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Additive Layer Manufacturing using Metal Deposition

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

Deadline for manuscript submissions: closed (30 April 2019) | Viewed by 29236

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Special Issue Editor

Prof. Dr. Patrice Peyre

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Guest Editor

PIMM-Laboratory of Processes and Engineering in Mechanics and Materials, French National Centre for Scientific Research, 75016 Paris, France
Interests: additive manufacturing with lasers; laser surface treatments; laser welding of dissimilar metals
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Among the additive layer manufacturing techniques for metals, metal deposition techniques, including Laser Metal Deposition (LMD) (with powder or wire) and Wire Arc Additive Manufacturing (WAAM), are known as versatile, efficient, and robust processes dedicated to the fabrication of low to average complexity parts, with a higher built volume per hour than powder bed techniques. Although the LMD process is derived from the usual laser cladding techniques, it is still the object of a large number of research activities due to the increasing industrial demand for this attractive laser-based technique. Moreover, the WAAM process is currently the object of growing industrial interest.

For this reason, a Special Issue on additive layer metal deposition is proposed, including the most recent scientific developments on various topics involving novel process developments, the manufacturing of new materials, and up-to-date numerical works on the employed processes.

More in detail, this Special Issue aims to address: (1) new LMD or WAAM procedures (new wavelengths, pulsed laser regimes, dedicated instrumentations, or process controls) and the resulting effects on surface finish, microstructures, and mechanical properties; (2) the additive manufacturing of innovative metals and graded materials; (3) the mechanical (static, fatigue, wear) or corrosion behaviour of built parts; and (4) the analytical or numerical modeling of WAAM or LMD (such as the numerical optimization of powder streams and nozzles, multiphysic modeling, melt-pool hydrodynamics, and the reduction of models to address large or complex parts).

We are looking forward to receiving your most recent works on all of these topics, which render this Special Issue a highly valuable scientific contribution to the current conversation.

Prof. Dr. Patrice Peyre
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

LMD
WAAM
Laser
Arc
Deposition
Hydrodynamics
Microstructures
Modeling
Graded
Corrosion
Fatigue
Additive

Published Papers (7 papers)

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Editorial

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3 pages, 160 KiB

Open AccessEditorial

Additive Layer Manufacturing using Metal Deposition

by Patrice Peyre

Metals 2020, 10(4), 459; https://doi.org/10.3390/met10040459 - 01 Apr 2020

Cited by 3 | Viewed by 1899

Abstract

Among the additive layer manufacturing techniques for metals, those involving metal deposition, including laser cladding/Direct Energy Deposition (DED, with powder feeding) or Wire and Arc Additive Manufacturing (WAAM, with wire feeding), exhibit several attractive features [...] Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

Research

Jump to: Editorial

15 pages, 8169 KiB

Open AccessArticle

Mechanical Properties of Tool Steels with High Wear Resistance via Directed Energy Deposition

by Gyeong Yun Baek, Gwang Yong Shin, Ki Yong Lee and Do Sik Shim

Metals 2019, 9(3), 282; https://doi.org/10.3390/met9030282 - 01 Mar 2019

Cited by 21 | Viewed by 5943

Abstract

This study focused on the mechanical and metallurgical characteristics of high-wear-resistance steel (HWS) deposited using directed energy deposition (DED) for metal substrate hardfacing or repairing. As post-deposition heat treatment changes the metallurgical characteristics of deposits, the effect of post-deposition heat treatment on the mechanical properties was investigated via microstructure observation and by conducting hardness, wear, and impact tests. The obtained micro-images showed that the deposited HWS layers exhibit cellular and columnar dendrites, and the microstructure of heat-treated HWS (HT-HWS) transformed its phase during quenching and tempering. The hardness and wear resistance of the HT-HWS deposits were higher than those of the HWS deposited specimen, whereas the latter exhibited a higher fracture toughness. The matrix microstructure and carbide characteristics, which are characterized by the chemical composition of the materials, significantly influenced the mechanical properties. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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13 pages, 8309 KiB

Open AccessArticle

Fe–Si–Al Coatings with Stable Wear Resistance Prepared by Laser Cladding Industrial Wastes

by Xue Liu, Bin-Bin Ma, Li-Wei Hu, Jin-Feng Li, Feng-Sheng Qu, Guo-Min Le and Xiu-Yan Li

Metals 2019, 9(1), 96; https://doi.org/10.3390/met9010096 - 17 Jan 2019

Cited by 9 | Viewed by 2675

Abstract

Because wear is one of the most common reasons for the failure of metals, the development of a low-cost coating with enhanced wear resistance is of great importance. In the present study, Fe–Si–Al coatings with superior and stable wear resistance were prepared by laser cladding Fe–Si–Al industrial waste onto 1045 carbon steel. The microstructure, as well as the wear mechanism of the Fe–Si–Al coatings, was investigated. The Fe–Si–Al coatings consist of a (Al, Fe, Si) solid solution phase in both columnar grain form and equiaxed grain form. The Fe–Si–Al coatings possess enhanced microhardness of 494 ± 15 HV_0.3 and low mass loss of 5 × 10⁻⁵ mg·(N·m)⁻¹. The wear resistance is ten times higher than that of the 1045 carbon steel matrix. The wear of the Fe–Si–Al coatings is mainly dominated by abrasive wear and adhesive wear. This work provides important insight into the preparation of low-cost, wear-resistant coatings, as well as stable, superior wear resistance. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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Graphical abstract

