Submit to Applied Sciences Review for Applied Sciences Propose a Special Issue

Journal Menu

Journal Browser

Metal Additive Manufacturing and Welding

Print Special Issue Flyer
Special Issue Editors
Special Issue Information
Benefits of Publishing in a Special Issue
Published Papers

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (31 January 2024) | Viewed by 24778

Share This Special Issue

Special Issue Editors

Dr. Chaoqun Zhang

E-Mail Website
Guest Editor

Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: metal additive manufacturing; laser powder bed fusion; multi-material additive manufacturing; dissimilar welding
Special Issues, Collections and Topics in MDPI journals

Dr. Alphons Anandaraj Antonysamy

E-Mail Website
Guest Editor

Additive Manufacturing Centre, GKN Aerospace, Bristol BS34 6FB, UK
Interests: additive manufacturing (AM-EBM and laser powder bed, powder and wire fed laser and EBM including binder jet); powder metallurgy (PM); net-shape HIP; liner and rotational friction welding technologies
Special Issues, Collections and Topics in MDPI journals

Dr. Bram Neirinck

E-Mail Website
Guest Editor

Rue d'Abhooz 31, 4040 Herstal, Belgium
Interests: multi-material additive manufacturing; sinter based additive manufacturing

Special Issue Information

Dear Colleagues,

Both additive manufacturing (AM) and welding are vital for the fabrication of metallic components. In recent years, metal additive manufacturing and welding techonoliges have advanced significantly. AM of metallic parts with no geometric limitations has enabled new product design possibilities and opportunities, reduced part weight, improved product performance, increased heat transfer performance, provided a quick response in part production, and enable the use of multiple materials in one part, etc. Consequently, AM technologies have attracted significant industrial and academic interest. Meanwhile, advanced welding technologies are also progressing rapidly, including laser welding, ultrasonic welding, and friction stir welding.

This Special Issue is devoted to publishing original research and high-quality review articles relevant to recent advances in metal additive manufacturing and welding. Potential topics covered by this Special Issue will include, but are not limited to, the following:

Wire arc additive manufacturing;
Laser-based additive manufacturing technologies;
Sinter-based/binder jetting additive manufacturing technologies;
Additive manufacturing of titanium, copper, magnesium and their alloys;
Multi-material additive manufacturing technologies;
High speed additive manufacturing technologies;
Solid-state additive manufacturing;
Additive manufacturing in aerospace;
Laser welding, ultrasonic welding, friction stir welding, and dissimilar material welding.

Dr. Chaoqun Zhang
Dr. Alphons Anandaraj Antonysamy
Dr. Bram Neirinck
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Benefits of Publishing in a Special Issue

Ease of navigation: Grouping papers by topic helps scholars navigate broad scope journals more efficiently.
Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
e-Book format: Special Issues with more than 10 articles can be published as dedicated e-books, ensuring wide and rapid dissemination.

Further information on MDPI's Special Issue polices can be found here.

Published Papers (11 papers)

Download All Papers

Order results

Result details

Show export options Show export options

Select all

Export citation of selected articles as:

Research

20 pages, 14899 KiB

Open AccessArticle

High-Temperature Creep and Microstructure Evolution of Alloy 800H Weldments with Inconel 625 and Haynes 230 Filler Materials

by Wenjing Li, Lin Xiao, Lori Walters, Qingshan Dong, Maurizio Ienzi and Robyn Sloan

