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Crystals
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Additive Manufacturing of Metallic Alloys
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Additive Manufacturing of Metallic Alloys

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

Deadline for manuscript submissions: closed (31 October 2023) | Viewed by 9242

Special Issue Editors

Dr. Jinoop Arackal Narayanan

E-Mail Website
Guest Editor
Mechanical Engineering, School of Computing, Engineering & Digital Technologies, Teesside University, Middlesbrough TS1 3BX, UK
Interests: sustainable additive manufacturing; laser additive manufacturing; metal additive manufacturing; material characterization
Special Issues, Collections and Topics in MDPI journals
Dr. V. Anil Kumar

E-Mail Website
Guest Editor
Scientist SG, Materials & Mechanical Entity, Vikram Sarabhai Space Centre, Trivandrum 400076, India
Interests: materials processing; titanium alloys; superalloys; metal additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Christ Prakash Paul

E-Mail Website
Guest Editor
Head Laser Additive Manufacturing Lab, Raja Ramanna Centre for Advanced Technology, Indore, India
Interests: laser rapid manufacturing (LRM); laser additive manufacturing (LAM); LAM of bio-implants; laser clad
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive Manufacturing is a technique for manufacturing complex-shaped components and components with intricate features in a layer-by-layer fashion directly from a digital file. AM evolved to build metallic components by transforming itself from a process for “design validation and prototyping” to a process for building “near-net shaped components”. The segment of additive manufacturing processes used for building metallic components is called metal additive manufacturing. Metal additive manufacturing provides freedom of shape design, material design, post-processing, and logistics, which attracts its deployment in several sectors, including aerospace, oil and gas, power, medical, and automotive, to build high-performance components. However, metal additive manufacturing suffers from various limitations, such as a lack of dimensional accuracy, defect formation, non-homogenous microstructure, anisotropic mechanical properties, etc. Thus, significant research is underway to make the metal additive manufacturing process more robust, reliable, and sought after for industrial applications in high technology sectors.

This special issue is devoted to publishing original research (full-length and short communication) and high-quality review articles relevant to recent advances in metal additive manufacturing. Potential topics for this Special Issue will include, but are not limited to, the following:

  • Process optimization for metal additive manufacturing of different alloy systems;
  • Metallurgical characterization of metal additive manufactured components;
  • Process–structure–property relationships in metal additive manufacturing;
  • Application of artificial intelligence and machine learning in metal additive manufacturing for process improvements, quality control, and inspection;
  • In situ monitoring and closed-loop control of the metal additive manufacturing process;
  • Emerging metal additive manufacturing technologies;
  • Development of functionally graded and multi-material components using metal additive manufacturing;
  • Tribological and corrosion behaviors of additively manufactured metallic parts;
  • In-direct metal additive manufacturing processes such as fused deposition modeling, binder jetting, etc.;
  • Post-processing of metal additive manufactured components;
  • Metal additive manufacturing for nuclear, aerospace, and automotive applications;
  • Metal additive manufacturing in microgravity.

We look forward to receiving your contributions.

Dr. Arackal Narayanan Jinoop
Dr. V. Anil Kumar
Dr. Christ Prakash Paul
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. Crystals 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 2100 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

  • metal additive manufacturing
  • powder bed fusion
  • directed energy deposition
  • microstructure
  • mechanical properties
  • characterization
  • functionally graded materials
  • multi-material components
  • post-processing
  • in situ monitoring
  • artificial intelligence
  • machine learning
  • process control
  • process optimization

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Published Papers (5 papers)