9 pages, 3562 KiB

Open AccessArticle

Residual Stress, Mechanical Properties, and Grain Morphology of Ti-6Al-4V Alloy Produced by Ultrasonic Impact Treatment Assisted Wire and Arc Additive Manufacturing

by Yichong Yang, Xin Jin, Changmeng Liu, Muzheng Xiao, Jiping Lu, Hongli Fan and Shuyuan Ma

Metals 2018, 8(11), 934; https://doi.org/10.3390/met8110934 - 12 Nov 2018

Cited by 56 | Viewed by 4860

Abstract

Ultrasonic Impact Treatment (UIT) is an effective technique for surface refinement and residual stress reduction, which is widely used in welding. This study investigates UIT-assisted Wire and Arc Additive manufacturing (WAAM). The residual stress, grain morphology and mechanical properties of post-UIT and as-deposited samples are studied. The result demonstrates that the UIT has a significant influence on the decrease of the residual stress. Moreover, the residual stress of the post-UIT samples is much lower than that of the as-deposited samples. The samples fabricated by UIT-assisted WAAM have a novel, bamboo-like distribution of prior-β grains, an alternating distribution of short columnar grains and equiaxed grains. The grain size of this bamboo-like structure is much smaller than the coarsen columnar grains. In addition, the mechanical properties of the post-UIT and as-deposited samples are compared. The results indicate that the average tensile strength of the post-UIT samples is higher, while the average elongation of the post-UIT samples is lower. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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11 pages, 4381 KiB

Open AccessArticle

Heat Treatment of In Situ Laser-Fabricated Titanium Aluminide

by Shaik E. Hoosain, Sisa Pityana, Christopher S. Freemantle and Monnamme Tlotleng

Metals 2018, 8(9), 655; https://doi.org/10.3390/met8090655 - 22 Aug 2018

Cited by 11 | Viewed by 3579

Abstract

Direct energy deposition (DED) via laser processing, operated under standard conditions with a localised shielding gas, is a potential method for the manufacture of the γ-TiAl alloy. The freedom of operation, which includes the production of components via in situ melting of elemental powders, makes this method economically attractive. The goal of this study was to optimise the mass flow rates that lead to gamma phase formation during laser in situ melting of Ti and Al. A 3 kW Nd:YAG laser was used to melt Ti and Al elemental powders. Single clads were produced on Ti6Al4V substrates under localised argon shielding. The samples were heat-treated to promote microstructural homogenization and to provide thermal stress relief, after which they were characterized. Lamellar and duplex microstructures were obtained; depending on the Al feed rate and heat treatment temperatures. The Vickers microhardness was found to be predominantly dependent on Al content and the amount of twinning present. X-ray diffraction detected a proportional increase in the intensity of the γ phase peak with an increase in Al content, while α₂ peaks were dissolved and the twin γ-Ti₃Al₅ peaks diminished slightly. An alloy produced in this work achieved the target microstructure and properties associated with superior ductility and tensile strength in these materials, indicating that the technology has future potential in the production of Ti-Al materials for applications such as structural components or thermal barrier coatings. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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13 pages, 8022 KiB

Open AccessArticle

Microstructure and Wear Resistance of Fe-Cr-Mo-Co-C-B Amorphous Composite Coatings Synthesized by Laser Cladding

by Xiangchun Hou, Dong Du, Kaiming Wang, Yuxiang Hong and Baohua Chang

Metals 2018, 8(8), 622; https://doi.org/10.3390/met8080622 - 07 Aug 2018

Cited by 32 | Viewed by 4657

Abstract

A novel amorphous composite coating was synthesized successfully on 3Cr13 stainless steel by laser cladding Fe-Cr-Mo-Co-C-B amorphous alloy powder. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD) were used to analyze the microstructure, composition, and phase structure of the coatings. Hardness and friction wear testers were used to analyze the hardness and wear resistance of the coatings. Results show that the cladding layer has an amorphous/crystalline composite structure, which is composed of a columnar grain region at the bottom and an amorphous region in the upper layer. The solute redistribution between the coating and the substrate in the bonding zone and the lower cooling rate at bottom account for the occurrence of crystallization. The highest hardness of the cladding layer is 1179

{HV}_{0.5}

, which is about 6 times that of the 3Cr13 stainless steel substrate (200

{HV}_{0.5}

). The cladding layer greatly improves the wear resistance of the substrate with a much lower coefficient of friction and wear mass loss compared with the substrate. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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12 pages, 3818 KiB

Open AccessArticle

Formation of SUS304/Aluminum Alloys Using Wire and Arc Additive Manufacturing

by Zhizhuang Hao, Sansan Ao, Yangchuan Cai, Wei Zhang and Zhen Luo

Metals 2018, 8(8), 595; https://doi.org/10.3390/met8080595 - 30 Jul 2018

Cited by 7 | Viewed by 4714

Abstract

In this study, wire and arc additive manufacturing (WAAM) was used to form SUS304/aluminum alloys. The buildup wall was well shaped using a pulse current consisting of a base current of 150 A and peak current of 200 A and a 0.2 m/min travel speed. Metallographic observation revealed that the original grains were columnar grains and transformed into equiaxed grains in the top area. The increased content of alloying elements in the fused layer improved the hardness of the buildup wall. The buildup wall formed using pulsed current exhibited improved anti-electrochemical corrosion performance when compared with that formed using constant current. The tensile strength of the alloy decreased but its elongation increased compared with those of Fe-Al alloys. The tensile fracture along the fusing direction was plastic fracture. However, the tensile fracture perpendicular to the fusing direction consisted of a combination of plastic and brittle fracture. Full article

(This article belongs to the Special Issue Additive Layer Manufacturing using Metal Deposition)

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