial strain of 5.93%. The aluminium alloy AA1050-O demonstrated a negligible strain rate sensitivity in the forming region, thus eliminating tool velocity from the key process parameters that should be considered during FEA simulations. A 50% increase in hardness was recorded after strain hardening.

Surface roughness remains a major drawback in metal additive manufacturing (AM) processes. Even though finishing operations are applied, the surface roughness is still of interest because additive manufacturing is mainly applied in expensive materials and, in some cases, hard-to-machine materials. Additionally, conventional finishing operations are not viable for intricate components like fine porous structures or cavities, which make AM attractive. Therefore, improving the surface quality of parts created through laser powder bed fusion (LPBF) requires direct optimisation during manufacturing. In this study, the authors investigated the effect of contour process parameters on the surface roughness of vertical surfaces and sloped surfaces associated with up and down surfaces fabricated by LPBF using 304 stainless steel (304 SS) powder feedstock. The study explored the impact of varying laser power and scanning speed separately while holding other parameters constant. The obtained results showed that increasing the speed decreases the surface roughness on the vertical surfaces whereas there was no clear dependency of the roughness on the laser power. The sloped surface consistently exhibited higher roughness on the down skin than the up skin, which can be attributed to deeper laser penetration. Additionally, printed samples indicated reductions in clearance from the CAD model, attributed to unmolten powder particles adhering to the surface. Understanding and optimising surface finish and dimensional accuracy could further accelerate the adoption of LPBF technology in fabricating net- shaped direct-to-service components.

United Nations (UN) sustainable development goal 6 focuses on clean water and sanitation for all. To date, one-third of the world's population lack access to clean, safe water. The traditional water purification methods cannot monitor and control water quality parameters from the early stages. In this paper, Internet of Things (IoT) is used to develop a real-time water quality monitoring and control system for a water treatment plant. A microcontroller is developed and interfaced with sensors to detect any deviations in the water quality parameters from the World Health Organization (WHO) standards. Every stage of the water treatment process is tested for quality, and deviations from the WHO standard triggers an autonomous control measure. A simulation model and a working prototype are developed. The research produces the expected results: accurate monitoring and control of water parameters.

The transition from polylithic (composed of many parts) to monolithic (one part) design in automotive components presents an opportunity for a reduction in part count, weight, processing routes, and production time without compromising performance. The traditional design approaches for rooftop tents assemble various sheet metal and extrusions together using different joining processes such as welding, adhesive bonding, bolting, and riveting. This is often associated with disadvantages, such as increased weight, high production time, and leaking joints. This research, therefore, presents the development of a monolithic, lightweight, stiffened, non-rotational automotive rooftop tent that is manufactured via the deep-drawing process. An onsite company case study was conducted to analyze the polylithic product and its production process to determine its limitations. This was followed by the design of a lightweight, non-rotational monolithic product whose purpose is to eliminate the identified disadvantages. The stiffness geometries were developed to enhance the overall structural integrity without adding unnecessary weight. The Analytic Hierarchy Process (AHP) was used to analyze and evaluate alternative layouts against criteria such as complexity, tool design, symmetry, rigidity, and cost. Simulations conducted using NX 2024 software confirmed the effectiveness of this design. The results show that the monolithic rooftop tent has a comparable stiffness performance between the lightweight, monolithic rooftop tent and the heavy, polylithic rooftop tent. At the same time, the part count was reduced from twenty-three (23) single parts (polylithic) to a one (1) part (monolithic) rooftop tent, the weight was reduced by 15.6 kg, which translates to a 30% weight reduction without compromising the performance, processing routes were reduced from eight (8) to three (3), production time was reduced by 120 min, and leaking was eliminated. It can, therefore, be concluded that the design and manufacturing of monolithic rooftop tents leads to a lighter and stronger product.

This article discusses the Quality Management (QM) implementation at South Africa’s Nuclear Energy Cooperation (Necsa) for the reconditioning of Ti6Al4V. The reconditioning serves to spheroidise Ti6Al4V from selective laser melting. The quality management tool was implemented to ensure the consistent output of the spheroidised Ti6Al4V. Steps taken to spheroidise Ti6Al4V were documented, and the tools and resources required to ensure the process flows smoothly were highlighted. Standard operating procedures were developed to provide a guide for operators of the spheroidisation facility on the operating parameters needed to consistently spheroidise Ti6Al4V. The main process parameter investigated was the relationship between power and spheroidisation and vaporisation. There are two types of process parameters for effective reconditioning of Ti6Al4V. There are the parameters that operate with the aim of ensuring consistent quality, and the second set ensures economic reconditioning of Ti6Al4V. QM would also ensure that there are standard operating procedures developed within an organisation. For the research, the operating parameters to economically spheroidise Ti6Al4V were determined-

The environmental impact was assessed for the spheroidisation process to compare its advantages versus mining titanium from the ground. Energy consumption was used to compare the environmental impact. With the introduction of spheroidisation at Necsa, there was a need to investigate the environmental impact of the process. The environmental impact of plasma spheroidisation making use of the 15 kW Tekna plasma system was investigated. Environmental impact assessment is part of a bigger study to investigate the holistic impact of the spheroidisation of titanium powder at Necsa. The study was carried out using ASTM standards, ensuring that the results from the experiments are acceptable. The primary focus of the paper was the 15-kW spheroidisation system. The energy consumption of the reconditioning of titanium alloys was compared to conventionally producing titanium. The role spheroidisation plays in the additive manufacturing lifecycle was also assessed. This life cycle assessment also included the other processes in additive manufacturing to give an overview of how the spheroidisation process can fit in and improve the additive manufacturing value stream.

The paper focuses on the evolution of the South African iron and steel industry from the industrial engineering perspective. The earliest ironmaking in South Africa dates to the fifth century CE; but the major evolution of the industry began in 1882 and, by the year 1934, steel production from native ore was in full swing. The study highlights the major developments in South Africa's iron and steel industry, and ends by exploring the extent of the application of industrial engineering techniques to published research into the steel industry.

Contract manufacturing is a pivotal strategy for brand owners, yet small-to-medium enterprises (SMEs) in emerging economies struggle to evolve beyond transactional roles into sustainable strategic partners. This study addresses this gap by empirically validating and refining the Mahove–Matope Sustainable Contract Manufacturing Company Maturity Model (SCMC-MM), a novel framework designed to guide SMEs through a holistic transformation. Through a seven-month longitudinal case study grounded in design science research approach within a South African food manufacturing SME, the model was implemented and evaluated using structured assessments, in-depth interviews, and longitudinal operational data. The application catalysed a system-wide transformation, yielding significant results, including a 133% increase in revenue, ISO 22000 certification, and perfect delivery reliability. Furthermore, the study theoretically refines the framework by identifying and incorporating novel critical success factors for contract manufacturing companies, such as industrial clustering and transformational leadership. The results demonstrate that the SCMC-MM offers a practical, actionable, and scalable tool for building resilient supply chain partnerships. It provides a structured pathway for SMEs to achieve simultaneous gains in economic performance, social equity through enhanced workforce capability and ethical practices, and environmental stewardship via formalised safety, health, and environmental and risk management systems, thereby contributing directly to the United Nations Sustainable Development Goals (SDGs) 8 and 9 in emerging markets.