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Advanced Additive Manufacturing and Surface Modifications of Metallic Materials
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Advanced Additive Manufacturing and Surface Modifications of Metallic Materials

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Surface Characterization, Deposition and Modification".

Deadline for manuscript submissions: 31 May 2025 | Viewed by 2582

Special Issue Editors

Prof. Dr. Xie Xinliang

E-Mail Website
Guest Editor
Key Laboratory for Light-Weight Materials, Nanjing Technology University, Nanjing 211816, China
Interests: laser powder bed fusion process; cold spray technique; friction stir processing; coating modification
Special Issues, Collections and Topics in MDPI journals
Dr. Hongjian Wu

E-Mail Website
Guest Editor
Institute of Materials Technology, Helmut Schmidt University/University of the Federal Armed Forces Hamburg, Hamburg, Germany
Interests: additive manufacturing modeling; cold spray technique; robot-assisted manufacturing; coatings; material characterization; mechanical properties

Special Issue Information

Dear Colleagues,

Metal additive manufacturing is a rapidly expanding area owing to its flexibility to fabricate components of intricate geometries with customized features for a wide range of applications. However, these parts generally exhibit inadequate and poor surface quality in the as-built configuration. Surface modification techniques including cold spraying, friction stir processing, and laser or electron beam-based deposition processes are widely used to further improve the surface properties of metallic materials, such as corrosion resistance, wear resistance, microhardness, oxidation resistance, etc. This Special Issue focuses on various additive manufacturing techniques, such as laser powder bed fusion (LPBF), direct energy deposition (DED), cold spraying (CS), friction stir processing (FSP), etc., and various surface modification techniques are also included in this Special Issue, like friction stir processing, micro-arc oxidation, laser remelting, laser shot peening, etc. The materials studied can be pure metals, alloys, and composites. The properties for surface modification include but are not limited to corrosion resistance, wear resistance, oxidation resistance, cavitation resistance, antibacterial properties, and magnetic properties.

Prof. Dr. Xie Xinliang
Dr. Hongjian Wu
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. Coatings 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 additive manufacturing
  • solid-state additive manufacturing
  • surface modification
  • coatings
  • mechanical properties
  • corrosion property

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (3 papers)

