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Applied Sciences
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Additive Manufacturing of Alloys: Microstructure and Mechanical Performance
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Additive Manufacturing of Alloys: Microstructure and Mechanical Performance

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (10 July 2025) | Viewed by 5293

Special Issue Editors

Dr. Nthabiseng Maledi

E-Mail Website
Guest Editor
School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg 2050, South Africa
Interests: additive manufacturing; advanced engineering materials; welding corrosion; high temperature applications
Special Issues, Collections and Topics in MDPI journals
Dr. Fredrick Mwema

E-Mail Website
Guest Editor
Department of Mechanical & Construction Engineering, Northumbria University, Newcastle, UK
Interests: advanced manufacturing; surface engineering; thin film technologies; materials characterization

Special Issue Information

Dear Colleagues,

The inception of additive manufacturing and advances in its technologies have led to a steady increase in the production of advanced materials with unmatched mechanical properties. The adaptability of additive manufacturing made it possible to develop a wide range of alloys that could not be produced via conventional processing routes. These alloys are used in various industries such as the aerospace industry, the automotive industry, biomedical applications and the energy sector.

It is imperative that during the production of advanced alloys the synergy between the processing parameters, microstructure, mechanical properties, post processing methods and the environment is well-understood in order to successfully produce materials that meet specific performance requirements.

This Special Issue will be dedicated to research that focuses on recent developments in advanced materials and their mechanical performance in various industries.

Subjects that will be discussed in this Special Issue will focus not only on the development of advanced materials, but also on the optimization of processing parameters, post processing treatments and the interaction of the advanced materials with the environment.

Dr. Nthabiseng Maledi
Dr. Fredrick Mwema
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 250 words) can be sent to the Editorial Office for assessment.

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. Applied Sciences is an international peer-reviewed open access semimonthly 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 2400 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
  • parameter optimization
  • advanced materials
  • phase transformation
  • metals
  • mechanical properties
  • corrosion resistance
  • oxidation
  • heat treatment
  • post processing techniques

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Published Papers (3 papers)

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Research

12 pages, 2949 KB  
Article
Micro-Mechanical Properties and Corrosion Resistance of Zr-Based Metallic Glass Matrix Composite Coatings Fabricated by Laser Cladding Technology
by Wenle Wang and Zhifeng Yan
Appl. Sci. 2025, 15(17), 9698; https://doi.org/10.3390/app15179698 - 3 Sep 2025
Viewed by 734
Abstract
Laser cladding with ultrafast cooling rates enables effective fabrication of metallic glass matrix composite (MGMC) coatings, significantly enhancing the hardness, corrosion resistance, and mechanical properties of metallic substrates. In this study, a multi-layer Zr65Al7.5Ni10Cu17.5 (at. %) [...] Read more.
Laser cladding with ultrafast cooling rates enables effective fabrication of metallic glass matrix composite (MGMC) coatings, significantly enhancing the hardness, corrosion resistance, and mechanical properties of metallic substrates. In this study, a multi-layer Zr65Al7.5Ni10Cu17.5 (at. %) MGMC coating was successfully fabricated by laser cladding technology. The effects of the region-dependent microstructural evolution on micro-mechanical properties and corrosion resistance were systematically investigated. The results indicated that the high impurity content of the powder feedstock promoted the crystallization of the coating during laser cladding. Moreover, coarse columnar crystals in the bottom region of the coating nucleated epitaxially at the coating/substrate interface and propagated along the thermal gradient parallel to the building direction, while dendritic crystals dominated the middle region under moderate thermal gradients. In the top region, fine dendritic and equiaxed crystals deposited in the amorphous matrix, due to the lowest thermal gradient and the highest cooling rate. Correspondingly, nanoindentation results revealed that the top region exhibited peak hardness (H), maximum elastic modulus (E), and optimal H/E ratio, exceeding values in both the bottom region and substrate. Simultaneously, the metallic glass matrix composite coating demonstrated significantly better corrosion resistance than the substrate due to its amorphous phase and protective passive film formation. This work advances amorphous solidification theory while expanding applications of metallic glasses in surface engineering. Full article
(This article belongs to the Special Issue Additive Manufacturing of Alloys: Microstructure and Mechanical Performance)
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14 pages, 7337 KB  
Article
The Effects of Laser Power on the Performance and Microstructure of Inconel 718 Formed by Selective Laser Melting
by Yalong Wang, Lei Gao, Liyuan Yang, Tao Liu, Jianyin Miao, Yong Zang and Sheng Zhang
Appl. Sci. 2024, 14(21), 9686; https://doi.org/10.3390/app14219686 - 23 Oct 2024
Cited by 2 | Viewed by 2097
Abstract
In this study, the effects of laser power on the microstructure and mechanical properties of Inconel 718 formed by SLM were systematically studied. The results show that with the increase in laser power from 285 W to 360 W, the increase in working [...] Read more.
In this study, the effects of laser power on the microstructure and mechanical properties of Inconel 718 formed by SLM were systematically studied. The results show that with the increase in laser power from 285 W to 360 W, the increase in working temperature in the molten pool promoted the evaporation of gas and the vaporization of the low-melting-point alloy components, and the relative density gradually increased from 99.31% to 99.79%. In addition, with the increase in laser energy density, the microstructure gradually coarsened from columnar dendrites to cellular crystals. The nano-hardness of the material decreased with the increase in laser power. The nano-hardness of four groups of samples from 285 W to 360 W decreased form 3.43 GPa to 2.09 GPa, and the elastic modulus decreased form 205.72 GPa to 199.91 GPa. Full article
(This article belongs to the Special Issue Additive Manufacturing of Alloys: Microstructure and Mechanical Performance)
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12 pages, 2222 KB  
Article
Investigation into Process Parameter Optimization of Selective Laser Melting for Producing AlSi12 Parts Using ANOVA
by Neo Kekana, Mxolisi Brendon Shongwe, Khumbulani Mpofu and Rumbidzai Muvunzi
Appl. Sci. 2024, 14(15), 6519; https://doi.org/10.3390/app14156519 - 26 Jul 2024
Cited by 1 | Viewed by 1786
Abstract
In this study, AlSi12 alloy samples were produced via the selective laser melting (SLM) technique to produce high-density components with complex and customized parts for railway applications. Nonetheless, the production of dense samples necessitates the optimization of production process parameters. As a statistical [...] Read more.
In this study, AlSi12 alloy samples were produced via the selective laser melting (SLM) technique to produce high-density components with complex and customized parts for railway applications. Nonetheless, the production of dense samples necessitates the optimization of production process parameters. As a statistical design of the experimental method, response surface methodology was applied to optimize different combinations of SLM parameters. The outcomes were analyzed via analysis of variance (ANOVA) and signal-to-noise(S/N) ratios. The relationship between the hardness response to the process parameters (scanning speed and laser power) for determining the optimal processing conditions were examined. A hardness value of 133 HV was obtained. The process parameters were successfully optimized and the relationship between the parameters and the structures of the fabricated samples were reported. Full article
(This article belongs to the Special Issue Additive Manufacturing of Alloys: Microstructure and Mechanical Performance)
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