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Laser Surface Engineering and Additive Manufacturing
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Laser Surface Engineering and Additive Manufacturing

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Laser Coatings".

Deadline for manuscript submissions: 20 March 2025 | Viewed by 8919

Special Issue Editor

Dr. Chi Wai Chan

E-Mail Website
Guest Editor
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, University Road, Belfast BT7 1NN, Northern Ireland, UK
Interests: laser surface engineering; laser additive manufacturing; laser welding/joining for high-value manufacturing applications
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Laser surface engineering (LSE) and laser additive manufacturing (LAM) are transforming the landscape of modern manufacturing. LSE focuses on enhancing and tailoring the surface properties of diverse materials, ranging from metals to polymers and ceramics. Recent advances in ultrafast laser technology have enhanced LSE’s ability to precisely alter surface attributes without introducing undue surface defects. Simultaneously, LAM has emerged as a transformative method in manufacturing, allowing for the layer-by-layer fabrication of bespoke objects from digital 3D models. What sets LAM apart is its adaptability, emphasis on customisation, and ability to work with a variety of materials. This versatility makes it especially effective for producing high-quality, specific components. In sectors such as aerospace, automotive, and healthcare, both LSE and LAM prove invaluable, meeting the intersecting demands for tailor-made solutions and durability.

In this Special Issue, our goal is to spotlight the latest advances, address challenges, and present innovative solutions within the LSE and LAM domains. We invite researchers to submit articles that delve into the intricate facets of these technologies, highlighting their current achievements and anticipated future developments.

Highlighted areas of interest for this Special Issue include the following:

Laser Surface Engineering (LSE):

  • Exploration and development of advanced coatings and materials using LSE;
  • Biomedical applications of LSE, particularly in improving antibacterial properties and biocompatibility of surfaces;
  • Techniques using LSE to combat common material challenges like corrosion, oxidation, and wear;
  • Strategies for restoring and repairing high-value engineered components using LSE.

Laser Additive Manufacturing (LAM):

  • Deep dives into the diverse materials suitable for LAM, such as metals, polymers, and ceramics;
  • Optimising the LAM process for enhanced precision, efficiency, and end-product quality;
  • Integrating traditional manufacturing techniques with the capabilities of LAM;
  • Eco-friendly and efficient approaches in LAM to minimise waste and maximise output.

If you are at the forefront of research in LSE, LAM, or any intersecting domains, this is an ideal platform for your insights. Through this Special Issue, we aim to showcase the important roles of LSE and LAM in shaping the trajectory of advanced manufacturing.

Dr. Chi Wai Chan
Guest Editor

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. Coatings is an international peer-reviewed open access monthly 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 2600 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.

Keywords

  • laser surface engineering
  • laser additive manufacturing
  • ultrafast laser technology
  • advanced coatings and materials
  • eco-efficiency in manufacturing

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

Published Papers (8 papers)

