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Editorial Board Members’ Collection Series: Additive Manufacturing Technology
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Editorial Board Members’ Collection Series: Additive Manufacturing Technology

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (20 September 2024) | Viewed by 9408

Special Issue Editors

Prof. Dr. Evgeny A. Kolubaev

E-Mail Website
Guest Editor
Institute of Strength Physics and Materials Science, Siberian Branch of Russian Academy of Sciences, 634055 Tomsk, Russian
Interests: electron beam additive manufacturing; non-stational local metallurgy; friction; wear; direct energy deposition; friction stir welding; friction stir processing; composite materials
Special Issues, Collections and Topics in MDPI journals
Dr. Carlo Alberto Biffi

E-Mail Website
Guest Editor
National Research Council, Institute of Condensed Matter Chemistry and Technologies for Energy, Via G. Previati 1E, 23900 Lecco, Italy
Interests: National Research Council, Institute of Condensed Matter Chemistry and Technologies for Energy, Via G. Previati 1E, 23900 Lecco, Italy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The development of additive manufacturing technologies is becoming increasingly important due to the development of technical devices and the need for new materials and products for machines and mechanisms. A wide range of developing technologies for manufacturing parts, including selective laser or electron beam alloying of powders, direct energy deposition, wire electron beam, electric arc technologies, etc., allow for obtaining parts with different accuracy, productivity, structure, properties, or dimensions. Powder technologies have higher accuracy compared to wire technologies but lower productivity. Wire technologies are characterized by large-size products with high printing speeds and relatively large average grain sizes, especially in the case of electron beam printing. After printing using various methods, a wide range of materials are characterized by internal residual stresses, which influence the need for further heat treatment of the products. Many printing technologies make it possible to form products combining two or more materials with different interfaces between the components. It is also possible to obtain volumetric or surface composites in situ in various printing processes while maintaining the product as a whole. In the process of printing such products, the processes of mutual diffusion of components in the melt bath, formation of solid solutions and intermetallic phases play an important role, which is caused by the corresponding state diagrams, with a difference in the form of their localization in the melt bath and being time limited. This situation requires a deeper understanding of the processes occurring in the melt bath during printing, studying the mechanisms of melting and crystallization of the material and structural phase changes in the course of obtaining products. Analysis of the current state of research in the field of additive technologies for manufacturing products from metals and alloys shows that specific conditions of non-stationary metallurgical processes are formed, which are not typical for traditional technologies and lead to the formation of material structure and properties different from those formed by other production methods. Therefore, it is of great importance to identify the physical nature of the processes implemented in the production of parts using additive methods. Additionally, the great impact on the built parts performances regards the correlation between the specific Additive Manufacturing technology and the corresponding microstructure and mechanical behavior, which can be induced by the different thermal loads specific to the process.  

In this Special Issue, we expect articles presenting the results of studies of the structure organization and forming of mechanical properties in metals and alloys obtained using the methods of various additive technologies. A special interest of the Issue is the problems related to the production of products using methods of high-performance additive manufacturing.

Prof. Dr. Evgeny A. Kolubaev
Dr. Carlo Alberto Biffi
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. Metals 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 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

  • additive manufacturing
  • electron beam additive manufacturing
  • non-stational local metallurgy
  • selective laser melting
  • direct energy deposition
  • composite materials
  • metals and alloys
  • microstructure
  • mechanical properties
  • friction and wear

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Published Papers (7 papers)

