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Laser Deposition Processes
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Laser Deposition Processes

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 9495

Special Issue Editor

Prof. Sabina Luisa Campanelli

E-Mail Website
Guest Editor
Polytechnic University of Bari, Bari, Italy
Interests: metal additive manufacturing; laser materials processing; welding

Special Issue Information

Dear Colleagues,

Laser deposition processes (LDP) are growing additive deposition technologies, which fall within the category of processes called direct energy deposition (DED). LDP are well suited for the manufacturing of complex metal parts, low-volume production, repair, and modification of components. These processes use a laser beam to melt an additional material (powder or wire) in order to create coatings or 3D components.

Currently, there is a great interest in these processes for the purpose of repair, remanufacturing or fabrication of components. However, these processes require accurate control of the main process parameters, and depending on the materials, even pre- and post-heating cycles. Process parameters and the final properties of parts are strongly dependent on the properties of the single processed material. Moreover, for a successful process, especially for the 3D manufacturing of components, it is essential to define deposition strategies and to provide monitoring and/or process control.

Many problems still need to be solved in order to obtain a process that ensures the right quality and sustainability of the components.

This Special Issue aims to share recent highlights and trends in the research activities around these technologies. Therefore, review or original research articles concerning process monitoring, the study of particular deposition strategies, metallurgical and mechanical characterization of deposited materials, especially those requiring pre- and/or post-heating cycles, and analytical or finite element modeling, are welcome.

Prof. Sabina Luisa Campanelli
Guest Editor

Manuscript Submission Information

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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

  • laser deposition processes
  • direct energy deposition
  • 3D manufacturing
  • repair
  • monitoring
  • deposition strategies
  • modeling
  • metallurgical and mechanical characterization of deposited parts

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Published Papers (3 papers)

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Research

23 pages, 10706 KiB  
Article
Additive Manufacturing of β-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders
by Michael Müller, Bastian Heinen, Mirko Riede, Elena López, Frank Brückner and Christoph Leyens
Materials 2021, 14(9), 2246; https://doi.org/10.3390/ma14092246 - 27 Apr 2021
Cited by 8 | Viewed by 2644
Abstract
The additive manufacturing (AM) technique, laser metal deposition (LMD), combines the advantages of near net shape manufacturing, tailored thermal process conditions and in situ alloy modification. This makes LMD a promising approach for the processing of advanced materials, such as intermetallics. Additionally, LMD [...] Read more.
The additive manufacturing (AM) technique, laser metal deposition (LMD), combines the advantages of near net shape manufacturing, tailored thermal process conditions and in situ alloy modification. This makes LMD a promising approach for the processing of advanced materials, such as intermetallics. Additionally, LMD allows the composition of a powder blend to be modified in situ. Hence, alloying and material build-up can be achieved simultaneously. Within this contribution, AM processing of the promising high-temperature material β-NiAl, by means of LMD, with elemental powder blends, as well as with pre-alloyed powders, was presented. The investigations showed that by applying a preheating temperature of 1100 °C, β-NiAl could be processed without cracking. Additionally, by using pre-alloyed, as well as elemental powders, a single phase β-NiAl microstructure can be achieved in multi-layer build-ups. Major differences between the approaches were found within substrate near regions. For in situ alloying of Ni and Al, these regions are characterized by an inhomogeneous elemental distribution in a layerwise manner. However, due to the remelting of preceding layers during deposition, a homogenization can be observed, leading to a single-phase structure. This shows the potential of high temperature preheating and in situ alloying to push the development of new high temperature materials for AM. Full article
(This article belongs to the Special Issue Laser Deposition Processes)
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16 pages, 3929 KiB  
Article
Coaxial Monitoring of AISI 316L Thin Walls Fabricated by Direct Metal Laser Deposition
by Vito Errico, Sabina Luisa Campanelli, Andrea Angelastro, Michele Dassisti, Marco Mazzarisi and Cesare Bonserio
Materials 2021, 14(3), 673; https://doi.org/10.3390/ma14030673 - 1 Feb 2021
Cited by 27 | Viewed by 3208
Abstract
Direct metal laser deposition (DMLD) is an additive manufacturing technique suitable for coating and repair, which has been gaining a growing interest in 3D manufacturing applications in recent years. However, its diffusion in the manufacturing industry is still limited due to technical challenges [...] Read more.
Direct metal laser deposition (DMLD) is an additive manufacturing technique suitable for coating and repair, which has been gaining a growing interest in 3D manufacturing applications in recent years. However, its diffusion in the manufacturing industry is still limited due to technical challenges to be solved—both the sub-optimal quality of the final parts and the low repeatability of the process make the DMLD inadequate for high-value applications requiring high-performance standards. Thus, real-time monitoring and process control are indispensable requirements for improving the DMLD process. The aim of this study was the optimization of deposition strategies for the fabrication of thin walls in AISI 316L stainless steel. For this purpose, a coaxial monitoring system and image processing algorithms were employed to study the melt pool geometry. The comparison tests carried out highlighted how the region-based active contour algorithm used for image processing is more efficient and stable than others covered in the literature. The results allowed the identification of the best deposition strategy. Therefore, it is shown how this monitoring methodology proved to be suitable for designing and implementing the right building strategy for DMLD manufactured 3D components. A fast and stable image processing method was achieved, which can be considered for future closed-loop monitoring in real-time applications. Full article
(This article belongs to the Special Issue Laser Deposition Processes)
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19 pages, 4374 KiB  
Article
Ultrasonic Characterization of Components Manufactured by Direct Laser Metal Deposition
by Anna Castellano, Marco Mazzarisi, Sabina Luisa Campanelli, Andrea Angelastro, Aguinaldo Fraddosio and Mario Daniele Piccioni
Materials 2020, 13(11), 2658; https://doi.org/10.3390/ma13112658 - 11 Jun 2020
Cited by 14 | Viewed by 2590
Abstract
Direct laser metal deposition (DLMD) is an innovative additive technology becoming of key importance in the field of repairing applications for industrial and aeronautical components. The performance of the repaired components is highly related to the intrinsic presence of defects, such as cracks, [...] Read more.
Direct laser metal deposition (DLMD) is an innovative additive technology becoming of key importance in the field of repairing applications for industrial and aeronautical components. The performance of the repaired components is highly related to the intrinsic presence of defects, such as cracks, porosity, excess of dilution or debonding between clad and substrate. Usually, the quality of depositions is evaluated through destructive tests and microstructural analysis. Clearly, such methodologies are inapplicable in-process or on repaired components. The proposed work aims to evaluate the capability of ultrasonic techniques to perform the mechanical characterization of additive manufactured (AM) components. The tested specimens were manufactured by DLMD using a nickel-based superalloy deposited on an AISI 304 substrate. Ultrasonic goniometric immersion tests were performed in order to mechanical characterize the substrate and the new material obtained by AM process, consisting of the substrate and the deposition. Furthermore, the relationship was evaluated between the acoustic and the mechanical properties of the AM components and the deposition process parameters and the geometrical characteristics of multiclad depositions, respectively. Finally, the effectiveness of the proposed non-destructive experimental approach for the characterization of the created deposition anomalies has been investigated. Full article
(This article belongs to the Special Issue Laser Deposition Processes)
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