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Additive Manufacturing Methods and Modeling Approaches (Volume II)
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Additive Manufacturing Methods and Modeling Approaches (Volume II)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: closed (20 March 2022) | Viewed by 9139

Special Issue Editors

Prof. Dr. Massimiliano Avalle

E-Mail Website
Guest Editor
DIME—Department of Mechanical, Energy, Management and Transportation Engineering Polytechnic School, University of Genoa, 16145 Genoa, Italy
Interests: materials characterization and modeling; design and optimization of AM structures; cellular materials
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Giovanni Berselli

E-Mail Website
Guest Editor
Department of Mechanical, Energy, Management and Transportation Engineering, University of Genova, 16145 Genova, Italy
Interests: compliant mechanisms; smart-material-based transducers; variable stiffness actuators
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Nowadays, materials and technologies related to additive manufacturing (AM) are quickly evolving, both in terms of production processes and in terms of available materials. Additive manufactured components have already started to represent final products rather than mere prototypes. Indeed, one should notice that the term AM has basically substituted the terms rapid prototyping and 3D printing, in order to underline a closer link to the end-use components.

Regarding AM of metal parts, the main challenges are represented by the costs and the capability to obtain good performances. As for plastic parts, the current issues are similar, although the 3D printing of some low-cost plastics is already widely available. In this case, several materials can now be employed, ranging from the well-known ABS and PLA up to soft, rubber-like polymers. As for composites, this technology is rather new and offers interesting challenges and perspectives (including, also, the potential to replace metal).

Within this context, this Special Issue aims to provide an opportunity for researchers from both academia and industry to share recent advances in the field, with special attention to material modeling, design methods and criteria, software tools, and case studies, in this case, including industrial applications.

Prof. Dr. Massimiliano Avalle
Prof. Dr. Giovanni Berselli
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. Materials 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 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

  • AM materials: metals, plastics, and composites
  • material characterization, especially fatigue, fracture, aging
  • AM product design and simulation methods and tools; design rules
  • process simulations; residual stresses
  • post-treatment: surface finish, heat treatment, and machining
  • case studies, industrial applications
  • new technologies (e.g., hybrid AM, 4D printing)
  • lattice and cellular structures
  • AM-related standards and specs: materials, technologies, material recycling, and environmental issues
  • inspection techniques, defect identification, and characterization

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Published Papers (3 papers)