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Research

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18 pages, 7292 KiB  
Article
Part-Scale Thermomechanical and Grain Structure Modeling for Additive Manufacturing: Status and Perspectives
by Yancheng Zhang, Gildas Guillemot, Théophile Camus, Oriane Senninger, Michel Bellet and Charles-André Gandin
Metals 2024, 14(10), 1173; https://doi.org/10.3390/met14101173 - 16 Oct 2024
Viewed by 552
Abstract
Thermomechanical modeling of additively manufactured parts made by laser powder bed fusion aims to control stresses and distortions built during processing. This is, by nature, a multiscale metallurgical and mechanical problem, notably due to the strong texture of the grain structure that results [...] Read more.
Thermomechanical modeling of additively manufactured parts made by laser powder bed fusion aims to control stresses and distortions built during processing. This is, by nature, a multiscale metallurgical and mechanical problem, notably due to the strong texture of the grain structure that results from the process and may locally dictate the thermomechanical behavior law. Similarly, stresses and distortions are directly influenced by the heat transfer process at the system scale, including the consequences of the link between the part and the substrate and the weaker interactions with the powder bed and the gas environment. To achieve relevant modeling, we first demonstrate capabilities to assess at part scale, both i- the prediction of the grain structure and ii- the thermomechanical analyses. A discussion follows that summarizes the foreseen directions to achieve coupling and/or chaining between grain structure simulations and mechanical analyses at part scale. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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14 pages, 3601 KiB  
Article
Analyzing Impact of Processing Parameters and Material Properties on Symmetry of Wire-Arc Directed Energy Deposit Beads
by Stephen Price, Kiran Judd, Matthew Gleason, Kyle Tsaknopoulos, Danielle L. Cote and Rodica Neamtu
Metals 2024, 14(8), 905; https://doi.org/10.3390/met14080905 - 9 Aug 2024
Viewed by 1118
Abstract
Wire arc-directed energy deposit (wire-arc DED) enables the efficient manufacturing of large-scale metal parts. Many factors can impact overall part quality during manufacturing, including processing parameters such as feed rate, travel speed, and various material properties. Previous works have sought to use machine [...] Read more.
Wire arc-directed energy deposit (wire-arc DED) enables the efficient manufacturing of large-scale metal parts. Many factors can impact overall part quality during manufacturing, including processing parameters such as feed rate, travel speed, and various material properties. Previous works have sought to use machine learning to evaluate and predict these impacts, but they have primarily focused on the width and height of single-layer deposits. Building upon these studies, this work offers a novel technique to characterize and evaluate the asymmetry of deposited beads to better understand the impact these parameters have. Specifically, leveraging time-series analysis techniques, the surface profiles of beads can be compared and analyzed to identify the degree of asymmetry. Additionally, this work relates these factors to the extent to which substrates warp during the depositing of material. With a better understanding of these impacts, manufacturing processes can be optimized for improved quality and reduced waste. These findings highlight that, while material selection and processing parameters do not strongly correlate with bead asymmetry, beads are deposited with varying degrees of asymmetry, requiring further analysis to identify the source. In contrast, substrate warping is significantly influenced by the thermal properties of the materials used. Of the properties analyzed, heat capacity, thermal diffusivity and thermal conductivity were found to be most relevant to substrate warping. Additionally, while to a lesser extent, material properties of the wire were found to be similarly correlated to warping as their substrate counterparts. These insights can inform the optimization of manufacturing processes, leading to improved part quality and reduced material waste. This study also underscores the need for further research into the interplay between processing conditions and material characteristics in wire-arc DED. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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21 pages, 29925 KiB  
Article
The Impact of Multiple Thermal Cycles Using CMT® on Microstructure Evolution in WAAM of Thin Walls Made of AlMg5
by Vinicius Lemes Jorge, Felipe Ribeiro Teixeira, Sten Wessman, Americo Scotti and Sergio Luiz Henke
Metals 2024, 14(6), 717; https://doi.org/10.3390/met14060717 - 17 Jun 2024
Cited by 1 | Viewed by 1103
Abstract
Wire Arc Additive Manufacturing (WAAM) of thin walls is an adequate technology for producing functional components made with aluminium alloys. The AlMg5 family is one of the most applicable alloys for WAAM. However, WAAM differs from traditional fabrication routes by imposing multiple thermal [...] Read more.
Wire Arc Additive Manufacturing (WAAM) of thin walls is an adequate technology for producing functional components made with aluminium alloys. The AlMg5 family is one of the most applicable alloys for WAAM. However, WAAM differs from traditional fabrication routes by imposing multiple thermal cycles on the material, leading the alloy to undergo cyclic thermal treatments. Depending on the heat source used, thermal fluctuation can also impact the microstructure of the builds and, consequently, the mechanical properties. No known publications discuss the effects of these two WAAM characteristics on the built microstructure. To study the influence of multiple thermal cycles and heat source-related thermal fluctuations, a thin wall was built using CMT-WAAM on a laboratory scale. Cross-sections of the wall were metallographically analysed, at the centre of a layer that was re-treated, and a region at the transition between two layers. The focus was the solidification modes and solubilisation and precipitations of secondary phases. Samples from the wall were post-heat treated in-furnace with different soaking temperatures and cooling, to support the results. Using numerical simulations, the progressive thermal cycles acting on the HAZ of one layer were simplified by a temperature sequence with a range of peak temperatures. The results showed that different zones are formed along the layers, either as a result of the imposed thermal cycling or the solidification mode resulting from CMT-WAAM deposition. In the zones, a band composed of coarse dendrites and an interdendritic phase and another band formed by alternating sizes of cells coexisted with the fusion and heat-affected zones. The numerical simulation revealed that the thermal cycling did not significantly promote the precipitation of second-phase particles. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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21 pages, 18973 KiB  
Article
Evaluation of Melting Efficiency in Cold Wire Gas Metal Arc Welding Using 1020 Steel as Substrate
by R. A. Ribeiro, P. D. C. Assunção and A. P. Gerlich
Metals 2024, 14(4), 484; https://doi.org/10.3390/met14040484 - 21 Apr 2024
Viewed by 1502
Abstract
A key welding parameter to quantify in the welding process is the ratio of the heat required to melt the weld metal versus the total energy delivered to the weld, and this is referred to as the melting efficiency. It is generally expected [...] Read more.
A key welding parameter to quantify in the welding process is the ratio of the heat required to melt the weld metal versus the total energy delivered to the weld, and this is referred to as the melting efficiency. It is generally expected that the productivity of the welding process is linked to this melting efficiency, with more productive processes typically having higher melting efficiency. A comparison is made between the melting efficiency in standard gas metal arc welding (GMAW) and cold wire gas metal arc welding (CW-GMAW) for the three primary transfer modes: short-circuit, globular, and spray regime. CW-GMAW specimens presented higher melting efficiency than GMAW for all transfer modes. Moreover, an increase in plate thickness in the spray transfer regime caused the melting efficiency to increase, contrary to what is expected. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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12 pages, 16670 KiB  
Article
The Regularities of Metal Transfer by a Nickel-Based Superalloy Tool during Friction Stir Processing of a Titanium Alloy Produced by Wire-Feed Electron Beam Additive Manufacturing
by Valery Rubtsov, Andrey Chumaevskii, Evgeny Knyazhev, Veronika Utyaganova, Denis Gurianov, Alihan Amirov, Andrey Cheremnov and Evgeny Kolubaev
Metals 2024, 14(1), 105; https://doi.org/10.3390/met14010105 - 15 Jan 2024
Cited by 1 | Viewed by 1513
Abstract
In this work, the interaction of an additively produced Ti-4Al-3V titanium alloy with a nickel superalloy tool and the features of the stir zone formation during friction stir processing have been studied. The stop-action technique was used to produce [...] Read more.
In this work, the interaction of an additively produced Ti-4Al-3V titanium alloy with a nickel superalloy tool and the features of the stir zone formation during friction stir processing have been studied. The stop-action technique was used to produce the samples to be studied using optical and scanning electron microscopy methods, as well as microhardness measurements. As a result, it was revealed that the tool, when moving, forms a pre-deformed area in front of it, which is characterized by a fine-grained structure. The presence of an interface layer between the workpiece material and primary fragmentation by the tool was revealed. It was demonstrated that the transfer of titanium alloy material occurs periodically following the ratio of feeding speed to tool rotation rate. Metal flow around the tool can occur in both laminar and vortex modes, as indicated by the tool material stirred into the transfer layer and used as a marker. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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13 pages, 3759 KiB  
Article
Tailoring the Microstructure of Laser-Additive-Manufactured Titanium Aluminide Alloys via In Situ Alloying and Parameter Variation
by Igor Polozov, Victoria Sokolova, Anna Gracheva and Anatoly Popovich
Metals 2023, 13(8), 1429; https://doi.org/10.3390/met13081429 - 9 Aug 2023
Cited by 1 | Viewed by 1284
Abstract
Titanium aluminide (TiAl) alloys have emerged as promising materials for high-temperature applications due to their unique combination of high-temperature strength, low density, and excellent oxidation resistance. However, the fabrication of TiAl alloys using conventional methods is challenging due to their high melting points [...] Read more.
Titanium aluminide (TiAl) alloys have emerged as promising materials for high-temperature applications due to their unique combination of high-temperature strength, low density, and excellent oxidation resistance. However, the fabrication of TiAl alloys using conventional methods is challenging due to their high melting points and limited ductility. Selective laser melting (SLM), an additive manufacturing technique, offers a viable solution for producing TiAl alloys with intricate geometries and the potential for tailoring their microstructure. This study investigates the effect of in situ copper alloying and multiple laser scans on the microstructure and mechanical properties of TiAl-based alloys fabricated using SLM. The results demonstrate that copper alloying enhances the formation of the α2-Ti3Al phase, refines the microstructure, and improves the mechanical properties of TiAl alloys. Multiple laser scans allow for the creation of distinct microstructural regions within a single component, enabling the tailoring of properties that are suitable for specific operating conditions. The findings provide valuable insights into the fabrication and optimization of TiAl intermetallic alloys with diverse applications. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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Review