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Research

19 pages, 18115 KiB  
Article
Research on Laser Cladding Inconel 625 Coating Process for TRT Blades
by Jian-Tao Yao, Guo-Dong Zhang, Ze-Lin Chen, Yu-Hu Qu, Li-Shuang Wang and Hui Dong
Coatings 2025, 15(2), 171; https://doi.org/10.3390/coatings15020171 - 3 Feb 2025
Viewed by 140
Abstract
In this study, Inconel 625 coatings were deposited onto the surface of 2Cr13 stainless steel via laser cladding technology to ensure their corrosion resistance and mechanical properties. The microstructure and characteristics of coatings were adjusted by varying laser power (1200, 1500, and 1800 [...] Read more.
In this study, Inconel 625 coatings were deposited onto the surface of 2Cr13 stainless steel via laser cladding technology to ensure their corrosion resistance and mechanical properties. The microstructure and characteristics of coatings were adjusted by varying laser power (1200, 1500, and 1800 W), scanning speed (10, 15, and 25 mm/s), and overlap rate (40%, 50%, and 70%). The results showed that the impact resistance of blades was improved by 23% to 30% compared to the substrate, whereas the self-corrosion current density was reduced by 94%–98%, which indicated the outstanding resistance of specimens to damage and corrosion. At the same time, the appropriate processing parameters enabled the surface hardness of the 2Cr13 substrate to be improved. This study provides practical technical guidance for the repair of 2Cr13 blades and a comprehensive enhancement of their corrosion resistance and mechanical properties through parameter optimization. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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10 pages, 25688 KiB  
Article
An Investigation of Carbon-Fiber-Reinforced Plastic Ablation by Femtosecond Laser Pulses for Further Material Cutting
by Paulius Šlevas, Justinas Minkevičius, Orestas Ulčinas, Sergej Orlov, Egidijus Vanagas, Anna Bilousova, Denys Baklan and Oleksiy Myronyuk
Coatings 2025, 15(1), 104; https://doi.org/10.3390/coatings15010104 - 18 Jan 2025
Viewed by 595
Abstract
Carbon-fiber-reinforced plastic (CFRP) is a popular material possessing great properties, such as strength, lightness, and resistance to corrosion and the environment. Important steps in the production of various parts made of CFRP are surface structuring, milling, drilling and cutting processes. Here, we propose [...] Read more.
Carbon-fiber-reinforced plastic (CFRP) is a popular material possessing great properties, such as strength, lightness, and resistance to corrosion and the environment. Important steps in the production of various parts made of CFRP are surface structuring, milling, drilling and cutting processes. Here, we propose to use ultrashort pulse lasers to achieve the high-quality, low-heat-affected-zone ablation of CFRP. We investigated the ablation efficiency dependence on the processing parameters, such as the pulse duration, pulse energy and pulse overlap. We showed that good-quality results could be achieved using just low-/mid-average-power femtosecond laser equipment. We also discuss further cutting process optimization possibilities using ultrashort pulse lasers and show the possibility of HAZ-free CFRP cutting by femtosecond laser ablation. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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19 pages, 14262 KiB  
Article
Study on the Microstructure and Properties of Al Alloy/Steel CMT Welding–Brazing Joints Under Different Pulse Magnetic Field Intensities
by Juan Pu, Tingmu Chen, Jiawei Rao, Yubo Sun, Yunxia Chen, Changhua Jiang and Huawei Sun
Coatings 2024, 14(12), 1515; https://doi.org/10.3390/coatings14121515 - 30 Nov 2024
Viewed by 702
Abstract
Butt welding experiments on 6061 Al alloy and Q235B steel of 2 mm thickness were conducted using an ER4047F flux-cored wire as the filler metal, after adding a pulsed magnetic field into the process of cold metal transfer (CMT) welding. The effect of [...] Read more.
Butt welding experiments on 6061 Al alloy and Q235B steel of 2 mm thickness were conducted using an ER4047F flux-cored wire as the filler metal, after adding a pulsed magnetic field into the process of cold metal transfer (CMT) welding. The effect of the pulsed magnetic field intensity on the macro morphology, microstructure, tensile strength and corrosion resistance of the welding–brazing joint was analyzed. The results showed that when the pulsed magnetic field intensity increased from 0 to 60 mT, the wettability and spreadability of the liquid metal were improved. As a result, the appearance of the Al alloy/steel joint was nice. However, when the pulsed magnetic field intensity was 80 mT, the stability of the arc and the forming quality of the joint decreased, which resulted in a deterioration in the appearance of the joint. A pulsed magnetic field with different intensities did not alter the microstructure of the joint. All of the joint was composed of θ-Fe2(Al,Si)5 and τ5-Al7.2Fe1.8Si at the interface and Al-Si eutectic phase and α-Al solid solution at the weld seam zone. Actually, with the pulsed magnetic field intensity increasing from 0 mT to 60 mT, the IMC thickness in the interfacial layer gradually reduced under the action of electromagnetic stirring. Also, the grain in the weld seam was refined, and elements were distributed uniformly. But when the pulsed magnetic field intensity was 80 mT, the grain in the weld seam began to coarsen, and the intermetallic compound (IMC) thickness was too small, which was unfavorable for the metallurgical bonding of Al alloy and steel. Therefore, with the increase in pulsed magnetic field intensity, the tensile strength of the joints first increased and then decreased, and it reached its maximum of 187.7 MPa with a pulsed magnetic field intensity of 60 mT. Similarly, the corrosion resistance of the joint first increased and then decreased, and it was best when the pulse magnetic field intensity was 60 mT. The Nyquist plot and Bode plot confirmed this result. The addition of a pulsed magnetic field caused less fluctuation in the anode current density, resulting in less localized corrosion of the joint using the scanning vibrating electrode technique (SVET). The XPS analysis showed the Al-Fe-Si compounds replacing the Fe-Al compounds in the joint was the main reason for improving its corrosion resistance under the action of a pulsed magnetic field. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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33 pages, 9739 KiB  
Article
Numerical Modelling and Experimental Validation of Selective Laser Melting Processes Using a Custom Argon Chamber Setup for 316L Stainless Steel and Ti6AI4V
by Gasser Abdelal, Daniel Higgins, Chi-Wai Chan and Brian G. Falzon
Coatings 2024, 14(11), 1406; https://doi.org/10.3390/coatings14111406 - 5 Nov 2024
Cited by 1 | Viewed by 1063
Abstract
Selective Laser Melting (SLM) is an advanced additive manufacturing technique that demands meticulous control over thermal dynamics to maintain the integrity and performance of manufactured parts. This study presents the development and validation of a thermal model designed to enhance the SLM process [...] Read more.
Selective Laser Melting (SLM) is an advanced additive manufacturing technique that demands meticulous control over thermal dynamics to maintain the integrity and performance of manufactured parts. This study presents the development and validation of a thermal model designed to enhance the SLM process for 316L stainless steel (316L SS) and titanium alloy Ti6Al4V. A specially constructed Argon Chamber Setup, equipped with a 200 W continuous-wave (CW) fibre laser system, was used to create an SLM-representative environment for 316L SS, enabling precise experimental validation of the model. This validation serves as a robust baseline, facilitating the model’s extension to more complex materials like Ti6Al4V, thereby supporting a cost-efficient and safe approach to initial testing. The rigorously validated thermal model offers a comprehensive link between experimental data and numerical simulations in SLM. It supports process optimisation by accurately predicting thermal behaviours, contributing significantly to additive manufacturing advancements. By fine-tuning processing parameters, this model enhances material characteristics, thereby providing practical insights applicable to industrial production and improving the consistency and quality of SLM-manufactured parts. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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11 pages, 2856 KiB  
Article
Influence of Heat Treatment on Microstructure and Mechanical Properties of Laser Cladding Coatings
by Chen Yang, Wenjing Chen, Bo Tan, Qingsong Luo, Tao Cao and Zhenlin Zhang
Coatings 2024, 14(10), 1251; https://doi.org/10.3390/coatings14101251 - 1 Oct 2024
Viewed by 1369
Abstract
This study investigates the influence of various heat treatment processes on the microstructure and properties of laser cladding Fe314 coatings. The microstructure, phases, and impact fracture morphology of the cladding layer were observed using X-ray diffraction and scanning electron microscopy, among other methods. [...] Read more.
This study investigates the influence of various heat treatment processes on the microstructure and properties of laser cladding Fe314 coatings. The microstructure, phases, and impact fracture morphology of the cladding layer were observed using X-ray diffraction and scanning electron microscopy, among other methods. The hardness and impact performance of the cladding layer were also tested. The results indicated that there was compositional segregation and non-equilibrium microstructure in the untreated cladding layer, with an average microhardness of 368.67 HV and an impact toughness of 27 J, exhibiting quasi-cleavage fracture. The stress-relief annealing treatment resulted in a uniform distribution of M23C6 carbides inside the cladding layer. The pinning effect generated by M23C6 reduced the microhardness by 16.26% and increased the impact toughness to 54 J. The impact fracture surface exhibited ductile fracture. After secondary normalizing and annealing, the microstructure of the cladding layer transformed into a fine single-phase austenite structure, and fine M7C3 carbides precipitated at the grain boundaries. Under the effects of fine grain strengthening and dispersion strengthening, the microhardness of the cladding layer decreased by 38.14%, and the average impact absorbed energy of the specimen was 64 J, showing complete ductile fracture. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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17 pages, 20152 KiB  
Article
Extreme High-Speed DED of AISI M2 Steel for Coating Application and Additive Manufacturing
by Min-Uh Ko, Julius Cüppers, Thomas Schopphoven and Constantin Häfner
Coatings 2024, 14(8), 953; https://doi.org/10.3390/coatings14080953 - 31 Jul 2024
Cited by 1 | Viewed by 1179
Abstract
This work focuses on the development of the 3D Extreme High-Speed DED process (EHLA3D), a variant of the laser-based Directed Energy Deposition (DED-LB), for the processing of the material HSS M2. Characteristics for the EHLA3D process are feed rates of >20 m/min, high [...] Read more.