Appl. Sci. 2024, 14(4), 1347; https://doi.org/10.3390/app14041347 - 6 Feb 2024

Cited by 1 | Viewed by 1412

Abstract

Alloy 800H stands as one of the few code-qualified materials for fabricating in-core and out-of-core components operating in high-temperature reactors. Welding is a common practice for assembling these components; however, the selection of a suitable filler material is essential for enhancing the high-temperature creep resistance of Alloy 800H weldments in high-temperature applications. In this study, Inconel 625 and Haynes 230 filler materials were used to weld Alloy 800H plates by employing the gas tungsten arc welding technique. The high-temperature tensile and creep rupture properties, microstructural stability, and evolution of the weldments after high-temperature exposure were investigated and compared with those of Alloy 800H. The results show that both weldments exhibit enhanced tensile and creep behavior at 760 °C. The creep rupture times of the weldments with Inconel 625 filler and Haynes 230 filler materials were about two and three time longer, respectively, than those of Alloy 800H base metal when tested at 80 MPa and 760 °C. Carbides (MC and M₂₃C₆) were commonly observed in the microstructures of both the weld and base metals in the two weldments after high-temperature creep tests. However, the Inconel 625 filler weldment displayed detrimental δ and Laves phases in the fusion zone, and these precipitates could be potential sites for initiating cracks following prolonged high-temperature exposure. This study shows that the weldment with Haynes 230 filler material exhibit better phase stability and creep rupture properties than the one with Inconel 625, suggesting its potential for use as a candidate filler material for Alloy 800H for further investigation. This finding also emphasizes the critical consideration of microstructural evolutions and phase stability in evaluating high-temperature materials and their weldments in high-temperature reactor applications. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

14 pages, 3464 KiB

Open AccessArticle

A Finite Element Study of Wire Arc Additive Manufacturing of Aluminum Alloy

by Yousung Han

Appl. Sci. 2024, 14(2), 810; https://doi.org/10.3390/app14020810 - 17 Jan 2024

Cited by 2 | Viewed by 1799

Abstract

Analyses in the present work focus on understanding the influence of the WAAM (wire arc additive manufacturing) deposition pattern and travel speed on residual stress and warpage in aluminum alloy. The thermal profiles are analyzed using thermomechanical FE simulations. Analysis shows that the out–in deposition pattern leads to the highest level of residual stress and warpage. It is also found that an increase in the travel speed decreases the peak temperature and thermal gradient during the AM deposition, which results in a lower level of residual stress generation. A comparison of results for the line-type patterns (raster and alternate) suggests that the deposition interval between each deposition has little influence on thermal profiles, residual stress generation, and warpage. However, the contour-type patterns significantly affect the heat transfer, thermal gradient, and cooling rate during the AM deposition. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

18 pages, 6610 KiB

Open AccessArticle

Applying Statistical Models to Optimize the Weld Bead Geometry in the Vertical Oscillation Arc Narrow Gap All-Position GMAW

by Hongsheng Liu, Ruilei Xue, Jianping Zhou, Yang Bao and Yan Xu

Appl. Sci. 2023, 13(11), 6801; https://doi.org/10.3390/app13116801 - 3 Jun 2023

Cited by 4 | Viewed by 1254

Abstract

Vertical oscillation arc welding for narrow gap gas metal arc welding (NG-GMAW) has a relatively simple structure, and it is widely used in all-position pipeline field welding. However, it has some shortcomings, such as incomplete fusion defects on the sidewall and interlayer. Aiming at resolving these shortcomings, a mathematical model is proposed to obtain appropriate welding parameters in different positions. In this model, the response surface methodology (RSM) based on the central composite design (CCD) was developed to study the interactions between welding parameters and the weld bead geometry. Then the analysis of variance (ANOVA) was used to evaluate the accuracy and significance of the proposed model. Finally, experiments were carried out in flat, vertical, and overhead positions to obtain the optimal parameters. The macroscopic metallography of the transversal section of the weld bead under the optimizing welding parameters showed that the weld beads were free of defects in the sidewall and interlayers. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

13 pages, 3502 KiB

Open AccessArticle

Influence of Several Heat Treatments on Residual Stress in Laser Powder Bed-Fused Maraging 18Ni-300 Steel

by Jae Hyun Yu, Qing-Ye Jin, Kyeongsik Ha and Wookjin Lee

Appl. Sci. 2023, 13(11), 6572; https://doi.org/10.3390/app13116572 - 29 May 2023

Cited by 5 | Viewed by 1522

Abstract

In laser powder bed fusion, process-inherited thermal residual stress is developed due to the thermal strain misfit between each layer. Detailed analysis and a prediction of the residual stress are needed because it can induce distortions of the components and, in some serious cases, stress-induced defects such as cracking. In this work, the effects of heat treatment conditions on residual stress in maraging 18Ni-300 steel, fabricated by laser powder bed fusion, were investigated. Cantilever-shaped specimens were used to experimentally analyze residual stress caused by the distortions of the specimens while cutting them from the supporters. The cantilever samples showed complex distortion behavior in the as-built state. They bent downward while cutting them from the supporter when the thickness was relatively thin, and the bending deformation became upward instead of downward with increasing thickness. Interpreting this behavior by finite element simulation showed that the downward bending was due to the compressive stress state at the top layer of the maraging steel. When the cantilever specimens were aging heat treated, the distortions were significantly reduced, implying that the process-inherited residual stress was diminished. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

