Shiraz UniversityIranian Journal of Materials Forming2383-004213120260101Iranian Journal of Materials Forming, Issue 1, January 202623841510.22099/ijmf.2025.8415ENRaminEbrahimiDepartment of Materials Science and Engineering, School of Engineering, Shiraz University, Shiraz, IranJournal Article20251123The “<strong>Iranian Journal of Materials Forming (IJMF)</strong>” has been in existence for twelve years and is now in its thirteenth year, with the first issue of the 13<sup>th</sup> already published. This is an international open access journal in the fields of materials deformation and forming processes, which was established at Shiraz University in 2014. The journal welcomes submission from scientists and engineers in both academic and industrial sectors, covering all manufacturing processes. Additionally, the journal addresses various forms of material deformation, including elastic and plastic behaviors, as well as deformations caused by failure. The journal’s quality and credibility are upheld by a distinguished editorial board, featuring some of the world’s most renowned professors. Furthermore, the diverse group of referees selected for the journal underscores its scientific rigor. Here we are proud to announce that, for the sixth consecutive year, the journal has been successfully published quarterly, with the first issue of 2026 having been released. The strong attention and interest from researchers in IJMF enabled this issue to be published ahead of schedule, even before the start of 2026. We hope that by maintaining this momentum, the journal will continue to publish on time well into the future.https://ijmf.shirazu.ac.ir/article_8415_252b3c53557e0f13300d0578a115722b.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Influence of Homogenization Duration on Interdendritic Phase Elimination and Hardness Behavior in AD730 Nickel-based Superalloy414840510.22099/ijmf.2025.54121.1346ENSaeedMortezaeiFaculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, IranSeyyed MehdiAbbasiFaculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, IranMaryamMorakabatiFaculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, IranJournal Article20250904In this study, the effect of homogenization time on the microstructural evolution and mechanical properties of the cast AD730 superalloy at 1100 °C was investigated. The as-cast microstructure consisted of a dendritic structure along with interdendritic phases, including η phase, Laves phase, γ/γ′ eutectic, and MC carbides. Microscopic examinations and localized analyses revealed that the eutectic and Laves phases were completely dissolved during the early stages of homogenization, while the η phase disappeared after 10 hours of treatment. Prolonging the homogenization time promoted chemical uniformity and gradual elimination of the dendritic structure, resulting in a nearly uniform microstructure after 25 hours. However, at this stage, the formation of voids was detected, indicating adverse effects due to over-homogenization. Hardness measurements showed a continuous decrease in hardness with increasing homogenization time, attributed to the gradual dissolution of the strengthening γ′ precipitates. Based on these results, an optimal homogenization duration of 15 to 20 hours at 1100 °C is suggested, which can eliminate undesirable phases and enhance compositional uniformity while avoiding structural defects.https://ijmf.shirazu.ac.ir/article_8405_a2e01f071505d336a65dc03bc9553c6c.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Effect of Incremental Forming Parameters and Annealing Condition on Principal Strain Distribution and Formability During Straight Groove Forming1529840810.22099/ijmf.2025.53969.1343ENAmir HoseinNeshastegir KashiFaculty of Mechanical Engineering, University of Kashan, Kashan, IranMohammadHonarpishehFaculty of Mechanical Engineering, University of Kashan, Kashan, IranHosseinTalebi-GhadikolaeeFaculty of Mechanical Engineering, University of Kashan, Kashan, IranJournal Article20250812Incremental forming is a highly flexible sheet metal forming process that enables the production of complex components without the need for specialized molds or dies. In this study, the effects of key process parameters—including tool rotational speed, vertical step size, annealing condition, and tool movement direction—on the formability of aluminum 3105H14 sheets were systematically investigated through experimental testing. A Taguchi design of experiments was employed to efficiently examine the influence of these parameters on the maximum forming depth, principal strain distribution, and thickness variation. The results indicate that vertical step size and annealing condition are the most significant factors affecting sheet formability. A maximum forming depth of 10.5 mm and a minimum sheet thickness of 0.584 mm were achieved with a vertical step size of 0.25 mm, spindle speed of 2000 rpm, and tool movement parallel to the rolling direction. Annealed sheets exhibited higher principal strains in intact regions, confirming the positive influence of heat treatment on material ductility. Furthermore, increasing spindle speed enhanced frictional heating, further improving material formability, while forming direction primarily affected strain distribution and localized thinning.https://ijmf.shirazu.ac.ir/article_8408_ac0fed0fef836e93fb1d8bfb59569b6f.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Feasibility of Deep Crack Repair Using a Novel Friction Stir Chip Welding Process3044841010.22099/ijmf.2025.54371.1351ENAliBazrafshan TanhaDepartment of Mechanical Engineering, University of Birjand, Birjand, IranSeyed Mohammad HosseinSeyedkashiDepartment of Mechanical Engineering, University of Birjand, Birjand, IranMoosaSajedDepartment of Mechanical Engineering, Azarbaijan Shahid Madani University, Tabriz, IranHabibollahRastegariDepartment of Mechanical and Materials Engineering, Birjand University of Technology, Birjand, IranJournal Article20250924A new friction stir chip welding (FSCW) method is presented to use waste machining chips for repairing deep cracks. This technique provides an economical solution for industry by reducing landfill waste and minimizing the energy-intensive demand for primary aluminum production. Aluminum 7075 was used to evaluate the feasibility of this method. The crack was removed by an in-depth hole and filled with machining chips, which were subsequently welded using non-consumable tools. The most effective parameter for achieving a proper joint was the input heat, governed by the tool rotational speed and holding time. The effects of these parameters on weld quality, microstructure and hardness across different welding zones were investigated. The results showed that increasing the tool rotational speed and holding time led to higher heat input. The specimen welded at the highest speed and holding time exhibited the greatest hardness and strength. Specimens with a continuous structure demonstrated higher hardness, and vice versa.https://ijmf.shirazu.ac.ir/article_8410_1cf139fa676a159240537a99e3a6dfcd.