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Research

32 pages, 15559 KiB  
Article
High-Temperature Mechanical Properties of Stress-Relieved AlSi10Mg Produced via Laser Powder Bed Fusion Additive Manufacturing
by Dirk Lehmhus, Thomas Rahn, Adrian Struss, Phillip Gromzig, Tim Wischeropp and Holger Becker
Materials 2022, 15(20), 7386; https://doi.org/10.3390/ma15207386 - 21 Oct 2022
Cited by 11 | Viewed by 3042
Abstract
The present study is dedicated to the evaluation of the mechanical properties of an additively manufactured (AM) aluminum alloy and their dependence on temperature and build orientation. Tensile test samples were produced from a standard AlSi10Mg alloy by means of the Laser Powder [...] Read more.
The present study is dedicated to the evaluation of the mechanical properties of an additively manufactured (AM) aluminum alloy and their dependence on temperature and build orientation. Tensile test samples were produced from a standard AlSi10Mg alloy by means of the Laser Powder Bed Fusion (LPBF) or Laser Beam Melting (LBM) process at polar angles of 0°, 45° and 90°. Prior to testing, samples were stress-relieved on the build platform for 2 h at 350 °C. Tensile tests were performed at four temperature levels (room temperature (RT), 125, 250 and 450 °C). Results are compared to previously published data on AM materials with and without comparable heat treatment. To foster a deeper understanding of the obtained results, fracture surfaces were analyzed, and metallographic sections were prepared for microstructural evaluation and for additional hardness measurements. The study confirms the expected significant reduction of strength at elevated temperatures and specifically above 250 °C: Ultimate tensile strength (UTS) was found to be 280.2 MPa at RT, 162.8 MPa at 250 °C and 34.4 MPa at 450 °C for a polar angle of 0°. In parallel, elongation at failure increased from 6.4% via 15.6% to 26.5%. The influence of building orientation is clearly dominated by the temperature effect, with UTS values at RT for polar angles of 0° (vertical), 45° and 90° (horizontal) reaching 280.2, 272.0 and 265.9 MPa, respectively, which corresponds to a 5.1% deviation. The comparatively low room temperature strength of roughly 280 MPa is associated with stress relieving and agrees well with data from the literature. However, the complete breakdown of the cellular microstructure reported in other studies for treatments at similar or slightly lower temperatures is not fully confirmed by the metallographic investigations. The data provide a basis for the prediction of AM component response under the thermal and mechanical loads associated with high-pressure die casting (HPDC) and thus facilitate optimizing HPDC-based compound casting processes involving AM inserts. Full article
(This article belongs to the Special Issue Additive Manufacturing Methods and Modeling Approaches (Volume II))
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15 pages, 90428 KiB  
Article
Investigation of Path Planning to Reduce Height Errors of Intersection Parts in Wire-Arc Additive Manufacturing
by Gyeong-Hwan Song, Choon-Man Lee and Dong-Hyeon Kim
Materials 2021, 14(21), 6477; https://doi.org/10.3390/ma14216477 - 28 Oct 2021
Cited by 13 | Viewed by 2482
Abstract
Additive manufacturing (AM) has the advantages of reducing material usage and geometrical complexity compared to subtractive manufacturing. Wire arc additive manufacturing (WAAM) is an additive manufacturing process that can be used to rapidly manufacture medium-and large-sized products. This study deals with the path-planning [...] Read more.
Additive manufacturing (AM) has the advantages of reducing material usage and geometrical complexity compared to subtractive manufacturing. Wire arc additive manufacturing (WAAM) is an additive manufacturing process that can be used to rapidly manufacture medium-and large-sized products. This study deals with the path-planning strategy in WAAM, which can affect the quality of deposited components. It aims at suggesting effective path planning to reduce the height error of intersection parts. A comparative analysis of the bead width and height at the intersection parts was performed to verify the effectiveness of the proposed path. The initial parameters were determined through single-layer deposition experiments, and multi-layer deposition experiments were performed. The resultant height error in the intersection part was 0.8%, while that in the non-intersection part was absent at the maximum height. Path planning is considered to be an effective method. Full article
(This article belongs to the Special Issue Additive Manufacturing Methods and Modeling Approaches (Volume II))
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18 pages, 9338 KiB  
Article
Numerical Simulations of Components Produced by Fused Deposition 3D Printing
by Martina Scapin and Lorenzo Peroni
Materials 2021, 14(16), 4625; https://doi.org/10.3390/ma14164625 - 17 Aug 2021
Cited by 12 | Viewed by 2817
Abstract
Three-dimensional printing technology using fused deposition modeling processes is becoming more and more widespread thanks to the improvements in the mechanical properties of materials with the addition of short fibers into the polymeric filaments. The final mechanical properties of the printed components depend, [...] Read more.
Three-dimensional printing technology using fused deposition modeling processes is becoming more and more widespread thanks to the improvements in the mechanical properties of materials with the addition of short fibers into the polymeric filaments. The final mechanical properties of the printed components depend, not only on the properties of the filament, but also on several printing parameters. The main purpose of this study was the development of a tool for designers to predict the real mechanical properties of printed components by performing finite element analyses. Two different materials (nylon reinforced with glass or carbon fibers) were investigated. The experimental identification of the elastic material model parameters was performed by testing printed fully filled dog bone specimens in two different directions. The obtained parameters were used in numerical analyses to predict the mechanical response of simple structures. Blocks of 20 mm × 20 mm × 160 mm were printed in four different percentages of a triangular infill pattern. Experimental and numerical four-point bending tests were performed, and the results were compared in terms of load versus curvature. The analysis of the results demonstrated that the purely elastic transversely isotropic material model is adequate for predicting behavior, at least before nonlinearities occur. Full article
(This article belongs to the Special Issue Additive Manufacturing Methods and Modeling Approaches (Volume II))
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