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Crystals
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New Materials and Concepts for Additive Manufacturing with Metals
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New Materials and Concepts for Additive Manufacturing with Metals

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 February 2023) | Viewed by 10329

Special Issue Editors

Dr. Kay-Peter Hoyer

E-Mail Website
Guest Editor
Chair of Materials Science, Paderborn University, 33098 Paderborn, Germany
Interests: additive manufacturing; alloy design; microstructure; mechanical properties; biomedical applications; soft-magnetic materials
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Bolv Xiao

E-Mail Website
Guest Editor
Institute of Metal Research Chinese Academy of Sciences, Shenyang, China
Interests: metal matrix composites; friction stir welding; hot working; aluminium alloys; magnesium alloys
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As you all know, laser powder bed-based additive manufacturing techniques for processing metals are almost established techniques for producing highly complex components and parts. The almost unrestricted freedom of geometry, for example, enables the integration of cooling channels close to the contour to minimize local hot spots so that the processing time can be shortened and the component distortion of the semi-finished product can be minimized. In addition to the high design flexibility, components can be generated close to the contour due to the layer-by-layer material application, i.e., work- and energy-intensive post-machining is often not required.

Still, the limited material spectrum and low process speeds have so far impeded the breakthrough of additively manufactured components on a large scale. For this reason, new materials are increasingly being developed explicitly for the AM process employing computer-based materials design.

The present Special Issue on “New Materials and Concepts for Additive Manufacturing with Metals” may become a status report summarizing the progress achieved in the last five years, as well as recent research.

Dr. Kay-Peter Hoyer
Prof. Dr. Bolv Xiao
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

  • additive manufacturing
  • alloy design
  • coating
  • fatigue performance
  • functionally graded materials
  • functional integration
  • laser powder bed fusion
  • mechanical properties
  • microstructure
  • new materials for AM
  • phase transformation
  • powder analysis
  • post-processing
  • x-ray diffraction

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Related Special Issue

Published Papers (5 papers)

