Kartikey Sharma, Ravi Ranjan Kumar, Rajeev Verma, Robert Johnson, S. V. S. Narayana Murty
{"title":"Repeatability and Reproducibility in Microstructural and Mechanical Properties of Laser Powder Fusion Processed Inconel 718","authors":"Kartikey Sharma, Ravi Ranjan Kumar, Rajeev Verma, Robert Johnson, S. V. S. Narayana Murty","doi":"10.1007/s11665-026-14596-2","DOIUrl":"10.1007/s11665-026-14596-2","url":null,"abstract":"<div><p>In this paper, the repeatability of laser powder bed fusion (LPBF) process during the additive manufacturing (AM) of Inconel Alloy 718 (IN718) is thoroughly investigated. The main objective is to study batch to batch consistency with respect to repeatably and reproducibility of the AM process and its effect on mechanical and microstructural characteristics. This study further compares properties of LPBF IN718 alloy with its wrought counterpart. The results indicate high repeatability in microstructural characteristics, such as grain size and phase distribution, across multiple printing batches of Inconel Alloy 718. Microscopic analysis showed presence of long columnar grains parallel to build direction and fine equiaxed grains perpendicular to it. Additionally, evaluations of mechanical properties including yield strength (YS), ultimate tensile strength (UTS), and elongation at fracture (<i>e</i><sub>f</sub>) generally show little variation across various batches, demonstrating excellent repeatability and reproducibility. YS and UTS were observed to be ~ 1200 and ~ 1400 MPa, respectively, for all samples with near isotropy. On the other hand, elongation to failure exhibited anisotropy with orientation parallel to build direction having higher elongation (> 20%) compared to orientation perpendicular to it (< 20%). Upon comparison with its wrought counterpart, the tensile strength of specimens printed through LPBF was higher than specimens processed through conventional wrought manufacturing, whereas elongation revealed an opposite tread.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 Focus—Space","pages":"38422 - 38437"},"PeriodicalIF":2.6,"publicationDate":"2026-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149214572","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Asiah Shamsudin, Al Basir, Rodianah Alias, Nashrah Hani Jamadon, Animesh K. Basak, Afifah Zakiyyah Juri
{"title":"Optimization of Low-Temperature Sintering of Tantalum-Coated Cryogenic Machined Stainless Steel","authors":"Asiah Shamsudin, Al Basir, Rodianah Alias, Nashrah Hani Jamadon, Animesh K. Basak, Afifah Zakiyyah Juri","doi":"10.1007/s11665-026-14431-8","DOIUrl":"10.1007/s11665-026-14431-8","url":null,"abstract":"<div><p>Failure of orthopaedic implants due to surface and mechanical degradation remains a critical clinical challenge. To address this, biocompatible tantalum (Ta) coatings have been explored for their ability to enhance the durability and performance of implants under physiological conditions. This study investigates the microstructural, surface, and mechanical properties of 316L stainless steel cryogenically machined, coated with Ta by direct current magnetron sputtering, and sintered at 250 and 450 °C. Uniform coatings with stable thickness (~ 2 µm) and high Ta content (> 95 wt.%) exhibited robust thermal stability, with sintering facilitating Ta grain expansion and densification. At 450 °C, the mechanical properties were substantially strengthened, with hardness increasing from 5.5 to 10.5 GPa and Young’s modulus increasing from 115 to 309 GPa. Sintering at 250 °C substantially reduced surface roughness, with both average and root mean square values decreasing by 45-50%, yielding smooth surfaces. All Ta-coated surfaces exhibited moderate contact angles of 86° to 90°, supporting conditions that inhibit bacterial adhesion and facilitate early osseointegration. These findings demonstrate a clear process–property relationship for Ta coatings on stainless steel within the investigated range, highlighting surface refinement at 250 °C and enhanced mechanical strengthening at 450 °C for potential load-bearing orthopaedic applications.