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Research

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16 pages, 9074 KiB  
Article
Preliminary Parametric Investigations into Macro-Laser Polishing of Laser-Directed Energy Deposition of SS 304L Bulk Structures
by Vijay Kumar Saini, Jinoop Arackal Narayanan, Niraj Sinha and Christ Prakash Paul
Crystals 2023, 13(11), 1604; https://doi.org/10.3390/cryst13111604 - 20 Nov 2023
Viewed by 1202
Abstract
The higher surface roughness of laser-directed energy deposition (LDED)-built components necessitates advanced and sustainable surface quality enhancement techniques like laser polishing. In the present work, a parametric study involving experimental investigation and numerical analysis is conducted to determine the effect of macro-laser polishing [...] Read more.
The higher surface roughness of laser-directed energy deposition (LDED)-built components necessitates advanced and sustainable surface quality enhancement techniques like laser polishing. In the present work, a parametric study involving experimental investigation and numerical analysis is conducted to determine the effect of macro-laser polishing on LDED-built SS 304L structures. A thermophysical model is developed to simulate the effect of laser power and scan speed on the melt pool depth of the LDED-built samples. The simulated melt pool depth is compared with experimental results and is found to be in good agreement. Further, the correlation between the melt pool depth and surface behaviour is studied based on shallow surface melting and shallow over-melting mechanisms. A maximum reduction in surface roughness from 21.3 µm to 9 µm (~57%) is achieved with laser polishing, and process parameters’ effect on the surface roughness is investigated. Scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS) mapping, and X-ray diffraction (XRD) are used to further characterize the laser-polished surface. SEM-EDS analysis shows that the segregation is more evident in laser-polished samples, while the XRD results indicate the absence of phase change during the process. This study paves the way to a greater understanding of the effect of macro-laser polishing on LDED-built SS 304L structures. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Alloys)
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12 pages, 2640 KiB  
Article
Optimization of Additively Manufactured and Lattice-Structured Hip Implants Using the Linear Regression Algorithm from the Scikit-Learn Library
by Rashwan Alkentar and Tamás Mankovits
Crystals 2023, 13(10), 1513; https://doi.org/10.3390/cryst13101513 - 19 Oct 2023
Cited by 1 | Viewed by 1783
Abstract
As the name implies, patient-specific latticed hip implants vary in design depending on the properties required by the patient to serve as a valid suitable organ. Unit cells are typically built based on a 3D design of beams, and the properties of unit [...] Read more.
As the name implies, patient-specific latticed hip implants vary in design depending on the properties required by the patient to serve as a valid suitable organ. Unit cells are typically built based on a 3D design of beams, and the properties of unit cells change depending on their geometries, which, in turn, are defined by two main parameters: beam length and beam thickness. Due to the continuous increase in the complexity of the unit cells’ designs and their reactions against different loads, the call for machine learning techniques is inevitable to help explore the parameters of the unit cells that can build lattice structures with specific desirable properties. In this study, a machine learning technique is used to predict the best defining parameters (length and thickness) to create a latticed design with a set of required properties (mainly porosity). The data (porosity, mass, and latticed area) from the properties of three unit-cell types, applied to the latticed part of a hip implant design, were collected based on the random length and thickness for three unit-cell types. Using the linear regression algorithm (a supervised machine learning method) from the scikit-learn library, a machine learning model was developed to predict the value of the porosity for the lattice structures based on the length and thickness as input data. The number of samples needed to generate an accurate result for each type of unit cell is also discussed. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Alloys)
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13 pages, 4388 KiB  
Article
Robust γ-TiAl Dual Microstructure Concept by Advanced Electron Beam Powder Bed Fusion Technology
by Marcel Reith, Martin Franke and Carolin Körner
Crystals 2023, 13(9), 1348; https://doi.org/10.3390/cryst13091348 - 5 Sep 2023
Viewed by 1543
Abstract
The dual microstructure concept for gamma titanium aluminides (γ-TiAl) processed via electron beam–powder bed fusion (PBF-EB) provides a huge potential for more efficient jet turbine engines. While the concept is feasible and the mechanical properties are promising, there are still some challenges. For [...] Read more.
The dual microstructure concept for gamma titanium aluminides (γ-TiAl) processed via electron beam–powder bed fusion (PBF-EB) provides a huge potential for more efficient jet turbine engines. While the concept is feasible and the mechanical properties are promising, there are still some challenges. For an industrial application, the heat treatment window has to match the conditions in industrial furnaces. This study shows how the required heat treatment window can be achieved via advanced PBF-EB technology. Through using an electron beam with 150 kV acceleration voltage, the difference in aluminum between the designed aluminum-rich and aluminum-lean regions of the part is increased. Moreover, the aluminum content within each of these regions, respectively, is more homogenous compared to the 60 kV acceleration voltage. This combination provides a heat treatment window of 25 °C, enabling the industrial application of the dual microstructure concept for γ-TiAl. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Alloys)
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16 pages, 8016 KiB  
Article
Hybrid Printing of Silver-Based Inks for Application in Flexible Printed Sensors
by Jakub Krzemiński, Dominik Baraniecki, Jan Dominiczak, Izabela Wojciechowska, Tomasz Raczyński, Daniel Janczak and Małgorzata Jakubowska
Crystals 2023, 13(5), 720; https://doi.org/10.3390/cryst13050720 - 24 Apr 2023
Viewed by 1634
Abstract
This study explores the potential benefits of combining different printing techniques to improve the production of flexible printed sensors, which is a relevant application for modern coating and surface design. The demand for cheap, flexible, precise, and scalable sensors for wearable electronics is [...] Read more.
This study explores the potential benefits of combining different printing techniques to improve the production of flexible printed sensors, which is a relevant application for modern coating and surface design. The demand for cheap, flexible, precise, and scalable sensors for wearable electronics is increasing, and printed electronics techniques have shown great potential in meeting these requirements. To achieve higher performance and synergy, the paper introduces the concept of hybrid printing of electronics by combining aerosol jet printing and screen printing. This multi-process approach allows for large-scale production with high printing precision. The study prepares hybrid connections on a flexible substrate foil for use in flexible printed sensor manufacturing. The research team tests different combinations of printed layers and annealing processes and finds that all prepared samples exhibit high durability during mechanical fatigue tests. Surface morphology, SEM images, and cross-section profiles demonstrate the high quality of printed layers. The lowest resistance among the tested hybrid connections obtained was 1.47 Ω. The study’s findings show that the hybrid printing approach offers a novel and promising solution for the future production of flexible sensors. Overall, this research represents an interdisciplinary approach to modern coating and surface design that addresses the need for improved production of wearable electronics. By combining different printing techniques, the study demonstrates the potential for achieving high-volume production, miniaturization, and high precision, which are essential for the ever-growing market of wearable sensors. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Alloys)
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Review

