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Design of New Metallic Alloys for AM
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Design of New Metallic Alloys for AM

A special issue of Alloys (ISSN 2674-063X).

Deadline for manuscript submissions: 31 December 2025 | Viewed by 13794

Special Issue Editor

Prof. Dr. Pavel Krakhmalev

E-Mail Website
Guest Editor
Department of Engineering and Physics, Karlstad University, SE-651 88 Karlstad, Sweden
Interests: additive manufacturing; laser and electron beam powder bed fusion techniques; direct energy deposition; advanced character-ization of microstructure–properties relationship of additively manufactured materials; material design for additive manufac-turing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is a key technology enabling the development of future manufacturing systems. In recent years, there has been an increase in interest regarding the use of additive manufacturing (AM) technologies in different industrial applications, e.g., aerospace, automotive, tooling, biomedical, etc. The development of AM manufacturing technology goes hand in hand with the development of novel high-performance metallic materials specially designed for AM. In this respect, theoretical predictions and experimental investigations of novel AM materials are of highest interest for the development of high-performance AM components. The Special Issue “Design of New Metallic Alloys for AM” aims to share existing theoretical and experimental knowledge concerning the development and properties of novel metallic materials designed for additive manufacturing.

The Special Issue invites submission of short communications, full-length articles and reviews dedicated to the development of novel commercial and experimental ferrous and nonferrous metallic alloys, intermetallic alloys, high-entropy alloys, and metal matrix composites. All AM methods suitable for metallic materials will be taken into consideration. The main topics of interest include, but are not limited to, the following:

  • Design of novel material for AM, thermodynamic calculations, simulation and properties prediction, and experimental verification.
  • Influence of novel alloy composition on characteristic defects in AM, e.g., hot cracks, precipitates on colony boundaries, etc.
  • Manufacturing process for novel AM metallic materials, in situ alloying, modification of powder with nanoparticles, powder prealloying and premixing, etc.
  • Microstructure and properties (physical, mechanical, corrosion, tribological, etc.) of novel structural and functional AM materials.

Hybrid manufacturing technologies, multimaterials, gradient materials, AM manufacturing of dissimilar materials, etc.

Prof. Dr. Pavel Krakhmalev
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. Alloys is an international peer-reviewed open access quarterly 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 1000 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

  • design of novel material for AM
  • thermodynamic calculations
  • multimaterials
  • gra-dient materials
  • in situ alloying
  • modification of powder with nanoparticles
  • metallic alloys
  • intermetallic alloys
  • high-entropy alloys
  • metal matrix composites

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Published Papers (6 papers)