20 pages, 98592 KiB

Open AccessArticle

Effect of Heat Treatment on the Microstructure and Mechanical Properties of Rotary Friction Welded Dissimilar IN718 to SS304L Alloys

by Perumandla Pavan, Mahesh Kumar Talari, Nagumothu Kishore Babu, Ateekh Ur Rehman and Prakash Srirangam

Appl. Sci. 2023, 13(6), 3584; https://doi.org/10.3390/app13063584 - 10 Mar 2023

Cited by 3 | Viewed by 2058

Abstract

The present study investigated the effect of heat treatment (pre- and post-weld) on the microstructure and mechanical properties of an SS304L/IN718 dissimilar rotary friction welded alloy. Optical and scanning electron micrographs of the dissimilar rotary friction welded SS304L/IN718 joints in solution-treated (ST), solution-treated and aged (STA), and post-weld heat treatment (PWHT) conditions revealed defect-free welds. Furthermore, various zones were observed across the weld region, namely the fully deformed zone (FDZ), thermomechanical affected zone (TMAZ), heat affected zone (HAZ), and base material (BM). Among the SS304L/IN718 dissimilar friction welds with different heat treatment conditions (prior ST and STA, PWHT), the PWHTed dissimilar welds exhibited excellent mechanical properties, which could be attributed to the formation of the strengthening precipitates γ′ and γ″ during double aging in PWHT. In contrast, the mechanical properties were found to be the poorest in the STA condition, possibly due to the dissolution of the strengthening precipitates γ′ and γ″ during friction welding. It was observed that the SS304L/IN718 dissimilar friction welds in the ST and STA conditions failed in the HAZ of the SS304L side, away from the weld interface, indicating that the weld region was stronger than the weakest base metal (SS304L) in the various joints. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

18 pages, 6970 KiB

Open AccessArticle

Optimization of Bead Morphology for GMAW-Based Wire-Arc Additive Manufacturing of 2.25 Cr-1.0 Mo Steel Using Metal-Cored Wires

by Jay Vora, Nipun Parikh, Rakesh Chaudhari, Vivek K. Patel, Heet Paramar, Danil Yurievich Pimenov and Khaled Giasin

Appl. Sci. 2022, 12(10), 5060; https://doi.org/10.3390/app12105060 - 17 May 2022

Cited by 28 | Viewed by 3467

Abstract

The fabrication of components involves the deposition of multiple beads in multiple layers for wire-arc additive manufacturing (WAAM). WAAM performed using gas metal arc welding (GMAW) allows for the manufacturing of parts through multiple-bead multi-layer deposition, which depends on the process variables. Thus, the selection of process parameters along with their required levels is mandatory to deposit multiple layers for WAAM. To obtain the desired levels of parameters, bead-on-plate trials were taken on the base plate of low alloy steel by following an experimental matrix produced through the Box–Behnken design (BBD) on GMAW-based WAAM. Wire feed speed, travel speed, and voltage were chosen as the input parameters and bead width and bead height were chosen as the output parameters. Furthermore, the robustness and adequacy of the obtained regression equations were analyzed by using analysis of variance (ANOVA). For both responses of BW and BH, values of R² and adj. R² were found to be near unity, which has shown the fitness of the model. Teaching–learning-based optimization (TLBO) technique was then employed for optimization. Within the selected range of process variables, the single-objective optimization result showed a maximum bead height (BH) of 7.81 mm, and a minimum bead width (BW) of 4.73 mm. To tackle the contradicting nature of responses, Pareto fronts were also generated, which provides a unique non-dominated solution. Validation trials were also conducted to reveal the ability and suitability of the TLBO algorithm. The discrepancy between the anticipated and measured values was observed to be negligible, with a deviation of less than 5% for all the validation trials. This demonstrates the success of the established model and TLBO algorithm. The optimum feasible settings for multi-layer metal deposition were determined after further tuning. A multi-layer structure free from any disbonding was successfully manufactured at the optimized variables. The authors suggest that the optimum parametric settings would be beneficial for the deposition of layer-by-layer weld beads for additive manufacturing of components. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

