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Metals
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Additive Manufacturing of Metallic Materials
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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: 25 April 2025 | Viewed by 2899

Special Issue Editors

Prof. Dr. Paul Wood

E-Mail Website
Guest Editor
Institute of Innovation in Sustainable Engineering, College of Science and Engineering, University of Derby, Derby DE22 1GB, UK
Interests: process–microstructure–property relation in the additive manufacturing and machining of high-temperature superalloys for transport and nuclear applications
Special Issues, Collections and Topics in MDPI journals
Dr. Urvashi Fowdar Gunputh

E-Mail Website
Guest Editor
Institute of Innovation in Sustainable Engineering, College of Science and Engineering, University of Derby, Derby DE22 1GB, UK
Interests: additive manufacturing; healthcare; nuclear; metals and alloys; AM post processing

Special Issue Information

Dear Colleagues,

The additive manufacturing of metals and their alloys is driven by freedom of design and efficiency in manufacturing. It has shown the greatest impact in industries in the healthcare, aviation, space, construction, and nuclear sectors. Nonetheless, there are limitations to the use of metal additive manufacturing (AM) related to feedstock properties, process parameters, heat treatments, microstructural defects, and post-process issues and their effect on the properties of the AM-produced metal and alloy parts. To accelerate the wider adoption of AM, for this Special Issue, we invite papers that discuss the state of the art, with a focus on the effect of the feedstock, processing, and heat treatment on the microstructure, properties, and integrity of materials produced via AM using either powder or wire feed. We invite experimental and review papers that enhance our scientific understanding of the AM processing of hard and light metal alloys such as stainless steel, nickel-based alloys, titanium and aluminium alloys, exotic alloys, and mild steel. Contributions on subjects related to AM processes, such as laser melting, powder bed fusion, electron beam and laser powder deposition, sintering, and wire arc AM, are also invited. Specific areas of interest include, but are not limited to, the following:

  1. Feedstock characterisation and reuse and the effects on the integrity of the AM-produced material.
  2. Defects in the material and their effects on properties and how these can be mitigated by improvements in processing, heat treatment, and the management of feedstocks, especially those that are reused, or, alternatively, how defects could be used to tailor the properties of a material to enhance its thermal, acoustic, or other properties.
  3. Microstructures and their influence on material properties, particularly how microstructures can be tailored to enhance material properties or create new functionally graded materials.
  4. AM processing that minimises residual stress and part distortion.
  5. Post-processing heat treatments such as HIP, stress relief, and precipitation hardening that improve the integrity of a material.
  6. Surface roughness in additively manufactured metals and its effect on the durability of the material.
  7. AM and finishing process optimisation to achieve net shape, reduce material waste, and reduce machining requirements.
  8. AM processing and characterisation of metamaterials, random open cell foams, lattice arrangements, and auxetics.
  9. Sustainability of metal AM, covering feedstock material, designs for metal AM, and part obsolescence, among other topics.

Prof. Dr. Paul Wood
Dr. Urvashi Fowdar Gunputh
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
  • powder and wire
  • feedstock reuse
  • metallic alloys
  • process–microstructure–property relation
  • defects
  • porosity
  • grain morphology
  • fatigue
  • lattice structures

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Published Papers (3 papers)

