Green production is a modern sustainable production strategy, and as such takes into account the needs of the economy, society and the environment. The research covered the implementation of an interdisciplinary view of the implementation and monitoring of green production. Emphasis is placed on material removal processes, deformation processes and technologies based on selected electric arc welding processes.

In the part of the research related to material removal processes, the research focuses on further investigating the machinability of metal foams produced from aluminium chips. The research group conducted preliminary drilling studies on closed-cell aluminum foams (A380), focusing on investigating the influence of machining parameters on drilling force, tool wear and dimensional accuracy of the machined surface. In addition, the influence of the homogeneity of the foam and the machining parameters on the cutting forces during turning, milling and drilling processes will be examined, with the focus on the metal foams A380 and EN AW 7075. Future research work will concentrate on investigating the influence of cutting (cooling) techniques on the corrosion resistance of machined metal foams. In addition, vibration damping will be investigated for different cutting processes. The modal properties will be investigated for different tools on the Spinner VC 560 machine and on a universal lathe. A thermo-mechanical numerical model of orthogonal cutting of aluminum alloys will be developed using a coupled Euler-Lagrange formulation. An optimization of the size of the finite element used to discretize the workpiece volume has already been performed. Conclusions and guidelines for future research were drawn from the preliminary studies: the development and application of appropriate hardening laws and tool-workpiece contact conditions will be necessary to develop a numerical model that predicts the output variables with sufficient accuracy compared to the experimental results.

Research related to welding technologies would aim to deepen knowledge about the effect of the various welding processes on engineering metals. The emphasis would be on light, but also modern metals such as aluminum and its alloys, and aluminum recycled using innovative methods without remelting the metal. The comparison of the weldability of recycled aluminum and conventional aluminum alloys will be done, considering that recycled aluminum has a slightly higher percentage of aluminum oxide and porostiy in the microstructure. Likewise, metals characterized by excellent corrosion resistance, such as stainless steel, and titanium and its alloys, then high entropy alloys, materials produced with severe plastic deformation etc., would be investigated. Planned research would deepen knowledge about the dynamics of the formation of the melting zone during arc welding by combining the experimental method with the scientific method of modelling. Research would include electric arc welding processes (primarily TIG but also MIG/MAG), electric resistance welding, and related procedures such as thermal spray. One of the main goals of future research would be to determine the influence of selected welding parameters on the shape and dimensions of the melting zone, mechanical and physical properties, metallographic and surface characteristics of welded joints. In part, these goals would be achieved using mathematical modelling and optimization techniques. The possibility of robotic welding and the application of modern additive manufacturing technologies that use welding processes and show great potential for industrial application would be investigated. Despite the great progress in the field of welding technology, there is still a need for a better understanding of arc welding processes and their interaction with the base metal. The complexity of electric arc processes results from a large number of process parameters, i.e. their influence on complex physical events in the electric arc and the base metal. New findings in this field can have a positive impact on the energy and environmental impact of welding technologies since they have the potential to increase the productivity of the observed welding processes.

The main idea of the research related to deformation processing is to design an innovative process of direct recycling without melting using the principles of severe plastic deformation and hot or cold compression and extrusion processes. Given the ecological and economic justification of the process, the mechanical and physical properties of semi-finished products obtained by the new recycling process would be investigated in detail. With the technology of severe plastic deformation and manufactured tools, materials with a fine-grained structure would be made in order to improve the mechanical properties and for application in various technological processes. In order to describe innovative processes, mathematical models would be developed. Research will be carried out on the preparation of materials by severe plastic deformation techniques for the semi-solid casting process (Thixocasting) and the production of metal foams directly from waste material.