14 pages, 4733 KiB

Open AccessArticle

The Influence of Tuff Particles on the Properties of the Sintered Copper Matrix Composite for Application in Resistance Welding Electrodes

by Michał Łach, Kinga Korniejenko, Ponnambalam Balamurugan, Marimuthu Uthayakumar and Janusz Mikuła

Appl. Sci. 2022, 12(9), 4477; https://doi.org/10.3390/app12094477 - 28 Apr 2022

Cited by 4 | Viewed by 1513

Abstract

This paper presents modern copper-matrix composite materials in which volcanic tuff particles are used as a reinforcing phase. The aim of the research was to determine the optimal shares of volcanic tuff additive based on such criteria as softening temperature, relative density, electrical conductivity, and hardness. The properties of the produced and tested composites allowed us to determine the usefulness of this type of material for resistance welding electrodes. To confirm the assumptions made, preliminary investigations of the durability and behavior of electrodes made of the tested material during the processes of welding non-alloy steel sheets were carried out. As a result of the research, it was discovered that the addition of 5% tuff produces the best results in this type of composite. It was found that for the sample with a 5% share of tuff, a high softening point above 600 °C was obtained, high hardness after densification at the level of 62 HRB, and high relative density of approximately 95% and very good conductivity at the level of approximately 45 MS/m. The conducted tests did not show any electrode wear different from the commonly used alloys for resistance welding. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

15 pages, 7878 KiB

Open AccessArticle

Characterization of Microstructure, Weld Heat Input, and Mechanical Properties of Mg–Al–Zn Alloy GTA Weldments

by Nagumothu Kishore Babu, Mahesh Kumar Talari, Prakash Srirangam, Abdullah Yahia AlFaify and Ateekh Ur Rehman

Appl. Sci. 2022, 12(9), 4417; https://doi.org/10.3390/app12094417 - 27 Apr 2022

Cited by 1 | Viewed by 2331

Abstract

The present study investigated the influence of welding speed on the microstructure, hardness, and tensile properties of the AZ31 Mg alloy gas tungsten arc (GTA) welds that were prepared using alternating current (AC). A microstructural examination of the weld metal and base metal was performed using stereo, optical, and scanning electron microscopy (HR-SEM and EDS) techniques. The microstructure of all fusion zones consists of two parts: a columnar zone, adjacent to the fusion boundary, and equiaxed grains, in the centre of the weld fusion zone. It is shown that the average width of the equiaxed zone present at the centre of the fusion zone increases with increasing welding speed. Metallographic examination shows that the highest welding speed (5 mm/s) results in the smallest average grain size. The welds prepared with high welding speed exhibit an increase in strength, hardness, and ductility compared with other welding speeds, which is attributed to low heat input. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

19 pages, 28872 KiB

Open AccessArticle

Altering the Supply of Shielding Gases to Fabricate Distinct Geometry in GMA Additive Manufacturing

by Bishal Silwal, Niraj Pudasaini, Sougata Roy, Anthony B. Murphy, Andrzej Nycz and Mark W. Noakes

Appl. Sci. 2022, 12(7), 3679; https://doi.org/10.3390/app12073679 - 6 Apr 2022

Cited by 9 | Viewed by 2929

Abstract

Wire arc additive manufacturing (WAAM) is the process by which large, metallic structures are built, layer-by-layer, using a welding arc to melt wire feedstock. In this process, the proper selection of the shielding gas plays a vital role in the achievement of structurally acceptable part geometries and quality surface finishes. In this study, the authors used either a ternary mix (He, Ar and CO₂) or a binary mix (Ar and CO₂) of shielding gases to deposit wall geometries using an open loop-controlled WAAM system developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility. The binary blend produced a wider and shorter geometry, while the ternary blend resulted in a narrower build that was more equivalent to the CAD geometry. The data indicated that the binary blend provided a higher oxygen concentration in the weld as compared to that of the ternary blend. The results imply that the arc characteristics and heat input had a significantly higher impact on the weld penetration than the surface tension effect of surface active elements. This was further verified by developing and applying a high-fidelity computational fluid dynamics (CFD) model of the thermophysical properties of gas mixtures. The results from the model showed that, while the influence of increased oxygen concentration on the surface tension for the binary blend led to a deeper penetration, the ternary blend gave rise to heat flux to the workpiece. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

