Aerospace, automobile and biomedical sector focuses on innovative rapid manufacturing processes, which can enable product customization, reduction in cost and manufacturing lead time. Aerospace, automobile and biomedical industries mostly use magnesium AZ31 and aluminium 6061 alloy materials for manufacturing of products because of their lower elastic modulus, excellent corrosion and fatigue resistance. The conventional sheet metal forming processes often require additional tools like punch and die and would not be economically viable to produce the customized structure for applications. An emerging forming technique known as warm incremental sheet forming process is evolved, which is capable of forming intricate, asymmetrical components at elevated temperature with localized deformation method. The characteristics of warm incremental sheet forming process suggest the need for the investigation of magnesium AZ31 and aluminium 6061 alloy materials for wide application of the process. Experimental investigation on the influence of process parameters on warm incremental sheet metal forming of magnesium AZ31 and aluminium 6061 alloy materials using electric heating technique was studied. Experimental results revealed that magnesium AZ31 and aluminium 6061 alloy sheet metal component formed with incremental depth of 0.1 mm, wall angle of 50° and temperature of 300°C showed maximum formability and thickness reduction with minimum geometrical deviation.

Direct metal deposition (DMD) is a metal additive manufacturing (AM) process that builds objects layer by layer. The surface properties of DMD components are discussed in this study. The fluctuation of surface attributes such as roughness, finish, texture, and so on as a function of operation parameters has been investigated for a number of materials. This research assists in identifying the optimal process parameters for the material chosen, such as material feed rate, gas flow rate, and laser power, in order to generate the best surface characteristics. The results show that wire feed deposition surpasses powder feed deposition. The laser power and scanning speed of the laser were found to be the most influential process parameters. The study results reveal that the optimum process parameter combinations are material specific and is the keyfactor for obtaining better products with reduced surface roughness and waviness. The microstructural study also explores the material specfic effect in processs parameter combinations. This research could be used to determine or predict the best process parameters for a wide range of industrial materials.

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