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Metals
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Recent Developments in Laser Additive Manufacturing of Metallic Materials
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Recent Developments in Laser Additive Manufacturing of Metallic Materials

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

Deadline for manuscript submissions: 20 December 2024 | Viewed by 1888

Special Issue Editor

Dr. Zhanyong Zhao

E-Mail Website
Guest Editor
School of Materials Science and Engineering, North University of China, Taiyuan 030051, China
Interests: laser additive manufacturing; powder bed fusion; directed energy deposition; microstructure and performance
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Laser additive manufacturing, an advanced form of manufacturing, can manufacture parts directly from digital models by using the layer-by-layer approach to build up materials. This manufacturing method can prepare complexly shaped metal parts in a short time and with high precision. Laser additive manufacturing can be classified into two major groups: Powder Bed Fusion-based technologies and Directed Energy Deposition. Laser additive manufacturing provides the freedom to design complex and light-weight parts for applications in the aerospace, automobile, and other industries. The global market for laser additive manufacturing is mainly driven by the the fast development of the aerospace and automobile industries.

In this Special Issue, we welcome articles that focus on laser additive manufacturing materials and processes and their influence on the final products’ microstructure and performance, in order to provide guidance for the development of laser additive manufacturing technology.

Dr. Zhanyong Zhao
Guest Editor

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

  • laser additive manufacturing
  • powder bed fusion
  • directed energy deposition
  • microstructure
  • performance

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Published Papers (3 papers)

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Research

20 pages, 31298 KiB  
Article
Additive Manufacturing and Precipitation Hardening of Low-Alloyed Copper Alloys Containing Chromium and Hafnium
by Julia Dölling, Samira Gruber, Felix Kovermann, Lukas Stepien, Elmar Beeh, Elena Lopez, Christoph Leyens, Hans-Günther Wobker and Andreas Zilly
Metals 2024, 14(11), 1304; https://doi.org/10.3390/met14111304 - 19 Nov 2024
Viewed by 329
Abstract
Copper alloys with chromium and hafnium offer the possibility of precipitation hardening and combine enhanced strength with high electrical and thermal conductivities. The production process, which starts with raw materials, involves powder production by gas atomization and leads to additive manufacturing by laser [...] Read more.
Copper alloys with chromium and hafnium offer the possibility of precipitation hardening and combine enhanced strength with high electrical and thermal conductivities. The production process, which starts with raw materials, involves powder production by gas atomization and leads to additive manufacturing by laser powder bed fusion with different parameter sets. The aim is to utilize precipitation reactions afterwards in CuHf0.7Cr0.35 during temperature exposure for further property optimization. This research focuses on the low-alloyed copper alloy with hafnium and chromium, compares this with conventionally manufactured specimens, and relates the alloy to additively manufactured specimens of other benchmark alloys such as CuCr1Zr. Measurements of hardness and electrical conductivity are accompanied by metallographic investigations to understand the behavior of CuHf0.7Cr0.35 manufactured by generative methods. In the as-built condition, melting traces remain visible in the microstructure, and hardness values of 101 HV and an electrical conductivity of 17.5 MS/m are reached. Solution annealing completely recrystallizes the microstructure, and the following quenching holds further alloying elements in supersaturated solid solution, resulting in 73 HV and 16.5 MS/m. Subsequent target-oriented precipitation reactions enable peak values of about 190 HV and 42 MS/m. Future research will assess mechanical and physical properties at elevated temperatures and evaluate possible applications. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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17 pages, 4525 KiB  
Article
An Investigation of Thermomechanical Behavior in Laser Hot Wire Directed Energy Deposition of NAB: Finite Element Analysis and Experimental Validation
by Glenn W. Hatala, Edward Reutzel and Qian Wang
Metals 2024, 14(10), 1143; https://doi.org/10.3390/met14101143 - 8 Oct 2024
Viewed by 575
Abstract
Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime [...] Read more.
Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime applications. Understanding thermomechanical behavior during LHW DED of NAB is a critical step towards the production of high-quality NAB parts with desired performance and properties. In this paper, finite element simulations are first used to predict the thermomechanical time histories during LHW DED of NAB test coupons with an increasing geometric complexity, including single-layer and multilayer depositions. Simulation results are experimentally validated through in situ measurements of temperatures at multiple locations in the substrate as well as displacement at the free end of the substrate during and immediately following the deposition process. The results in this paper demonstrate that the finite element predictions have good agreement with the experimental measurements of both temperature and distortion history. The maximum prediction error for temperature is 5% for single-layer samples and 6% for multilayer samples, while the distortion prediction error is about 12% for single-layer samples and less than 4% for multilayer samples. In addition, this study shows the effectiveness of including a stress relaxation temperature at 500 °C during FE modeling to allow for better prediction of the low cross-layer accumulation of distortion in multilayer deposition of NAB. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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14 pages, 5940 KiB  
Article
Laser Cladding Path Planning for Curved Metal Parts
by Jinduo Liu, Zhiyong Ba and Da Shu
Metals 2024, 14(9), 1055; https://doi.org/10.3390/met14091055 - 16 Sep 2024
Viewed by 653
Abstract
In depositing multiple layers on the surface of failed metal parts, the overlap rate is a critical factor in determining the surface smoothness and uniformity of the coating thickness. Therefore, special attention must be given to the spacing between adjacent melt tracks when [...] Read more.
In depositing multiple layers on the surface of failed metal parts, the overlap rate is a critical factor in determining the surface smoothness and uniformity of the coating thickness. Therefore, special attention must be given to the spacing between adjacent melt tracks when planning laser paths on complex metal parts. A strategy for selecting the overlap rate for multi-track cladding is proposed, based on the key parameters of surface curvature, mass conservation, and the profile of single-track coatings. A multi-track overlap model is developed, expressing the relationship between coating morphology and the overlap rate. The optimal spacing value is determined to achieve the goal of high-quality coating remanufacturing. To verify the effectiveness of this method, nickel-based powder was used for laser forming on the surface of metal gears. The results showed that the surface of the cladding layer was smooth and flat, further demonstrating that this model helps improve the repair quality and overall performance of curved metal parts. Thus, it provides valuable guidance for the remanufacturing of failed metal parts. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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