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 Focus—Space","pages":"38966 - 38981"},"PeriodicalIF":2.6,"publicationDate":"2026-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149214629","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Effects of Multi-pass Equal Channel Angular Pressing on the Microstructure and Properties of Zn-0.8Mn Alloy","authors":"Yali Li, Xu Han, Xiaohao Sun, Debao Liu","doi":"10.1007/s11665-026-14508-4","DOIUrl":"10.1007/s11665-026-14508-4","url":null,"abstract":"<p>Zinc-based alloys have emerged as promising biodegradable metals, yet their inadequate mechanical strength significantly restricts their clinical applications. To address this limitation, multi-pass equal channel angular pressing (ECAP) was employed to process a Zn-0.8Mn alloy, providing a platform to systematically investigate the regulation mechanisms governing its microstructural evolution, mechanical performance, and corrosion behavior. The as-cast alloy initially consists of a Zn matrix and Zn/MnZn<sub>13</sub> eutectic phases. While multi-pass ECAP (2–8 passes) preserves the fundamental phase constitution, it induces significant grain refinement, dynamic precipitation of MnZn<sub>13</sub> at grain boundaries, and enhanced microstructural homogeneity. Mechanical testing reveals a simultaneous enhancement in both strength and ductility; specifically, after 8 passes, the tensile yield strength (TYS) and elongation (EL) reach 208.7 ± 1.5 MPa and 32.3 ± 4.4%, respectively. Concurrently, the corrosion resistance is improved with increasing ECAP passes, with the corrosion rate decreasing to 0.0233 mm/y after 8 passes. These findings suggest that the Zn-0.8Mn alloy is a promising candidate for biodegradable applications, and the ECAP process provides an effective route for the concurrent optimization of mechanical properties and degradation rates.</p>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 36","pages":"37658 - 37670"},"PeriodicalIF":2.6,"publicationDate":"2026-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149099128","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yan Wang, Jinkuan Liu, Pengrao Pang, Xiangkui Zhou, Shen Wu, Jianglei Fan
{"title":"Influence of TiC on the Tribological Properties of Copper-Based Powder Metallurgy Friction Materials","authors":"Yan Wang, Jinkuan Liu, Pengrao Pang, Xiangkui Zhou, Shen Wu, Jianglei Fan","doi":"10.1007/s11665-026-14586-4","DOIUrl":"10.1007/s11665-026-14586-4","url":null,"abstract":"<div><p>To improve the tribological performance of copper-based friction materials under high-speed braking conditions, TiC was introduced into copper-based friction materials. TiC-reinforced copper-based friction materials were fabricated using powder metallurgy (PM), and the effects of TiC content on microstructure, density, hardness, and friction and wear behavior at braking speeds of 150-350 km/h were systematically investigated. The results show that the density decreases from 5.19 to 4.92 g cm<sup>−3</sup> with increasing TiC content, while the hardness first increases and then decreases, reaching a maximum of 20.1 HBW at 2 wt.% TiC due to dispersion strengthening. As the braking speed increases, the friction coefficient exhibits a non-monotonic trend within the range of 0.37-0.41, while the wear rate first decreases and then increases. The optimal tribological performance is achieved at 2 wt.% TiC, which shows a stable friction coefficient and the lowest wear rate of 1.201 × 10<sup>−8</sup> cm<sup>3</sup>/J at 200 km/h, which enhances the load-bearing capacity and suppresses crack propagation. With a further increase in TiC content, particle agglomeration occurs and the wear mechanism transforms from abrasive wear to fatigue and delamination wear. This study provides new insights into the optimization of TiC-reinforced copper-based friction materials for high-speed braking applications.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 Focus—Space","pages":"38660 - 38673"},"PeriodicalIF":2.6,"publicationDate":"2026-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149214566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Conduction Band Offset Engineering and Computational Assessment of Buffer Layers for Copper-Based Ternary Chalcogenide Photovoltaics","authors":"Shankar Lal, Shyam Sunder Sharma, Sushila Rathore, Kinjal Patel, Jaymin Ray","doi":"10.1007/s11665-026-14468-9","DOIUrl":"10.1007/s11665-026-14468-9","url":null,"abstract":"<div><p>Copper-based ternary chalcogenides have emerged as promising absorber materials for heterojunction thin-film