This work focuses on the development of the 3D Extreme High-Speed DED process (EHLA3D), a variant of the laser-based Directed Energy Deposition (DED-LB), for the processing of the material HSS M2. Characteristics for the EHLA3D process are feed rates of >20 m/min, high cooling rates, and layer thicknesses in the range of 100 µm. This work covers the three subsequent stages: (1) a process parameter study on single-track deposition, (2) development of coating parameters, and (3) development of parameters for AM. In scope of stage 2, a coating parameter with a powder mass flow of ṁ = 1.9 kg/h was achieved. A variation in the deposition angles indicates that the coating process is feasible within a tilted deviation of up to 20°. In stage 3, a process parameter with a deposition rate of ṁ = 0.4 kg/h was developed. The hardness results of the as-built specimen with 67 HRC exceeds the hardness of conventionally manufactured and heat-treated M2 steel. The results of this work indicate that the EHLA3D process can be potentially utilized for the additive manufacturing with the material M2 as well as for the productive deposition of anti-wear coatings on free-form surfaces. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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13 pages, 8147 KiB  
Article
Enhancing Hardness and Wear Resistance of MgAl2O4/Fe-Based Laser Cladding Coatings by the Addition of CeO2
by Liangxun Li, Shaobai Sang, Tianbin Zhu, Yawei Li and Heng Wang
Coatings 2024, 14(5), 550; https://doi.org/10.3390/coatings14050550 - 28 Apr 2024
Cited by 1 | Viewed by 1388
Abstract
Laser cladding has unique advantages in improving the wear resistance of materials or workpiece surfaces. CeO2 could play a role in promoting the flow of the molten pool and grain refinement during the laser cladding process, which is likely to further improve [...] Read more.
Laser cladding has unique advantages in improving the wear resistance of materials or workpiece surfaces. CeO2 could play a role in promoting the flow of the molten pool and grain refinement during the laser cladding process, which is likely to further improve the wear resistance of the coating. In this work, CeO2 was introduced into the MgAl2O4/Fe-based laser cladding coating on the surface of GCr15 steel. The effects of the CeO2 content on the phase composition, microstructure, hardness, and wear resistance of the coatings were also systematically investigated. The results showed that the addition of CeO2 enhanced the continuity of the coating and reduced the size of the MgAl2O4 particles, which was associated with the addition of CeO2’s intensification of the melt pool flow. The metal grain size reduced and then increased as the CeO2 content increased, whereas the hardness and wear resistance of the MgAl2O4/Fe-based coatings increased and then decreased. Compared with the MgAl2O4/Fe-based coating without CeO2, the hardness of the MgAl2O4/Fe-based coating with 1.0 wt% CeO2 increased by 10% and the wear rate decreased by 40%, which was attributed to the metal grain refinement and particle dispersion strengthening. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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22 pages, 6463 KiB  
Article
Effect of Zinc Content on Powder Characteristics, Porosity, Microstructure, and Corrosion Behavior of SLM-Printed Mg-xZn-0.2Mn Alloys for Biomedical Applications
by Weijie Xie, Chen-Liang Wu, Hau-Chung Man and Chi-Wai Chan
Coatings 2023, 13(11), 1876; https://doi.org/10.3390/coatings13111876 - 31 Oct 2023
Viewed by 1774
Abstract
This study investigated the effects of Zinc (Zn) content, specifically in the range of 1 wt.% to 7 wt.%, on the powder characteristics, porosity, microstructure, and corrosion behavior of Mg-xZn-0.2Mn alloys produced using selective laser melting (SLM). To evaluate the porosity of the [...] Read more.
This study investigated the effects of Zinc (Zn) content, specifically in the range of 1 wt.% to 7 wt.%, on the powder characteristics, porosity, microstructure, and corrosion behavior of Mg-xZn-0.2Mn alloys produced using selective laser melting (SLM). To evaluate the porosity of the printed parts and various powder attributes, such as size, circularity, void spaces between powders, and inherent imperfections, scanning electron microscopy (SEM) and optical microscopy (OM) were employed. The alloy microstructure, composition, and phase were examined using energy dispersive X-ray (SEM-EDX) and X-ray Diffraction (XRD). The corrosion resistance and degradation behavior were assessed through electrochemical corrosion tests and immersion tests in Hanks’ solution at 37.5 °C, respectively. Finally, OM and SEM-EDX were used to characterize the corrosion products. The findings of this study indicated that the powder size increased with Zn content, maintaining a 0.8 circularity. Powder defects were minimal, with occasional satellite particles. For the SLM-printed samples, it was evident that porosity characteristics could be influenced by Zn content. As Zn content increased, the pore fraction rose from 1.0% to 5.3%, and the pore size grew from 2.2 μm to 3.0 μm. All printed samples consisted of an α-Mg matrix. Additionally, a higher Zn content resulted in more distinct grain boundaries. Corrosion resistance decreased with Zn, leading to more pronounced localized corrosion after immersion in Hanks’ solution. Ca-P was found as white corrosion products on all samples. Full article
(This article belongs to the Special Issue Laser Surface Engineering and Additive Manufacturing)
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