15 pages, 5608 KiB

Open AccessArticle

by Ateekh Ur Rehman, Nagumothu Kishore Babu, Mahesh Kumar Talari, Saqib Anwar, Yusuf Usmani and Ali M. Al-Samhan

Appl. Sci. 2021, 11(22), 10684; https://doi.org/10.3390/app112210684 - 12 Nov 2021

Cited by 7 | Viewed by 2647

Abstract

Dissimilar metal joining has always been a challenging task because of the metallurgical incompatibility and difference in melting points of alloys being joined. Diffusion and mixing of alloying elements from dissimilar base metals at the weld often cause unwanted metallurgical changes resulting in unsuccessful welds or underperformance of the weldment. Solid-state dissimilar friction welds of Inconel 718 and F22 were prepared in this study with an Inconel 625 interlayer to address the carbon enrichment of Inconel 718 during the welding. Defect-free rotary friction welds were produced in this study. Microstructural and mechanical properties investigation of the weldments and base metals was carried out, and results were analysed. Intermixing zone was observed at the weld interface due to the softening of the metal at the interface and rotatory motion during the welding. The high temperatures and the plastic deformation of the intermixing zone and thermo-mechanically affected zone (TMAZ) resulted in the grain refinement of the weld region. The highest hardness was observed at the Inconel 718/F22 weld interface due to the plastic strain and the carbon diffusion. The tensile specimens failed in the F22 base metal for the weld prepared with and without the Inconel 625 interlayer. Inconel 718/F22 welds exhibited lower toughness values compared to the Inconel 718/F22 welds prepared with Inconel 625 interlayer. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Figure 1

16 pages, 6153 KiB

Open AccessArticle

Characterisation of Microstructure and Mechanical Properties of Linear Friction Welded α+β Titanium Alloy to Nitinol

by Ateekh Ur Rehman, Nagumothu Kishore Babu, Mahesh Kumar Talari, Yusuf Usmani and Hisham Alkhalefah

Appl. Sci. 2021, 11(22), 10680; https://doi.org/10.3390/app112210680 - 12 Nov 2021

Cited by 4 | Viewed by 2298

Abstract

A variable area nozzle integrated into the design of a high-bypass-ratio turbofan engine effectively saves up to 10% in aircraft fuel consumption. Additionally, noise emissions can be lowered at airports during take-off and landing by having better control of the nozzle diameter. Shape memory capabilities of Nitinol alloys could be availed in the form of actuators in the construction of such a nozzle. However, these Nitinol actuators must be joined to Ti-6Al-4V, a prominent alloy making up most of the rest of the nozzle. Because of the huge differences in the physical and metallurgical properties of these alloys, fusion welding is not as effective as solid-state welding. In the current study, a linear friction welding process was adopted to join Ti-6Al-4V to Nitinol successfully. The effect of friction welding on the evolution of weld macro and microstructures; hardness and tensile properties were studied and discussed. The macrostructure of Ti-6Al-4V and Nitinol’s dissimilar joint revealed flash formation mainly on the Ti-6Al-4V side due to its reduced flow strength at high temperatures. Optical microstructures revealed fine grains in Ti-6Al-4V immediately adjacent to the interface due to dynamic recrystallisation and strain hardening effects. In contrast, Nitinol remained mostly unaffected. An intermetallic compound (Ti₂Ni) was seen to have formed at the interface due to the extreme rubbing action, and these adversely influenced the tensile strength and elongation values of the joints. Full article

(This article belongs to the Special Issue Metal Additive Manufacturing and Welding)

► Show Figures

Journal Menu

Journal Browser

Metal Additive Manufacturing and Welding

Share This Special Issue

Special Issue Editors

Special Issue Information

Benefits of Publishing in a Special Issue

Published Papers (11 papers)

Research

Further Information

Guidelines

MDPI Initiatives

Follow MDPI