solar cells (HJTFSCs) in recent years due to their excellent properties such as optimal band gap, high absorption coefficient, low cost, non-toxicity, sustainability and environmental friendliness. Researchers have made significant efforts to improve the performance of chalcogenide-based HJTFSCs through both numerical simulations and synthesis methods. Simulation of <i>p</i>-Cu<i>MX</i><sub>2</sub> (<i>M</i> = Sb, Bi; <i>X</i> = S, Se) such as <i>p</i>-type CuSbS<sub>2</sub> (CAS), CuSbSe<sub>2</sub> (CASe), CuBiS<sub>2</sub> (CBS) and CuBiSe<sub>2</sub> (CBSe)-based HJTFSCs using various buffer layers such as <i>n</i>-CdS, <i>n</i>-CdSe, <i>n</i>-SnS<sub>2</sub> and <i>n</i>-GaSe was done using the solar cell capacitance simulator one dimension (SCAPS-1D). The main objective is to identify the most suitable buffer layer for copper-based ternary chalcogenide HJTFSCs. The HJTFSC architecture used is ZnO:Al/i-ZnO/n-buffer/p-absorber/Mo. SCAPS-1D provides a reliable platform to study the properties of each layer, including thickness, carrier concentration, band gap, electron affinity and other physical parameters. The simulated results for the ZnO:Al/i-ZnO/n-buffer/p-absorber/Mo architecture present the essential performance matrix, including the short-circuit current density (<i>J</i><sub>sc</sub>), open-circuit voltage (<i>V</i><sub>oc</sub>), fill factor (FF) and efficiency (<i>η</i>). The best values of all the parameters were obtained for CASe/CdS junction as 31.8 mA, 0.67 V, 0.71 and 15.1%, respectively. The simulations help determine the best-performing buffer and absorber combinations at room temperature (300 K). The simulation conditions include a front internal transmission coefficient of 1 and a reverse voltage from right to left of − 1 V, under the AM 1.5 solar spectrum, with an illumination intensity of 100 mW/cm<sup>2</sup>.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 34","pages":"35677 - 35688"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148974860","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Manvendra Yadav, Virendra Pratap Singh, L. A. Kumaraswamidhas, Akant Kumar Singh, Ashish Kumar
{"title":"Machine Learning-Based Prediction of Solid Particle Erosion Wear of Aluminum Metal Matrix Composites through Powder Metallurgy Route","authors":"Manvendra Yadav, Virendra Pratap Singh, L. A. Kumaraswamidhas, Akant Kumar Singh, Ashish Kumar","doi":"10.1007/s11665-026-14499-2","DOIUrl":"10.1007/s11665-026-14499-2","url":null,"abstract":"<div><p>In this study, the application of machine learning (ML) approaches to predict solid-particle erosion (SPE) wear in aluminum metal matrix composites produced by powder metallurgy is explored. Four composite materials made of an aluminum substrate reinforced with different types of reinforcements, such as Al<sub>2</sub>O<sub>3</sub>, ZrO<sub>2</sub>, SiC, and WC, were investigated by varying the reinforcement content (0-10 wt.%). The experiments were performed in compliance with ASTM G76 standards and included four impingement angles (30, 45, 60, 90°), velocities ranging from 30 to 90 m/s, and types of reinforcements. A dataset comprising 121 experimental data points was collected. Various models, including SVM, SVR, ANN, decision tree, GBM, multiple linear regression, and random forest, were built in Python. The evaluation of the model’s performance relied on calculating <i>R</i><sup>2</sup>, RMSE, MAE, and the scattering index (SI). GBM appeared to be the most accurate model in the analysis (<i>R</i><sup>2</sup> = 0.95, SI = 0.06) along with SVR and SVM_PUK models. Predictive models exhibited low prediction errors from 2.70 to 9.05%. These results confirm that ML models can effectively capture nonlinear erosion behavior and provide a reliable predictive framework for PM-based AMMCs, thereby reducing experimental effort and improving material design optimization.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 36","pages":"37708 - 37721"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149098841","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Amit Prakash, Praveen Kumar Rai, Rahul Kumar, Sanjay Kumar
