Additive and Subtractive Manufacturing of Metallic Materials: Process-Structure-Property-Performance Relationships

A special issue of Crystals (ISSN 2073-4352). This special issue belongs to the section "Crystalline Metals and Alloys".

Deadline for manuscript submissions: closed (20 November 2024) | Viewed by 1561

Special Issue Editors


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Guest Editor
Intelligent Systems Center, Missouri University of Science and Technology, Rolla, MO 65401, USA
Interests: additive manufacturing; laser-material interaction; tribology; process automation, modelling
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Guest Editor
Intelligent Systems Center, Missouri University of Science and Technology, Rolla, MO 65401, USA
Interests: cyberphysical systems; distributed digital factories; cyber security

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Guest Editor
Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USA
Interests: metal additive manufacturing (AM); novel AM process development and process planning; rapid prototyping; multiscale multiphysics AM process modeling; remanufacturing automation; AM process monitoring and control; digital materials processing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The integration of additive manufacturing (AM) and subtractive manufacturing (SM) processes with in situ monitoring and feedback is a cutting-edge approach in the field of advanced manufacturing. This concept seeks to combine the strengths of both AM and SM, while incorporating near–real-time monitoring and feedback to enhance the overall manufacturing process. AM involves creating 3D objects by adding a material layer by layer, offering design freedom and complexity that traditional subtractive methods cannot achieve. However, it may suffer from issues, such as a poor surface finish and dimensional accuracy. On the other hand, SM removes the material to shape an object and excels in achieving precise dimensions and a high surface quality, but can be limited in terms of its complex geometries and material wastage. The integration of these two processes aims to overcome these limitations by leveraging the strengths of each technique. Additionally, in situ monitoring and feedback systems using digital twins are incorporated into the manufacturing process to ensure high-quality control, detect defects, and make necessary adjustments during manufacturing. The key benefits of this integration include an improved part quality, reduced material waste, shorter lead times, and enhanced design flexibility, thereby also supporting industry 4.0 and digital factories.

The primary purpose of this Special Issue is to deliver an intercontinental forum for ground-breaking research on experiments and modelling using additive and subtractive manufacturing processes, in situ monitoring and feedback via manufacturing processes, the development of new materials and their parameters optimization, and the development of sophisticated data-driven models and their implementation in manufacturing processes. 

Dr. Muhammad Arif Mahmood
Dr. Asad Waqar Malik
Prof. Dr. Frank Liou
Guest Editors

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Keywords

  • additive manufacturing
  • subtractive manufacturing
  • in situ monitoring and feedback
  • physics-based and data-driven modelling

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Published Papers (2 papers)

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Research

9 pages, 5837 KiB  
Article
Fabrication of Cu-Infiltrated Journal Bearing by Binder Jetting Additive Manufacturing
by Jin Man Jang
Crystals 2024, 14(11), 912; https://doi.org/10.3390/cryst14110912 - 22 Oct 2024
Viewed by 483
Abstract
In this study, considering the economic feasibility of products that can be produced through the binder jetting additive manufacturing process, 316L stainless steel, a widely used material with a wide particle size ranging from 15 to 106 μm, was used. The lubrication effect [...] Read more.
In this study, considering the economic feasibility of products that can be produced through the binder jetting additive manufacturing process, 316L stainless steel, a widely used material with a wide particle size ranging from 15 to 106 μm, was used. The lubrication effect was increased by internal patterning through design for additive manufacturing, and journal bearing parts with excellent load resistance and wear resistance were implemented by using wear-resistant Cu as an infiltration material. In addition, to investigate the amount of Cu infiltrated as a function of porosity, the parts were pre-sintered from 1423 K to 1573 K, and the best performance was obtained when Cu was infiltrated after pre-sintering at 1473 K. As a result of rig testing of Cu-infiltrated journal bearings, mechanical properties were obtained that were more than 50% improved compared to those of mass products. Full article
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20 pages, 35119 KiB  
Article
Effect of Rotational Shear and Heat Input on the Microstructure and Mechanical Properties of Large-Diameter 6061 Aluminium Alloy Additive Friction Stir Deposition
by Xiaohu Zhu, Rui Wang, Lin Wang, Mengmeng Liu and Songmo Li
Crystals 2024, 14(7), 581; https://doi.org/10.3390/cryst14070581 - 25 Jun 2024
Viewed by 648
Abstract
Additive friction stir deposition (AFSD), in which molten metal materials are formed into free-form stacked structural parts according to the path design, may have a wide range of applications in high-efficiency mass production. In this study, experiments were conducted for the rotational speed [...] Read more.
Additive friction stir deposition (AFSD), in which molten metal materials are formed into free-form stacked structural parts according to the path design, may have a wide range of applications in high-efficiency mass production. In this study, experiments were conducted for the rotational speed in the AFSD parameters of 6061 aluminium alloy bars to investigate the effects of different rotational shear conditions and heat inputs on the properties of the deposited layer for diameter bars based on the analysis of the micro-morphology, micro-tissue composition, and mechanical properties. The width and thickness of each layer were constant, approximately 40 mm wide and 2.5 mm thick. The particle undulations on the surface of the deposited layer were positively correlated with the AFSD rotational speed. Continuous dynamic recrystallisation in the AFSD process can achieve more than 90% grain refinement. When the rotational speed increases, it causes localised significant orientation and secondary deformation within the recrystallised grains. The ultimate tensile strength of the deposited layer was positively correlated with the rotational speed, reaching a maximum of 211 MPa, and the elongation was negatively correlated with the rotational speed, with a maximum material elongation of 37%. The cross-section hardness of the deposited layer was negatively correlated with the number of thermal cycles, with the lowest hardness being about 45% of the base material and the highest hardness being about 80% of the base material. Full article
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