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Research

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15 pages, 5027 KiB  
Article
Hybridization in Metal Wire Additive Manufacturing: A Case Study of an Impeller
by Shahu R. Karade, Siddhartha Siddhartha, Neel Kamal Gupta, Ganesan G, K. P. Karunakaran and Henning Zeidler
Metals 2025, 15(1), 71; https://doi.org/10.3390/met15010071 - 15 Jan 2025
Viewed by 594
Abstract
Additive manufacturing (AM) has evolved to enable the direct production of functional components through the hybridization of additive and subtractive processes. In metal wire AM, hybridization is key, encompassing process integration (addition/subtraction), energy source combinations (arc/laser), kinematic options (3/4/5 axis), and slicing techniques [...] Read more.
Additive manufacturing (AM) has evolved to enable the direct production of functional components through the hybridization of additive and subtractive processes. In metal wire AM, hybridization is key, encompassing process integration (addition/subtraction), energy source combinations (arc/laser), kinematic options (3/4/5 axis), and slicing techniques (planar/conformal). This paper focuses on these hybridization methods, with a unified system designed for single-machine setups, improving efficiency and accuracy. This study presents a detailed exploration of these hybridization levels through the fabrication of a complex 5-axis geometry—an impeller. The impeller was manufactured with hybridization using various levels and subsequently compared with manufacturing processes like additive manufacturing with interlayer machining and traditional machining methods. The hybrid approach significantly reduced the manufacturing time for the selected impeller geometry from 3536 min to 792 min (saving 77.6% manufacturing time) and minimized material waste to 9.3%, compared with 74.07% in traditional machining. This demonstrates a more efficient, precise, and cost-effective method to optimize metal wire AM for producing complex metal components, advancing capabilities and applications. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Materials)
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13 pages, 16022 KiB  
Article
Effects of Anisotropic Microstructure and Load Ratio on Fatigue Crack Propagation Rate in Additively Manufactured Ti-6Al-4V Alloy
by Elad Chakotay, Roni Z. Shneck, Oz Golan, Rami Carmi, Mor Mega, Igal Alon, Raziel Yakov and Arie Busiba
Metals 2024, 14(12), 1405; https://doi.org/10.3390/met14121405 - 9 Dec 2024
Viewed by 621
Abstract
Additive manufacturing (AM) refers to advanced technologies for building 3D objects by adding material layer upon layer using either electron beam melting (EBM) or selective laser melting. AM allows us to produce lighter and more complex parts. However, various defects are created during [...] Read more.
Additive manufacturing (AM) refers to advanced technologies for building 3D objects by adding material layer upon layer using either electron beam melting (EBM) or selective laser melting. AM allows us to produce lighter and more complex parts. However, various defects are created during the AM process, which severely affect fatigue behavior. In the current research, the effects of the anisotropic microstructure in the in-plane and out-of-plane orientations and defects on the fatigue crack propagation rate (FCPR) and crack path were studied. A resonance machine was used to determine the fatigue crack propagation rate (da/dN vs. ΔK) from the near-threshold up to the final fracture, accompanied by in situ Acoustic Emission (AE) monitoring. Micro-Computerized Tomography (µCT) enabled us to characterize surface and microstructural defects. Metallography was used to determine the microstructure vs. orientations and fractography to classify the fatigue fracture propagation modes. Calculations of the local stress distribution were performed to determine the interactions of the cracks with the defects. In the out-of-plane direction, the material exhibited high fatigue fracture toughness accompanied by a slightly lower fatigue crack propagation rate as compared to in-plane orientations. The near-threshold stress intensity factor was slightly higher in the out-of-plane orientation as compared to that in the in-plane one, accompanied by a lower exponent of the Paris law regime. The threshold decreased with an increasing load ratio as expected for both orientations. The crack propagation direction that crosses the elongated grains plays an important role in increasing fatigue resistance in the out-of-plane direction. In the in-plane directions, the crack propagates parallel to the grain boundary, interacts with more defects and exhibits more brittle striations on the fracture surface, resulting in lower fatigue resistance. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Materials)
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Review

Jump to: Research

43 pages, 13300 KiB  
Review
Research Progress of Metal Additive Manufacturing Technology and Application in Space: A Review
by Xunzuo Su, Peilei Zhang and Yuze Huang
Metals 2024, 14(12), 1373; https://doi.org/10.3390/met14121373 - 1 Dec 2024
Viewed by 1396
Abstract
Metal additive manufacturing in space is a cutting-edge technology that is designed to meet the needs of space exploration and space station construction. This technology is capable of customizing and repairing key metallic parts in a space microgravity environment, providing the feasibility for [...] Read more.
Metal additive manufacturing in space is a cutting-edge technology that is designed to meet the needs of space exploration and space station construction. This technology is capable of customizing and repairing key metallic parts in a space microgravity environment, providing the feasibility for long-term space tasks. It enables astronauts to perform on-site repairs and replace broken parts, significantly reducing the risk of mission failure on the International Space Station or during future deep space missions. Further, this technique opens new possibilities for constructing space bases by directly utilizing the materials from space, thereby reducing reliance on Earth’s resources. However, metal additive manufacturing in space faces challenges due to the unclear underlying mechanisms that lie in (I) the significant differences in the melting behaviors of materials in a space microgravity environment compared to those on Earth; and (II) extreme environmental factors, i.e., radiation and temperature fluctuations, that influence the metal additive manufacturing process and, consequently, the properties of the manufactured materials. This review provides a comprehensive analysis of those mechanisms underlying metal additive manufacturing in space, based on published works. Emphasis is placed on aluminum, titanium, iron, and copper-based metals. Our work may offer valuable guidance for reducing mission costs, improving safety, and enabling the on-demand production of complex components in the harsh environment of space by using metal additive manufacturing. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Materials)
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