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20 pages, 4545 KiB  
Review
Progress on the Effect and Mechanism of Ultrasonic Impact Treatment on Additive Manufactured Metal Fabrications
by Laibo Sun, Lujun Huang, Pengbo Wu, Ruisheng Huang, Naiwen Fang, Fujia Xu and Kai Xu
Crystals 2023, 13(7), 995; https://doi.org/10.3390/cryst13070995 - 22 Jun 2023
Cited by 4 | Viewed by 1915
Abstract
Metal fabrications experience complex physical metallurgical processes during additive manufacturing, leading to residual stress and coarse microstructure with directional growth. It significantly affects the comprehensive performance of the fabrications, which limits the application of additive manufacturing. Ultrasonic impact treatment (UIT), as a strengthening [...] Read more.
Metal fabrications experience complex physical metallurgical processes during additive manufacturing, leading to residual stress and coarse microstructure with directional growth. It significantly affects the comprehensive performance of the fabrications, which limits the application of additive manufacturing. Ultrasonic impact treatment (UIT), as a strengthening means to assist additive manufacturing, can effectively improve the stress state and refine the microstructure and the comprehensive performance. This paper introduces the effect of UIT on AM metal fabrications on microstructure morphology, stress distribution, surface roughness, internal defects, and comprehensive performance to gain a deeper understanding of the role of UIT on additively manufactured metal fabrications, which is based on the working principle and effect of process parameters. In addition, the strengthening mechanism of UIT in additive manufacturing is described from the perspective of surface plastic deformation and substructure formation, providing support for the shape and property control of metal fabrications in the process of additive manufacturing assisted by UIT. Finally, the issues that need to be studied in depth on UIT in additive manufacturing are summarized, and an outlook on future research directions is taken. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Alloys)
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