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Research

33 pages, 17525 KiB  
Article
Processing of Carbon Nanoparticle-Enriched AISI H11 Tool Steel Powder Mixtures in DED-LB/M for the AM of Forging Tools with Tailored Properties (Part II): Influence of Nanoscale Carbon Additives on Microstructure and Mechanical Properties
by Oliver Hentschel, Jan Kohlstruck, Pavel Krakhmalev, Dimitrios Nikas and Michael Schmidt
Alloys 2023, 2(4), 288-320; https://doi.org/10.3390/alloys2040020 - 14 Nov 2023
Cited by 2 | Viewed by 1641
Abstract
A promising approach for producing parts with outstanding properties in directed energy deposition (DED-LB/M) provides the application of tailored powder mixtures processed by applying in situ alloying strategies. In this work, DED-LB/M was used to manufacture multilayer specimens from AISI H11 steel powders [...] Read more.
A promising approach for producing parts with outstanding properties in directed energy deposition (DED-LB/M) provides the application of tailored powder mixtures processed by applying in situ alloying strategies. In this work, DED-LB/M was used to manufacture multilayer specimens from AISI H11 steel powders enriched with carbon nanoparticles (C-np) in concentrations of 0.1 wt.-% and 0.2 wt.-%. The scientific aim was to investigate the impact of C-np on the microstructural (particularly retained austenite content (RA-c) and grain size) and mechanical properties (specifically hardness and compression yield strength) of the manufactured specimens. It was shown that the addition of C-np to the H11 powder leads to a stronger distortion of martensite as well as significantly enhancing the RA-c. Furthermore, the C-np seem to favor the formation of finer martensite, as can be verified with XRD and EBSD. Under as-built conditions, the mean hardness increases from 653 ± 10 HV1 for the H11 sample to 770 ± 14 HV1 for the sample reinforced with 0.2 wt.-% C-np. At the same time, Y0.2% rises up from 1839 ± 61 MPa to 2134 ± 68 MPa. The hardness- and strength-increasing effect of the added C-np is retained even after heat treatment, similarly to the industrial standard. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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16 pages, 19582 KiB  
Article
On the Influence of Volumetric Energy Density and Inter-Layer Time on the Material Properties of Case-Hardening Steels
by Dominic Bartels, Moritz Elias Albert, Florian Nahr and Michael Schmidt
Alloys 2023, 2(3), 168-183; https://doi.org/10.3390/alloys2030013 - 25 Aug 2023
Viewed by 1593
Abstract
Case-hardening steels are gaining increasing interest in the field of laser powder bed fusion (PBF-LB/M) due to their excellent weldability. In combination with post-process carburization heat treatment, the surface properties can be improved to generate high-strength products. When manufacturing larger products by means [...] Read more.
Case-hardening steels are gaining increasing interest in the field of laser powder bed fusion (PBF-LB/M) due to their excellent weldability. In combination with post-process carburization heat treatment, the surface properties can be improved to generate high-strength products. When manufacturing larger products by means of PBF-LB/M, the in situ heat accumulation and the altered cooling rates affect the resulting material properties. Therefore, the fabrication of larger products requires an understanding on the influencing factors that affect the material properties. This work investigates the effect of different volumetric energy densities (VED) on the resulting microstructural and mechanical properties. It is found that the hardness decreases continuously along the build direction. The gradient depends on the applied energy and is stronger for higher energy inputs due to heat accumulation and lowered cooling rates. Furthermore, countering strategies are investigated to avoid process-specific hardness reduction along the build direction. This includes a reduced number of parts within the build job as well as a modified inter-layer time (ILT) between consecutive layers of the specimen. Applying a moderate inter-layer time helps to counter process-specific overheating, which is indicated by an almost homogeneous material hardness and melt pool size along the build direction. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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8 pages, 2857 KiB  
Article
Spectral Visualization of Alloy Reactions during Laser Melting
by Joerg Volpp, Himani Naesstroem, Lisanne Wockenfuss, Malte Schmidt and Knut Partes
Alloys 2023, 2(3), 140-147; https://doi.org/10.3390/alloys2030010 - 4 Jul 2023
Viewed by 1407
Abstract
Laser materials processing includes rapid heating to possibly high temperatures and rapid cooling of the illuminated materials. The material reactions can show significant deviations from equilibrium processing. During processing of complex materials and material combinations, it is mainly unknown how the materials react [...] Read more.
Laser materials processing includes rapid heating to possibly high temperatures and rapid cooling of the illuminated materials. The material reactions can show significant deviations from equilibrium processing. During processing of complex materials and material combinations, it is mainly unknown how the materials react and mix. However, it is important to know which chemical elements or compounds are present in the material to define the alloy. In addition, their distribution after rapid cooling needs to be better understood. Therefore, such alloy changes at rapid heating induced by laser illumination were created as pre-placed and pre-mixed powder nuggets. The energy input and the material ratio between the powder components were varied to identify characteristic responses. For the detection of reaction durations and mixing characteristics, the vapor plume content was assumed to contain the necessary information. Spectral measurements of the plume were used to identify indicators about process behaviors. It was seen that the spectral data give indications about the chemical reactions in the melt pool. The reactions of iron ore components with aluminum seem to require laser illumination to finish completely, although the thermite reaction should maintain the chemical reaction, likely due to the required melt mixing that enables the interaction of the reacting partners at all. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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10 pages, 6886 KiB  