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Research

23 pages, 7257 KiB  
Article
Effect of Nanosecond Laser Ablation and Oxidation on the Surface Wettability and Microstructure of Cu-ETP Copper Sheets
by Monika Walkowicz, Piotr Osuch, Małgorzata Zasadzińska, Paweł Strzępek and Klaudia Kludacz
Coatings 2025, 15(4), 383; https://doi.org/10.3390/coatings15040383 - 25 Mar 2025
Viewed by 334
Abstract
Nanosecond laser ablation effectively modifies Cu-ETP copper surfaces by controlling wettability and microstructure. This study examines the effects of nanosecond fiber laser processing and subsequent oxidation on surface evolution. The analyzed parameters include fluence (25.46–1018.59 J/cm2), wavelength (1064 nm), repetition rate [...] Read more.
Nanosecond laser ablation effectively modifies Cu-ETP copper surfaces by controlling wettability and microstructure. This study examines the effects of nanosecond fiber laser processing and subsequent oxidation on surface evolution. The analyzed parameters include fluence (25.46–1018.59 J/cm2), wavelength (1064 nm), repetition rate (25–1000 kHz), and pulse duration (2–500 ns). To investigate high energy densities, fluence values were set above typical ablation thresholds, inducing hierarchical surface structures affecting wettability. Post-ablation oxidation was examined under two conditions: natural oxidation in ambient air and accelerated oxidation via low-temperature annealing (200 °C) in air. Contact angle measurements revealed that over time, the initially hydrophilic (θ < 90°) laser-textured surfaces exhibited a transition toward hydrophobicity (θ > 90°), which can be attributed to the adsorption of airborne organic compounds rather than oxidation alone. In contrast, annealing significantly accelerated hydrophobicity, attributed to controlled copper oxide growth. SEM and EDS analyses confirmed that higher fluences enhanced roughness and oxidation, forming multi-scale textures and oxide layers, which influenced water repellency. These findings demonstrate that high-fluence laser ablation, combined with controlled oxidation, enables precise wettability engineering. This method provides an efficient strategy for tuning surface properties, offering potential applications in anti-corrosion coatings, self-cleaning surfaces, and heat exchangers, where hydrophobicity and durability are essential. Full article
(This article belongs to the Special Issue Advanced Additive Manufacturing and Surface Modifications of Metallic Materials)
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18 pages, 17663 KiB  
Article
Modification of Microstructure and Properties of Cold-Sprayed AlSi10Mg+TiB2 Composite by Friction Stir Process
by Yufei Jing, Xinliang Xie and Rengeng Li
Coatings 2024, 14(12), 1509; https://doi.org/10.3390/coatings14121509 - 29 Nov 2024
Viewed by 662
Abstract
This study investigates the influence of friction stir processing (FSP) on the microstructure, microhardness, and tribological properties of cold-sprayed AlSi10Mg+TiB2 composite coatings on Al substrates. Due to the limitation of particle deformation during cold spraying, there were still some porosities and poorly [...] Read more.
This study investigates the influence of friction stir processing (FSP) on the microstructure, microhardness, and tribological properties of cold-sprayed AlSi10Mg+TiB2 composite coatings on Al substrates. Due to the limitation of particle deformation during cold spraying, there were still some porosities and poorly bonded regions in the as-deposited AlSi10Mg+TiB2 composite coating, which decreased the mechanical performance. Applying FSP to the composite coating significantly reduced the porosity and improved metallurgical bonding. Further, the FSP process induced severe plastic deformation, leading to a more uniform distribution of TiB2 particles and a homogenized microstructure in the composite coating. The microhardness decreases progressively from the unaffected region through the heat-affected zone and thermomechanical-affected zone, and ultimately reaches its lowest value in the stir zone. The decreased microhardness is primarily attributed to the removal of the work-hardening effect. The FSP treatment seems to have little impact on the wear performance for both the pure AlSi10Mg and AlSi10Mg+TiB2 composite samples, as the coefficient of friction values and wear rates remain essentially unchanged after the FSP treatments. Full article
(This article belongs to the Special Issue Advanced Additive Manufacturing and Surface Modifications of Metallic Materials)
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15 pages, 3961 KiB  
Article
Forming Epoxy Coatings on Laser-Engraved Surface of Aluminum Alloy to Reinforce the Bonding Joint with a Carbon Fiber Composite
by Hongping Zhu, Jinheng Zhang, Fei Cheng, Jiangzhou Li, Bo Wu and Zhijie Zhao
Coatings 2024, 14(9), 1201; https://doi.org/10.3390/coatings14091201 - 18 Sep 2024
Cited by 2 | Viewed by 1185
Abstract
This study designed laser engraving and resin pre-coating (RPC) treatments on an aluminum alloy (AA) surface to construct through-the-thickness “epoxy pins” for improving the bonding strength with carbon fiber reinforced polymer (CFRP). A laser engraving treatment was used to create a pitted structure [...] Read more.
This study designed laser engraving and resin pre-coating (RPC) treatments on an aluminum alloy (AA) surface to construct through-the-thickness “epoxy pins” for improving the bonding strength with carbon fiber reinforced polymer (CFRP). A laser engraving treatment was used to create a pitted structure on the AA surface; higher wettability was acquired and greater vertical spaces were formed to impregnate epoxy resin, resulting in stronger mechanical interlocking. The RPC technique was further used to guide high-viscosity epoxy resin into pits to form the epoxy coatings and to minimize defects between the resin and the substrate. The bonding strength of the specimen treated with both laser engraving with a unit dimension of 0.3 mm and RPC increased up to 227.1% in comparison with that of the base. The failure modes of the hybrid composites changed from the debonding failure of the AA surface to the delamination-dominated failure of the laminated CFRP composites. It was confirmed that laser engraving is a feasible and effective method when combined with RPC for treating AAs to improve the bonding strength of AA-CFRP composites, which provides a reference for preparing high-performance hybrid composites with metals. Full article
(This article belongs to the Special Issue Advanced Additive Manufacturing and Surface Modifications of Metallic Materials)
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