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Research

17 pages, 66233 KiB  
Article
Computing the Durability of WAAM 18Ni-250 Maraging Steel Specimens with Surface Breaking Porosity
by Daren Peng, Victor K. Champagne, Andrew S. M. Ang, Aaron Birt, Alex Michelson, Sam Pinches and Rhys Jones
Crystals 2023, 13(3), 443; https://doi.org/10.3390/cryst13030443 - 3 Mar 2023
Cited by 11 | Viewed by 1498
Abstract
The durability assessment of additively manufactured parts needs to account for both surface-breaking material discontinuities and surface-breaking porosity and how these material discontinuities interact with parts that have been left in the as-built state. Furthermore, to be consistent with the airworthiness standards associated [...] Read more.
The durability assessment of additively manufactured parts needs to account for both surface-breaking material discontinuities and surface-breaking porosity and how these material discontinuities interact with parts that have been left in the as-built state. Furthermore, to be consistent with the airworthiness standards associated with the certification of metallic parts on military aircraft the durability analysis must be able to predict crack growth, as distinct from using a crack growth analysis in which parameters are adjusted so as to match measured data. To partially address this, the authors recently showed how the durability of wire arc additively manufactured (WAAM) 18Ni-250 maraging steel specimens, where failure was due to the interaction of small surface-breaking cracks with surface roughness, could be predicted using the Hartman–Schijve variant of the NASGRO crack growth equation. This paper illustrates how the same equation, with the same material parameters, can be used to predict the durability of a specimen where failure is due to surface-breaking porosity. Full article
(This article belongs to the Special Issue New Materials and Concepts for Additive Manufacturing with Metals)
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14 pages, 5702 KiB  
Article
Comparative Study of the Influence of Heat Treatment and Additive Manufacturing Process (LMD & L-PBF) on the Mechanical Properties of Specimens Manufactured from 1.2709
by Stefan Gnaase, Dennis Niggemeyer, Dennis Lehnert, Christian Bödger and Thomas Tröster
Crystals 2023, 13(2), 157; https://doi.org/10.3390/cryst13020157 - 17 Jan 2023
Cited by 3 | Viewed by 2185
Abstract
(1) This work answers the question of whether and to what extent there is a significant difference in mechanical properties when different additive manufacturing processes are applied to the material 1.2709. The Laser-Powder-Bed-Fusion (L-PBF) and Laser-Metal-Deposition (LMD) processes are considered, as they differ [...] Read more.
(1) This work answers the question of whether and to what extent there is a significant difference in mechanical properties when different additive manufacturing processes are applied to the material 1.2709. The Laser-Powder-Bed-Fusion (L-PBF) and Laser-Metal-Deposition (LMD) processes are considered, as they differ fundamentally in the way a part is manufactured. (2) Known process parameters for low-porosity parts were used to fabricate tensile strength specimens. Half of the specimens were heat-treated, and all specimens were tested for mechanical properties in a quasi-static tensile test. In addition, the material hardness was determined. (3) It was found that, firstly, heat treatment resulted in a sharp increase in mechanical properties such as hardness, elastic modulus, yield strength and ultimate strength. In addition to the increase in these properties, the elongation at break also decreases significantly after heat treatment. The choice of process, on the other hand, does not give either process a clear advantage in terms of mechanical properties but shows that it is necessary to consider the essential mechanical properties for a desired application. Full article
(This article belongs to the Special Issue New Materials and Concepts for Additive Manufacturing with Metals)
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15 pages, 11843 KiB  
Article
Additively Manufactured Nested and Non-Nested Cellular Solids for Effective Stress Distribution and Thermal Insulation Applications: An Experimental and Finite Element Analysis Study
by Sudipta Pramanik, Dennis Milaege, Kay-Peter Hoyer and Mirko Schaper
Crystals 2022, 12(9), 1217; https://doi.org/10.3390/cryst12091217 - 28 Aug 2022
Viewed by 2233
Abstract
In this study, the design, additive manufacturing and experimental as well as simulation investigation of mechanical and thermal properties of cellular solids are addressed. For this, two cellular solids having nested and non-nested structures are designed and additively manufactured via laser powder bed [...] Read more.
In this study, the design, additive manufacturing and experimental as well as simulation investigation of mechanical and thermal properties of cellular solids are addressed. For this, two cellular solids having nested and non-nested structures are designed and additively manufactured via laser powder bed fusion. The primary objective is to design cellular solids which absorb a significant amount of energy upon impact loading without transmitting a high amount of stress into the cellular solids. Therefore, compression testing of the two cellular solids is performed. The nested and non-nested cellular solids show similar energy absorption properties; however, the nested cellular solid transmits a lower amount of stress in the cellular structure compared to the non-nested cellular solid. The experimentally measured strain (by DIC) in the interior region of the nested cellular solid is lower despite a higher value of externally imposed compressive strain. The second objective of this study is to determine the thermal insulation properties of cellular solids. For measuring the thermal insulation properties, the samples are placed on a hot plate; and the surface temperature distribution is measured by an infrared camera. The thermal insulating performance of both cellular types is sufficient for temperatures exceeding 100 °C. However, the thermal insulating performance of a non-nested cellular solid is slightly better than that of the nested cellular solid. Additional thermal simulations predict a relatively higher temperature distribution on the cellular solid surfaces compared to experimental results. The simulated residual stress shows a similar distribution for both types, but the magnitude of residual stress is different for the cellular solids upon cooling from different temperatures of the hot plate. Full article
(This article belongs to the Special Issue New Materials and Concepts for Additive Manufacturing with Metals)
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18 pages, 4204 KiB  
Article
Influence of Physical Vapor Deposition on High-Cycle Fatigue Performance of Additively Manufactured Ti-6Al-7Nb Alloy
by Maxwell Hein
Crystals 2022, 12(9), 1190; https://doi.org/10.3390/cryst12091190 - 24 Aug 2022
Cited by 4 | Viewed by 1919
Abstract
Load-bearing permanent implants, such as hip or knee joint replacements, are permanently loaded in the human body and must withstand considerable high loading cycles. The characteristic properties of additively manufactured Ti-6Al-7Nb, manufactured by laser powder bed fusion (LPBF), such as a rough surface [...] Read more.
Load-bearing permanent implants, such as hip or knee joint replacements, are permanently loaded in the human body and must withstand considerable high loading cycles. The characteristic properties of additively manufactured Ti-6Al-7Nb, manufactured by laser powder bed fusion (LPBF), such as a rough surface and high residual stresses, have a detrimental effect on the fatigue behavior of such components. Functional physical vapor deposition (PVD) coatings and heat treatments offer the possibility to influence these properties. For this reason, the effects of stress-relief heat treatment (SR; 600 °C/4 h) and three PVD coatings (titanium nitride (TiN), titanium carbonitride (TiCN), and silver-containing amorphous carbon (a-C:Ag)) on the mechanical properties, in terms of high-cycle fatigue, are identified. Wöhler curves are determined and the staircase procedure ascertains the fatigue strengths. The fatigue strengths increase compared to the as-built condition by 105.4% (SR), 44.2% (TiN), 31.1% (TiCN), and 2.6% (a-C:Ag). Fracture surfaces are analyzed by scanning electron microscopy and show LPBF characteristic defects such as pores. The surfaces are partially divided into forced and fatigue fracture, the latter characterized by fatigue striations. Overall, PVD coatings, and especially SR, lead to an improved high-cycle fatigue behavior. Full article
(This article belongs to the Special Issue New Materials and Concepts for Additive Manufacturing with Metals)
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22 pages, 8102 KiB  
Article
Adjustment of AgCaLa Phases in a FeMn Matrix via LBM for Implants with Adapted Degradation
by Jan Tobias Krüger
Crystals 2022, 12(8), 1146; https://doi.org/10.3390/cryst12081146 - 15 Aug 2022
Cited by 1 | Viewed by 1629
Abstract
For many applications, implants overtake body function for a certain time. Bioresorbable implants reduce patient burden as they prevent adverse consequences due to remaining implants or operations for removal. Such materials are in clinical use but do not fulfill the requirements of all [...] Read more.
For many applications, implants overtake body function for a certain time. Bioresorbable implants reduce patient burden as they prevent adverse consequences due to remaining implants or operations for removal. Such materials are in clinical use but do not fulfill the requirements of all applications. Iron (Fe) is promising to develop further bioresorbable materials as it offers biocompatibility and good mechanical properties. Alloying, e.g., with manganese (Mn), is necessary to adapt the mechanical behavior and the degradation rate. However, the degradation rate of FeMn is too low. The creation of phases with high electrochemical potential evokes anodic dissolution of the FeMn, increasing the degradation rate. Therefore, silver (Ag), which is insoluble with Fe, has high potential, is biocompatible, and offers antibacterial properties, can be used. Powder-based processes such as laser beam melting (LBM) are favorable to process such immiscible materials. A degradable Ag alloy has to be used to enable the dissolution of Ag phases after the FeMn. This study reports first about the successful processing of FeMn with 5 wt.% of a degradable Ag–calcium–lanthanum (AgCaLa) alloy and enables further targeted adaption due to the gained understanding of the effects influencing the morphology and the chemical composition of the Ag phases. Full article
(This article belongs to the Special Issue New Materials and Concepts for Additive Manufacturing with Metals)
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