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34 pages, 31610 KiB  
Review
Untapped Opportunities in Additive Manufacturing with Metals: From New and Graded Materials to Post-Processing
by Mohammad Hossein Mosallanejad, Reza Ghanavati, Amir Behjat, Mohammad Taghian, Abdollah Saboori and Luca Iuliano
Metals 2024, 14(4), 425; https://doi.org/10.3390/met14040425 - 3 Apr 2024
Viewed by 1597
Abstract
Metal additive manufacturing (AM) is an innovative manufacturing method with numerous metallurgical benefits, including fine and hierarchical microstructures and enhanced mechanical properties, thanks to the utilization of a local heat source and the rapid solidification nature of the process. High levels of productivity, [...] Read more.
Metal additive manufacturing (AM) is an innovative manufacturing method with numerous metallurgical benefits, including fine and hierarchical microstructures and enhanced mechanical properties, thanks to the utilization of a local heat source and the rapid solidification nature of the process. High levels of productivity, together with the ability to produce complex geometries and large components, have added to the versatile applicability of metal AM with applications already implemented in various sectors such as medicine, transportation, and aerospace. To further enhance the potential benefits of AM in the context of small- to medium-scale bulk production, metallurgical complexities should be determined and investigated. Hence, this review paper focuses on three significant metallurgical aspects of metal AM processes: in situ alloying, functionally graded materials, and surface treatments for AM parts. The current text is expected to offer insights for future research works on metal AM to expand its potential applications in various advanced manufacturing sectors. Full article
(This article belongs to the Special Issue Editorial Board Members’ Collection Series: Additive Manufacturing Technology)
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