{"title":"Performance Analysis of PV Panel Cooling Using Nano-Dispersed Phase Change Material: A MATLAB Approach","authors":"Amit Prakash, Praveen Kumar Rai, Rahul Kumar, Sanjay Kumar","doi":"10.1007/s11665-026-14587-3","DOIUrl":"10.1007/s11665-026-14587-3","url":null,"abstract":"<div><p>Solar Photovoltaic (PV) panel performance is closely tied to its operating temperature, with efficiency tending to decline as temperatures increase. Phase change materials (PCMs) have garnered interest for their capacity to store thermal energy and facilitate passive cooling in response to this challenge. Due to the problem of low thermal conductivity, PCMs are not widely used nowadays. Instead, Nano Dispersed Phase Change Material (NDPCM) is being used as a thermal energy storage application. The Al<sub>2</sub>O<sub>3</sub> nanoparticles dispersed throughout the PCM create an NDPCM. The present paper utilizes a MATLAB-based thermal model to assess how effectively NDPCMs can regulate the temperature of a solar PV panel. Numerical simulations have been carried out under constant different solar irradiance conditions to compare temperature variations between PV systems with and without NDPCM integration. The average power output of the PV panel, as well as integrated with NDPCM, attains its maximum value at higher solar irradiance. The results demonstrate that NDPCM integration significantly reduces PV panel temperature and enhances thermal stability. Under high solar irradiance, the average power output increased by up to 11.7%, while the PV panel temperature decreased by approximately 30%.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 36","pages":"37902 - 37921"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149098934","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Lin-lin Zhu, Hong-mei Zuo, Xiaoqi Jin, Lidong Wen, Zhong-bi Chen, Song Fu
{"title":"3D-Printed Lightweight MXene-CNTs/Polylactic Acid Composite with Excellent Electromagnetic Interference Shielding and Mechanical Properties","authors":"Lin-lin Zhu, Hong-mei Zuo, Xiaoqi Jin, Lidong Wen, Zhong-bi Chen, Song Fu","doi":"10.1007/s11665-026-14563-x","DOIUrl":"10.1007/s11665-026-14563-x","url":null,"abstract":"<div><p>With the rapid popularization of electronic products and communication devices, the exploitation of electromagnetic interference (EMI) shielding composites has become extremely urgent to meet the requirements of electromagnetic protection. Herein, four kinds of MXene–carbon nanotubes/polylactic acid (MXene-CNTs/PLA) composites with 10 wt.% CNTs and different MXene content, respectively, of 0, 0.5, 1.0, and 1.5 wt.% were prepared by 3D printing technology. The results showed that MXene and CNTs were successfully introduced in PLA and they were uniformly distributed in PLA. Thermal decomposition temperature (<i>T</i><sub>2%</sub>) and maximum decomposition temperature (<i>T</i><sub>max</sub>) of all modified PLA decreased compared to pure PLA, while their residual carbon content increased significantly. The printed samples exhibited lightweight and excellent EMI shielding performances. Compared with the pure 3D-printed 10wt.% CNTs/PLA sample with an EMI shielding efficiency (EMI SE) with 3.43 dB, the EMI SE of 1.0wt.%MXene–10wt.%CNTs/PLA could reach up to 39.37 dB and its specific shielding effectiveness (<i>SSE</i><sub>t</sub>) was 176.63 dB·cm<sup>2</sup>·g<sup>−1</sup>. Moreover, its tensile strength could reach 104.76 MPa, significantly higher than that of pure PLA. The excellent EMI SE and mechanical performance endow 3D-printed PLA-related composite with great potential use in industry area.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 36","pages":"37805 - 37813"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149098933","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Comparative Study on the Microstructural Features and Mechanical Properties of an Mg-Zn Alloy Processed by Squeeze Casting and ECAP","authors":"D. Sudhakar, Pintu Kumar","doi":"10.1007/s11665-026-14571-x","DOIUrl":"10.1007/s11665-026-14571-x","url":null,"abstract":"<div><p>In the present work, Mg-4Zn alloys were produced by the squeeze casting method and subsequently processed by Equal Channel Angular Pressing (ECAP) to enhance their mechanical properties. The ECAP setup incorporated a constant channel diameter of 10 mm, a channel angle (<i>ϕ</i>) of 90°, and a corner angle (<i>Ψ</i>) of 20°. Microstructural evolution was studied using optical microscopy (OM), scanning electron microscopy (SEM), and x-ray diffraction (XRD). The <i>ɑ</i>-Mg and precipitated secondary Mg<sub>x</sub>-Zn<sub>y</sub> phases were observed in the as-cast condition; however, only the <i>ɑ</i>-Mg phase was observed in the ECAPed condition. ECAPed processing led to a refinement of the crystallite size from 38.28 nm in the as cast condition to 36.22 nm. Compared to the as cast state, the ECAPed specimens exhibited higher average hardness in both the transverse and longitudinal directions. An increase in hardness levels was attributed to grain refinement generated by deformation. The maximum load deformation for specimen lengths of 50 and 72 mm was estimated at 33 and 34 kN, respectively, using upper bound theory; however, during ECAP, these values reached 43.60 and 59.60 kN. The higher coefficient of friction, increased dislocation density, and material trapped between the punch and die clearance were the primary reasons for the higher ECAP load values. To assess the contribution of grain boundary strengthening, a semi-quantitative analysis based on the Hall-Petch relationship was carried out. The average grain size decreased from 136 <i>μ</i>m in the as cast condition to 19.65 <i>μ</i>m after ECAP, resulting an increase in from 0.0857 to 0.225 <i>μ</i>m<sup>−1/2</sup>. The evaluated increase in yield strength was 38 MPa. Grain refinement strengthening might have been slightly influenced by texture evolution and the recovery effect during ECAP at room temperature.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 36","pages":"37878 - 37890"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149098935","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sallam A. Kouritem, Wael A. Altabey, Mazen S. Hanafy, Ahmed M. Omran, Mazen Tarek, Omar M. Elnahrawy, Mohamed Hakam, Mohamed A. Al-Moghazy
{"title":"Hybrid Multi-objective Optimization of Crane Hook through Aided Deep Learning Algorithm","authors":"Sallam A. Kouritem, Wael A. Altabey, Mazen S. Hanafy, Ahmed M. Omran, Mazen Tarek, Omar M. Elnahrawy, Mohamed Hakam, Mohamed A. Al-Moghazy","doi":"10.1007/s11665-026-14496-5","DOIUrl":"10.1007/s11665-026-14496-5","url":null,"abstract":"<div><p>This paper represents the multi-objective optimization of a crane hook in such a way that the enhancement of structural performance will be achieved with guaranteed safety and durability. The research study applies a two-phase approach: the first phase, by using validation, a hybrid of Genetic Algorithms (GA), fmincon, and Gray Wolf Optimizer (GWO) (analytically) for the proper minimization of mass in a crane hook while enhancing its structural integrity. In the second case study, a hybrid optimization method of GA combined with fmincon will be applied, followed by topology (numerical) optimization. The proposed hybrid approach with GA-fmincon, along with topology optimization, has allowed a substantial reduction in mass by 26.91% without compromising the mechanical robustness of the crane hook. Such a reduction represents an important achievement over previous works. The improved design exhibits better distribution of stresses, an appropriate factor of safety, and increased fatigue resistance. These improvements are also corroborated by detailed analysis that shows the designed component can resist operational conditions with extreme changes and can also support a large number of loading cycles. A novel convolutional neural network (CNN) is designed, tested, and trained to predict the fatigue life (<i>N</i>) of the crane hook under repeated loading in order to save the time and avoid the complexity of repetition implementation finite element model (FEM). The CNN training phase produces promising results, showing the model performance with 94.79% accuracy, 92.34% regression, and 91.16% F-score at epoch 1000, which shows the effectiveness of the proposed approach. This work approves the optimization methodologies adopted and offers a sound approach that can be further applied in structural engineering applications, with the aim of making the most of advanced computational techniques to achieve material efficiency and structural performance.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"35 33","pages":"34240 - 34255"},"PeriodicalIF":2.6,"publicationDate":"2026-07-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148962261","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}