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Advances in 3D Printing Technologies of Metals—2nd Edition
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Advances in 3D Printing Technologies of Metals—2nd Edition

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

Deadline for manuscript submissions: 25 March 2025 | Viewed by 8770

Special Issue Editors

Dr. Irene Buj Corral

E-Mail Website
Guest Editor
Department of Mechanical Engineering, School of Engineering of Barcelona (ETSEIB), Universitat Politècnica de Catalunya, 08028 Barcelona, Spain
Interests: additive manufacturing; hip prostheses, roughness; porosity; dimensional accuracy; mechanical strength
Special Issues, Collections and Topics in MDPI journals
Dr. Felip Fenollosa-Artés

E-Mail Website
Guest Editor
1.Department of Mechanical Engineering, School of Engineering of Barcelona (ETSEIB), Universitat Politècnica de Catalunya, 08028 Barcelona, Spain
2.CIM UPC Technological Center, 08028 Barcelona, Spain
Interests: 3D printing; additive manufacturing; Industry 4.0; digital manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Research into the additive manufacturing (AM) of metals has expanded in recent years, with the aim being to obtain high-strength parts and/or parts with high electrical conductivity and complex shapes.

Metallic AM parts are applied in different sectors, including the automotive, aeronautical, medical, and electronics sectors, among many others.

For this Special Issue, we welcome the submission of articles that focus on the characterization of metallic parts obtained with different additive manufacturing processes and considering their metallurgy, surface finish, porosity, mechanical properties, geometry features, etc. Topics of interest for the SI include (but are not limited to) the following different AM processes:

  • VAT polymerization techniques such as stereolithography (SL) with metallic-filled resin.
  • Metal binder jetting techniques.
  • Material extrusion techniques such as fused deposition modeling (FDM), also known as fused filament fabrication (FFF) with metal-filled filament, direct ink writing (DIW) with metal-filled inks, solid-state friction welding and Joule printing.
  • Metallic material jetting techniques such as nano particle jetting (NPJ), liquid metal 3D printing and supersonic 3D deposition.
  • Powder bed fusion techniques such as selective laser melting (SLM) or electron beam melting (EBM).
  • Directed energy deposition processes such as powder DED and wire DED based on different energy sources.
  • Other (ultrasonic consolidation, etc.)

Dr. Irene Buj Corral
Dr. Felip Fenollosa-Artés
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

  • metal 3D printing
  • vat photopolymerization with metal-filled resins
  • metal binder jetting
  • fused filament fabrication (FFF) with metal-filled filament
  • direct ink writing (DIW) with metal-filled ink
  • selective laser melting (SLM, DLMS, LMF, etc.)
  • electron beam melting (EBM)
  • wire arc additive manufacturing (WAAM)
  • direct energy deposition (DED)
  • laser-engineered net shaping (LENS)

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Published Papers (5 papers)

