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Recent Advances in Directed Energy Deposition of High-Performance Alloys
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Recent Advances in Directed Energy Deposition of High-Performance Alloys

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 December 2024 | Viewed by 1945

Special Issue Editors

Dr. Alireza Vahedi Nemani

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, Canada
Interests: directed energy deposition; dynamic mechanical behaviour; high entropy alloys; heat treatment
Dr. Mahya Ghaffari

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, Canada
Interests: wire arc additive manufacturing; micromechanical properties, In-situ Inoculation; materials characterization; ferrous materials
Dr. Ali M. Nasiri

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, Canada
Interests: metal additive manufacturing; additive manufacturing; welding and joining; multi-scale materials characterization; corrosion; mechanical properties

Special Issue Information

Dear Colleagues,

Join us in advancing the frontiers of directed energy deposition (DED) technology and exploring exciting developments in the field.

DED revolutionizes the manufacturing industry by offering near-net shape production with less material waste, versatile material deposition for various applications, and the ability to clad, repair, or remanufacture industrial components. It is impactful across aerospace, automotive, and medical industries, though further research is needed to address its deployment challenges.

This Special Issue aims to provide a dedicated platform for sharing new innovative findings, discussing accomplishments, and exploring future directions in metal deposition research. We welcome case studies, reviews, short communications, and original research articles, including but not limited to the following areas:

  1. Methodologies for the design of high-performance metal components with a focus on high-entropy alloys, functionally graded materials, and multi materials utilizing DED techniques.
  2. The application of advanced metal powders and alloys customized for DED additive manufacturing, with a particular focus on metal matrix composites.
  3. Innovations in tailoring process–microstructure–properties relationships of DED-fabricated parts and components.
  4. Case studies of practical implementations of DED manufacturing in various industrial sectors, showcasing real-world applications and outcomes.
  5. Applications of DED technology in cladding, repair, and remanufacturing.

If your topic is not listed above, but you believe that your innovation in DED technology would capture the attention of the AM community, feel free to submit your article, and we will review its alignment with this Special Issue.

Dr. Alireza Vahedi Nemani
Dr. Mahya Ghaffari
Dr. Ali M. Nasiri
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. Journal of Manufacturing and Materials Processing 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 1800 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

  • directed energy deposition
  • repair and remanufacturing
  • microstructural features
  • mechanical properties
  • high-entropy alloys

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

Published Papers (2 papers)

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Research

27 pages, 9760 KiB  
Article
Precision Calibration in Wire-Arc-Directed Energy Deposition Simulations Using a Machine-Learning-Based Multi-Fidelity Model
by Fuad Hasan, Abderrachid Hamrani, Md Munim Rayhan, Tyler Dolmetsch, Dwayne McDaniel and Arvind Agarwal
J. Manuf. Mater. Process. 2024, 8(5), 222; https://doi.org/10.3390/jmmp8050222 - 2 Oct 2024
Viewed by 1003
Abstract
Thermal simulation is essential in wire-arc-directed energy deposition (W-DED) to accurately estimate temperature distributions, impacting residual stress and distortion in components. Proper calibration of simulation models minimizes inaccuracies caused by varying material properties, machine settings, and environmental conditions. The lack of standardized calibration [...] Read more.
Thermal simulation is essential in wire-arc-directed energy deposition (W-DED) to accurately estimate temperature distributions, impacting residual stress and distortion in components. Proper calibration of simulation models minimizes inaccuracies caused by varying material properties, machine settings, and environmental conditions. The lack of standardized calibration methods further complicates thermal predictions. This paper introduces a novel calibration method integrating both machine learning, as the high-fidelity (HF) model, and response surface modeling, as the low-fidelity (LF) model, within a multi-fidelity (MF) framework. The approach utilizes Bayesian optimization to effectively explore the search space for optimal solutions. A two-tiered model employs the LF model to identify feasible regions, followed by the HF model to refine calibration parameters, such as thermal efficiency (η), convection coefficient (h), and emissivity (ε), which are difficult to determine experimentally. A three-factor Box–Behnken design (BBD) is applied to explore the design space, requiring only thirteen parameter configurations, conserving resources and enabling robust model training. The efficacy of this MF model is demonstrated in multi-layer W-DED calibration, showing strong alignment between experimental and simulated temperatures, with a mean absolute error (MAE) of 7.47 °C. This method offers a replicable framework for broader additive manufacturing processes. Full article
(This article belongs to the Special Issue Recent Advances in Directed Energy Deposition of High-Performance Alloys)
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9 pages, 6143 KiB  
Communication
Impact of TiC/TiB2 Inoculation on the Electrochemical Performance of an Arc-Directed Energy-Deposited PH 13-8Mo Martensitic Stainless Steel
by Alireza Vahedi Nemani, Mahya Ghaffari, Khashayar Morshed-Behbahani, Salar Salahi and Ali Nasiri
J. Manuf. Mater. Process. 2024, 8(5), 212; https://doi.org/10.3390/jmmp8050212 - 27 Sep 2024
Viewed by 581
Abstract
This study investigates the impact of incorporating TiC and TiB2 inoculants on the microstructure and corrosion performance of an arc-directed energy-deposited PH 13-8Mo martensitic stainless steel. The microstructural characterizations revealed partial dissolution of the incorporated ceramic-based nanoparticles, resulting in the formation of [...] Read more.
This study investigates the impact of incorporating TiC and TiB2 inoculants on the microstructure and corrosion performance of an arc-directed energy-deposited PH 13-8Mo martensitic stainless steel. The microstructural characterizations revealed partial dissolution of the incorporated ceramic-based nanoparticles, resulting in the formation of in situ TiC phase in the TiC-inoculated sample, while TiC and chromium-enriched M3B2 phases were formed in the TiB2-inoculated sample. Further investigations into the electrochemical response of the fabricated samples confirmed that the applied inoculation strategy slightly enhanced the corrosion resistance of the alloy, offering a valuable advantage for in-service performance for applications in harsher environments. The slight improvement in the corrosion resistance of the inoculated samples was found to be attributed to the formation of a higher fraction of low-angle grain boundaries and enhanced retained austenite content in the microstructure. However, it is essential to note that the formation of chromium-enriched M3B2 phases in the TiB2-inoculated sample led to a slight deterioration in its corrosion resistance compared to the TiC-inoculated counterpart. Full article
(This article belongs to the Special Issue Recent Advances in Directed Energy Deposition of High-Performance Alloys)
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