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Investigating Hot Deformation Behavior of Ti-6Al-4V Alloy with Fully Lamellar Microstructure Using Work Hardening Rate Characteristic and Processing Map Development4558841410.22099/ijmf.2025.54341.1350ENRezaGostarianiReactor and Nuclear Safety Research School, Nuclear Science and Technology Research Institute, P.O. Box: 14395-836, Tehran, IranGholamrezaVaezReactor and Nuclear Safety Research School, Nuclear Science and Technology Research Institute, P.O. Box: 14395-836, Tehran, IranJournal Article20250921In this study, the hot deformation behavior of fully lamellar Ti-6Al-4V alloy was investigated through work hardening rate analysis and processing map development based on experimental hot compression data. Hot compression tests were performed over a temperature range of 700–1050 <sup>°</sup>C and strain rates from 0.001 to 1 s⁻¹. Work hardening rate curves were plotted against true stress and true strain using a numerical differentiation method. The results indicated that the work hardening rate increased during straining, reached a maximum, and subsequently decreased to zero due to the activation of dynamic softening mechanisms. The onset of dynamic recrystallization was identified by determining the critical stress from the work hardening rate–stress curve. Dynamic strain aging was detected<strong> </strong>as fluctuations in the work hardening rate–strain curve. A processing map at a strain of 0.8 was developed to characterize safe and unstable hot deformation domains. Furthermore, microstructural observations were employed to evaluate variations in power dissipation efficiency during hot deformation.https://ijmf.shirazu.ac.ir/article_8414_fee9f951ae8640f0fbf2ff1694838d71.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Uniaxial Compression Behavior of Ni-Open-Cell Structure Depending on the Electroforming Mass and Thickness5970844310.22099/ijmf.2025.54398.1352ENJavadArtaExpert Engineering, Rahyaft Advanced Sciences & Technologies knowledge-based company, Tehran, IranBehradYaghobzadehMaterial Science and Metallurgical Engineering, Amirkabir University of Technology, Tehran, IranSalarRohani NejadExpert Engineering, Rahyaft Advanced Sciences & Technologies knowledge-based company, Tehran, IranSeyed Mohammad HosseinMirbagheriMaterial Science and Metallurgical Engineering, Amirkabir University of Technology, Tehran, IranJournal Article20250928In this investigation, a series of nickel open-cell structures with cubic geometry were fabricated by electroforming onto stereolithography (SLA) resin 3D-printed templates. The thickness of the electroformed Ni foams was controlled under constant voltage conditions for two days in a warm nickel sulfamate bath. Ni open-cell samples with varying thicknesses and masses were subsequently subjected to uniaxial compression tests, and their deformation behavior was analyzed and modeled using load–displacement curves. The results show that the mass and apparent density of the Ni open-cell samples exhibit a linear relationship with electroforming time at 6 PPI, unlike the Ni thickness. However, the first maximum compressive strength of the samples, measured according to ISO 13314, does not show a linear dependence on thickness. In this work, Ni open-cell foams were successfully fabricated by warm electroforming under controlled temperature and voltage, achieving densities below 0.93 g/cm³, compressive strengths above 7.50 MPa, and energy absorption values exceeding 4.90 J/cm³. These outstanding mechanical properties, particularly the strength-to-density and energy-absorption-to-density ratios at 6 PPI, demonstrate significant potential for advancing the production of nickel open-cell foams.https://ijmf.shirazu.ac.ir/article_8443_ebc43515a5e3008e18c29d352ca14347.pdfShiraz UniversityIranian Journal of Materials Forming2383-004213120260101Design of Experiment (DOE) for Vibration Horns Using Modal Analysis to Improve Resonant Frequency in the Simple Shear Extrusion Process7182844710.22099/ijmf.2025.54294.1349ENMostafaBalaliMechanical Engineering Department, University of Birjand, Birjand, IranJournal Article20250916In most studies conducted to transmit ultrasonic vibrations to the target workpiece, vibration concentrators (horns) are employed, whose design, simulation (modal analysis), and manufacturing is critical. The use of vibration horns in the simple shear extrusion process, aimed at reducing the forming force, has been investigated both through simulation and experimentally. The effects of input parameters of the concentrators, including element type (cylindrical, conical, and exponential) and geometric dimensions, on the output parameter of resonant frequency have been examined. Design of experiments (DOE) based on the response surface methodology (RSM) and the Box-Behnken design was employed to precisely investigate and analyze the effects of each input parameter and their interactions on the resonant frequency. The design of experiments for the concentrators was conducted using Minitab software version 2019, while the process simulation was performed through modal analysis in Abaqus/Explicit software. The results indicated that to optimize the input parameters and achieve the maximum resonant frequency, the optimal element type across all three vibration zones is exponential. Furthermore, the vibration zone diameter and transducer connection zone diameter were found to have minimal impact and were eliminated. A comparison of the resonant frequency of the vibrating horn from modal analysis simulation with experimental vibration test values showed an error of less than 2%, indicating the high accuracy of the process. After obtaining the optimal horn parameters, the combined process of simple shear extrusion with the vibrating horn was simulated. Subsequently, a comparison and validation of the finite element simulation results for the forming force with the experimental values were carried out. The results from the experimental tests and the simulation of the combined simple shear extrusion process with the vibrating horn showed an error margin of 9%, confirming the efficacy of the new process.https://ijmf.shirazu.ac.ir/article_8447_8815b1f62c0df3197544109bd7688ab1.pdf