Article
Additive Manufacturing of MnAl(C)-Magnets
by Victor Pacheco, Björn Skårman, Fredrik Olsson, Dennis Karlsson, Hilmar Vidarsson and Martin Sahlberg
Alloys 2023, 2(2), 100-109; https://doi.org/10.3390/alloys2020007 - 15 May 2023
Cited by 3 | Viewed by 2192
Abstract
Permanent magnets are becoming more and more relevant for modern society. As the most widely used permanent magnets contain rare-earth elements, the increased dependence on these strategic elements is worrisome, and the pursuit for rare-earth free alternatives has become a strategic goal in [...] Read more.
Permanent magnets are becoming more and more relevant for modern society. As the most widely used permanent magnets contain rare-earth elements, the increased dependence on these strategic elements is worrisome, and the pursuit for rare-earth free alternatives has become a strategic goal in many countries. The metastable and ferromagnetic τ-phase that forms in the MnAl(C) system is one of the most promising alternatives, and since its discovery, major efforts have been made to improve its performance and realize its full potential. One major factor that has prevented a widespread commercialization of MnAl(C) permanent magnets is their relatively low coercivity. Here, we demonstrate that additive manufacturing, using laser powder bed fusion, can be used to produce MnAl in its high-temperature polymorph (ε, hcp), which can be subsequently transformed, through post-heat treatments to the ferromagnetic τ-phase. Although we successfully obtained a preferential orientation of the ε-phase with <001> parallel to the build direction, this did not translate into a strong preferential orientation in the τ-phase, thus indicating that the phase transformation occurs by the migration of incoherent interfaces. The MnAl(C) samples are characterized by a density of ≈4.4 g/cm3, a saturation magnetization of 39.3 Am2/kg, a coercivity of 168 kA/m, and a remanence of 17.5 Am2/kg. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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11 pages, 5335 KiB  
Article
Processing of Aluminum Alloy 6182 with High Scanning Speed in LPBF by In-Situ Alloying with Zr and Ti Powder
by Kirstin Riener, Alexander Nagler, Ilse Letofsky-Papst and Gerhard Leichtfried
Alloys 2022, 1(3), 277-287; https://doi.org/10.3390/alloys1030018 - 8 Dec 2022
Cited by 2 | Viewed by 2708
Abstract
The demand for high-strength aluminum alloys for the laser powder bed fusion (LPBF) process is still growing. However, to date, the crack susceptibility of conventional alloys as well as the high prices for specially developed alloys are the main obstacles for the use [...] Read more.
The demand for high-strength aluminum alloys for the laser powder bed fusion (LPBF) process is still growing. However, to date, the crack susceptibility of conventional alloys as well as the high prices for specially developed alloys are the main obstacles for the use of high-strength aluminum alloys for LPBF. In this paper, crack-free LPBF samples with a relative density >99.9% were processed from AlMgSi1Zr (6182 series alloy) powder, to which 0.5 wt.-% Zr and 0.5 wt.-% Ti were added via mechanical mixing. No hot cracks were found in the µCT scans. Moreover, a fully equiaxed microstructure with a mean size of the α-Al grains of 1.2 µm was observed in the as-built parts. Al3(Zr,Ti) particles were observed, acting as efficient heterogeneous grain refiners for α-Al by building a semi-coherent interface. Unmolten Ti and Zr particles with sizes up to 80 µm were found in the α-Al phase. The resulting fine-grained microstructure led to a tensile strength of 329 ± 4 MPa and a total elongation at a break of 11.4 ± 0.9% after solution heat treatment, quenching in water, and subsequent artificial ageing. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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14 pages, 7589 KiB  
Article
Relationship between Microstructure, Mechanical Properties and Creep Behavior of a Cr-Rich Ferritic Stainless Steel Produced by Laser Powder Bed Fusion
by Dennis Karlsson, Thomas Helander, Eleonora Bettini, Carl-Johan Hassila, Johan Cedervall, Martin Sahlberg, Peter Harlin and Ulf Jansson
Alloys 2022, 1(3), 263-276; https://doi.org/10.3390/alloys1030017 - 5 Dec 2022
Cited by 3 | Viewed by 2925
Abstract
Additive manufacturing (AM) techniques such as laser powder bed fusion (L-PBF) are rapidly growing due to the inherent design freedom and possibilities to produce components not available with other techniques. This could be utilized in, e.g., the design of new types of heat [...] Read more.
Additive manufacturing (AM) techniques such as laser powder bed fusion (L-PBF) are rapidly growing due to the inherent design freedom and possibilities to produce components not available with other techniques. This could be utilized in, e.g., the design of new types of heat exchangers in ferritic stainless steels often used for high-temperature applications. Ferritic stainless steels are, however, difficult to weld and could therefore imply obstacles when produced by AM. When establishing the AM-produced alloy in new applications, it is therefore important to increase the understanding of the mechanical properties and high-temperature creep resistance in relation to the unique microstructure and printability. In this study, we have investigated the microstructure of Cr-rich SS446 ferritic stainless steel produced by L-PBF by microscopical and crystallographic techniques. The properties were compared to the conventionally produced tubes. The rapid cooling and reheating during the application of the subsequent powder layers during L-PBF introduces an intriguing microstructure consisting of a ferritic matrix with precipitation of austenite showing a Kurdjumov–Sachs orientation relationship. Characteristic dislocation networks were observed in the L-PBF samples and contributed to the good mechanical properties in the as-built state (more than twice the yield strength of the conventionally produced tube). Furthermore, the creep resistance at 800 °C was superior to the conventionally produced component, suggesting that L-PBF-produced SS446 possesses many advantages regarding production as compared to the conventional route. Full article
(This article belongs to the Special Issue Design of New Metallic Alloys for AM)
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