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Research

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12 pages, 3335 KiB  
Article
Comparative Studies of the Properties of Copper Components: Conventional vs. Additive Manufacturing Technologies
by Witold Malec, Joanna Kulasa, Anna Brudny, Anna Hury, Bartlomiej Adamczyk, Ryszard Rzepecki, Robert Sekula, Grzegorz Kmita and Andrzej Rybak
Metals 2024, 14(9), 975; https://doi.org/10.3390/met14090975 - 28 Aug 2024
Viewed by 1235
Abstract
This article presents a comparative analysis of the crucial physical properties of electrically conductive components made of pure copper, produced by various additive manufacturing technologies such as binder jetting (BJ) and direct metal laser sintering (DMLS). The comparison concerned the assessment of critical [...] Read more.
This article presents a comparative analysis of the crucial physical properties of electrically conductive components made of pure copper, produced by various additive manufacturing technologies such as binder jetting (BJ) and direct metal laser sintering (DMLS). The comparison concerned the assessment of critical parameters important from the application point of view, such as: electrical conductivity, hardness, yield point, microstructure and the occurrence of internal material defects. Same-sized components made in a conventional casting and subtractive method (machining) were used as a reference material. Comprehensive tests and the comparison of a wide range of parameters allowed us to determine that among the selected methods, printing using the DMLS technique allowed for obtaining arcing contact with mechanical and electrical parameters very similar to the reference element. Therefore, the obtained results showed the possibility of using the copper elements made by additive manufacturing for the switching and protection devices used in electrification and energy distribution industrial sectors. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
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23 pages, 18628 KiB  
Article
TiAl Alloy Fabricated Using Election Beam Selective Melting: Process, Microstructure, and Tensile Performance
by Yu Zhang, Yan Li, Meihui Song, Yanchun Li, Shulin Gong and Bin Zhang
Metals 2024, 14(4), 482; https://doi.org/10.3390/met14040482 - 20 Apr 2024
Cited by 4 | Viewed by 1103
Abstract
TiAl alloy is one of the most attractive candidates for a new generation of high-temperature structural materials and has broad application prospects in the aerospace field. As a typical intermetallic material, TiAl is inevitably difficult to process using conventional methods. Election beam selective [...] Read more.
TiAl alloy is one of the most attractive candidates for a new generation of high-temperature structural materials and has broad application prospects in the aerospace field. As a typical intermetallic material, TiAl is inevitably difficult to process using conventional methods. Election beam selective melting (EBSM) is an effective method of addictive manufacturing to prepare TiAl alloy with a complex structure. However, the microstructure of TiAl alloy formed using EBSM often contains defects such as pores, which seriously reduces the mechanical properties of the material. In this work, the effects of EBSM and post-processing procedures on the microstructure and mechanical properties of Ti-48Al-2Cr-2Nb alloy were studied. The results show that the microstructure of Ti-48Al-2Cr-2Nb alloy formed using the EBSM process was dense and composed of equiaxed γ-phase and double-phase regions. A large number of dislocations that formed due to thermal stress were clearly observed inside the Ti-48Al-2Cr-2Nb alloy. When the EBSM process parameters were 13.5 mA, 4.0 m/s, and 40.50 J/mm3, as the current intensity increased, the Al content decreased, the content of α2 phase increased, and the microstructure of the material was coarse. The results of the tensile test fracture morphology indicate that the Ti-48Al-2Cr-2Nb alloy exhibited brittle fracture during tensile deformation, lacking the typical yield deformation of metal materials. As the energy density of the EBSM process increased, the mechanical properties of the Ti-48Al-2Cr-2Nb alloy first increased and then decreased. The samples prepared with an energy density of 34.50~40.50 J/mm3 had excellent mechanical properties, of which the maximum tensile strength and maximum elongation reached 643 MPa and 2.09%, respectively. The phase composition of the Ti-48Al-2Cr-2Nb alloy after hot isostatic pressing (HIP) treatment remained unchanged from the EBSM samples, but there was a slight difference in content. There was an increase in the amount of γ phase and a decrease in B2 phase, accompanied by the generation of a massive γ phase after HIP treatment. Moreover, the number of dislocations inside the material increased. The Ti-48Al-2Cr-2Nb alloy after HIP treatment exhibited obvious plastic deformation characteristics, with a tensile strength of 679 MPa and elongation of 2.5%. A heat treatment of 900 °C/5 h was performed on the Ti-48Al-2Cr-2Nb alloy after HIP. The dislocation density of the Ti-48Al-2Cr-2Nb alloy decreased, and the B2 phase transformed from massive to lamellar. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
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17 pages, 2741 KiB  
Article
An Experimental Investigation about the Dimensional Accuracy and the Porosity of Copper-Filled PLA Fused Filament Fabrication Parts
by Irene Buj-Corral and Maurici Sivatte-Adroer
Metals 2023, 13(9), 1608; https://doi.org/10.3390/met13091608 - 18 Sep 2023
Cited by 4 | Viewed by 1302
Abstract
In recent years, metal-filled plastic filaments have begun to be used in fused filament fabrication (FFF) technology. However, the characterization of the parts obtained is still under development. In this work, the results on dimensional accuracy and porosity of copper-filled 3D-printed parts are [...] Read more.
In recent years, metal-filled plastic filaments have begun to be used in fused filament fabrication (FFF) technology. However, the characterization of the parts obtained is still under development. In this work, the results on dimensional accuracy and porosity of copper-filled 3D-printed parts are presented. Cuboid parts were 3D-printed in the vertical position. The three dimensions of each part were measured, and the relative error was calculated for each one of them. Dimensional accuracy in terms of width and depth depends mainly on the layer height and printing temperature, while accuracy in height is mainly influenced by print speed and the interaction of layer height with print speed. Porosity is related to layer height, printing temperature and print speed. According to multiobjective optimization, to minimize dimensional error and obtain a porosity target value of 20%, it is recommended to select a low layer height of 0.1 mm, a high print speed of 40 mm/s, a low extrusion multiplier of 0.94 and a low temperature of 200 °C. The results of the present work will help to select appropriate 3D printing parameters when using metal-filled filaments in FFF processes. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
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Review

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66 pages, 14659 KiB  
Review
Advancements in Metal Processing Additive Technologies: Selective Laser Melting (SLM)
by Neetesh Soni, Gilda Renna and Paola Leo
Metals 2024, 14(9), 1081; https://doi.org/10.3390/met14091081 - 21 Sep 2024
Viewed by 1565
Abstract
Nowadays, the use of metal processing additive technologies is a rapidly growing field in the manufacturing industry. These technologies, such as metal 3D printing (also known as additive manufacturing) and laser cladding, allow for the production of complex geometries and intricate designs that [...] Read more.
Nowadays, the use of metal processing additive technologies is a rapidly growing field in the manufacturing industry. These technologies, such as metal 3D printing (also known as additive manufacturing) and laser cladding, allow for the production of complex geometries and intricate designs that would be impossible with traditional manufacturing methods. They also offer the ability to create parts with customized properties, such as improved strength, wear resistance, and corrosion resistance. In other words, these technologies have the potential to revolutionize the way we design and produce products, reducing costs and increasing efficiency to improve product quality and functionality. One of the significant advantages of these metal processing additive technologies is a reduction in waste and environmental impact. However, there are also some challenges associated with these technologies. One of the main challenges is the cost of equipment and materials, which can be prohibitively expensive for small businesses and individuals. Additionally, the quality of parts produced with these technologies can be affected by factors such as printing speed, temperature, and post-processing methods. This review article aims to contribute to a deep understanding of the processing, properties, and applications of ferrous and non-ferrous alloys in the context of SLM to assist readers in obtaining high-quality AM components. Simultaneously, it emphasizes the importance of further research, optimization, and cost-effective approaches to promote the broader adoption of SLM technology in the industry. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
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42 pages, 4508 KiB  
Review
The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review
by Alex Lanzutti and Elia Marin
Metals 2024, 14(8), 886; https://doi.org/10.3390/met14080886 - 2 Aug 2024
Cited by 1 | Viewed by 2936
Abstract
This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition, and Binder Jetting, and [...] Read more.
This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition, and Binder Jetting, and analyzes the impact of powder characteristics on the final part properties. This review highlights key challenges associated with powder recycling, including maintaining consistent particle size and shape, managing contamination, and mitigating degradation effects from repeated use, such as wear, fragmentation, and oxidation. Furthermore, it explores various recycling techniques, such as sieving, blending, plasma spheroidization, and powder conditioning, emphasizing their role in restoring powder quality and enabling reuse. Full article
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
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