Structural Integrity in Advanced Materials and Manufacturing: The Convergence of Structural Integrity and Advanced Manufacturing

Editorial

Structural Integrity in Advanced Materials and Manufacturing: The Convergence of Structural Integrity and Advanced Manufacturing

Abílio M. P. de Jesus

LAETA & Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal; ajesus@fe.up.pt

Received: 2 September 2024; Accepted: 3 September 2024; Published: 10 September 2024

1. Introduction

In recent years, the rapid advancement in materials science and manufacturing technologies has redefined the landscape of modern engineering. The intersection of these domains has given rise to a new frontier, where structural integrity is intricately tied to the innovative processes used to develop and fabricate materials. The journal Structural Integrity in Advanced Materials and Manufacturing (SIAMM) aims to stay at the forefront of this interdisciplinary convergence, providing a platform for researchers, engineers, and industry professionals to explore the challenges and opportunities in ensuring the durability, reliability, and performance of next-generation materials and structures.

This Editorial outlines the evolving scope of structural integrity within the context of advanced materials and manufacturing techniques, emphasizing this discipline’s critical role in driving technological innovation. We will discuss the significance of integrating structural integrity considerations early in the design and manufacturing process, the impact of novel materials, and the challenges posed by emerging manufacturing methods.

2. The Expanding Scope of Structural Integrity

Traditionally, structural integrity has ensured that materials and components can withstand operational loads and environmental conditions throughout their service life. This discipline has always been crucial in aerospace, automotive, railways, civil engineering, and energy sectors. However, the advent of advanced materials—such as composites including ceramic matrix ones, shape memory alloys, smart materials, high-entropy alloys, nanomaterials, superalloys, and biodegradable polymers, among others—has expanded the scope of structural integrity beyond conventional boundaries. These new materials, while offering superior properties such as enhanced strength-to-weight ratios, corrosion resistance, and tailored mechanical properties, also present unique challenges. For instance, composites’ heterogeneity and nanomaterials’ size-dependent properties require new approaches to predict failure modes accurately. Moreover, the multifunctional nature of smart materials necessitates a deeper understanding of how these materials respond to complex, dynamic loading conditions.

In this context, SIAMM seeks to promote research that explores the mechanical performance of advanced materials and their long-term behaviour under diverse conditions. The journal encourages contributions that address the interplay between material composition, microstructure, and external factors such as temperature, humidity, and mechanical loadings. By fostering a multidisciplinary approach, SIAMM aims to bridge the gap between material science and structural engineering, ensuring that the development of new materials is always accompanied by a thorough assessment of their structural integrity.

3. The Role of Advanced Manufacturing Techniques

The manufacturing landscape has undergone a profound transformation with the rise of advanced techniques such as additive manufacturing (AM), advanced casting, high-precision machining, novel joining processes, innovative surface processing, and hybrid manufacturing. These processes offer unprecedented design flexibility, enabling the production of complex geometries that were previously impossible to achieve through conventional methods. However, the structural integrity of components produced by these methods is often a subject of intense scrutiny. Additive manufacturing, for example, allows for layer-by-layer construction of components, which can lead to anisotropy, residual stresses, and microstructural defects. These factors can compromise the mechanical performance and reliability of the final product.

Similarly, advanced casting methods that utilize rapid solidification and novel mould designs may challenge grain structure control and defects management. High-precision machining and hybrid manufacturing techniques combine multiple processes and require meticulous attention to ensure that the final component meets stringent structural requirements. Advanced joining techniques, such as friction stir welding and laser welding, pose challenges in ensuring homogeneous microstructures and avoiding residual stress concentrations at the joints, which are critical for maintaining overall component integrity. Innovative surface processing methods, like laser surface texturing and plasma treatments, must be carefully controlled to enhance surface properties without inducing unwanted defects that could compromise fatigue resistance and wear performance.

SIAMM recognizes the importance of advancing our understanding of how these manufacturing processes influence structural integrity. The journal is committed to publishing cutting-edge research that explores the relationship between manufacturing parameters, material properties, and the structural performance of the finished product. By doing so, SIAMM aims to contribute to developing guidelines and standards that ensure the reliability and safety of components produced through advanced manufacturing techniques.

4. Integration of Structural Integrity in Design and Manufacturing

One of the essential messages that SIAMM seeks to convey is the necessity of integrating structural integrity considerations early in the design and manufacturing process. This proactive approach identifies and mitigates potential failure mechanisms before manifesting in the final product. It also promotes the development of materials and manufacturing processes that are inherently robust, reducing the need for costly post-production testing and quality control measures. SIAMM encourages collaboration between material scientists, mechanical engineers, and manufacturing experts to achieve this integration. By bringing together diverse perspectives, the journal aims to foster innovative solutions that address the complex challenges associated with advanced materials and manufacturing. In particular, SIAMM is interested in research that leverages computational modelling, machine learning, and data science to predict the behaviour of materials and structures under various conditions. These tools can provide valuable insights into how microstructural features, manufacturing defects, and environmental factors influence structural integrity, enabling more informed design decisions.

5. Challenges and Future Directions

As the structural integrity field continues to evolve, several challenges and opportunities lie ahead. One of the primary challenges is the need to develop standardized testing and evaluation methods for advanced materials and manufacturing processes. These materials’ unique properties and behaviours often fall outside the scope of traditional testing protocols, necessitating the creation of new methodologies that can accurately assess their structural performance.

Another challenge is the increasing complexity of modern engineering systems. As components become more intricate and materials more diverse, ensuring structural integrity requires a holistic approach considering the interactions between different system elements. This complexity also extends to the supply chain, where variability in material properties and manufacturing conditions can introduce uncertainties that must be accounted for in the design process.

Looking to the future, SIAMM envisions a world where the principles of structural integrity are seamlessly integrated into every stage of the material and manufacturing lifecycle. This vision includes the widespread adoption of advanced monitoring and diagnostic tools, such as non-destructive evaluation (NDE) techniques and digital twins, which can provide real-time insights into the condition of materials and structures. Additionally, the journal anticipates that ongoing advancements in computational modelling and simulation will play a critical role in predicting and mitigating potential failure modes, leading to safer and more reliable engineering systems.

6. Outlook

Structural Integrity in Advanced Materials and Manufacturing (SIAMM)  is dedicated to advancing the understanding of how materials and manufacturing processes impact the structural performance of engineering systems. By fostering interdisciplinary collaboration and promoting innovative research, the journal aims to contribute to developing materials and manufacturing methods that meet the highest reliability and safety standards. As we move forward, SIAMM will continue to serve as a platform for exchanging knowledge and ideas, driving progress in structural integrity, and ensuring that the next generation of materials and structures can withstand the demands of an ever-changing world.

Conflicts of Interest: The author declares no conflict of interest.