Additive Manufacturing Enabled Surface Engineering and Coatings on Conventional Steel Substrates

Dear Colleagues,

The Special Issue "Additive Manufacturing Enabled Surface Engineering and Coatings on Conventional Steel Substrates" invites original research articles, reviews and communications that explore the innovative use of additive manufacturing (AM) technologies as advanced tools for depositing functional coatings and performing surface modifications directly onto conventionally manufactured steel substrates. 

AM processes, particularly directed energy deposition (DED) variants such as laser cladding, laser metal deposition (LMD), extreme high-speed laser cladding (EHLA/HSLC), wire-fed DED and cold spray, enable precise, layer-by-layer deposition of metallic, composite or functionally graded materials. These AM-driven approaches offer distinct advantages over traditional coating methods (e.g., thermal spray, electroplating, or arc welding), including controlled dilution, strong metallurgical bonding, minimal heat-affected zones (HAZs), reduced distortion of the substrate, high deposition rates and the ability to tailor microstructures for enhanced performance. They are especially valuable for large-scale components, repair applications and creating thick, high-performance coatings on finished or in-service steel parts. 

Key research areas include, but are not limited to, the following:

• Process optimization (laser power, scan speed, powder/wire feed rate, shielding gas, deposition strategy) and its effects on coating geometry, dilution, interfacial bonding, residual stresses, and defect formation (e.g., porosity, cracks);
• Microstructure evolution, phase transformations, and mechanical properties (hardness, wear resistance, fatigue behavior) of coatings such as hardfacing alloys (e.g., Co-, Ni-, Fe-based), carbide-reinforced composites, stainless steels (e.g., 316L, 309L), or oxide-dispersion-strengthened (ODS) materials on steel substrates;
• Performance enhancements in wear resistance, corrosion protection (e.g., in aggressive environments such as seawater or high-temperature oxidation), tribological behavior, erosion resistance and repair/remanufacturing of high-value steel components in industries such as tooling, automotive, energy (power generation, wind turbines), petrochemical, maritime and aerospace;
• Comparative studies between conventional AM-DED techniques and high-speed variants, as well as hybrid approaches combining AM deposition with post-treatments;
• Modeling, simulation and in situ monitoring of melt pool dynamics, thermal history and solidification behavior;
• Sustainability aspects, including using recycled/waste materials as feedstock and energy-efficient processes.

This Special Issue will highlight how AM technologies drive next-generation surface engineering solutions for conventional steels, addressing industrial demands for durability, cost-effectiveness and extended service life while distinguishing from post-processing of additively manufactured components.

We welcome contributions that advance fundamental understanding, demonstrate practical applications or propose novel process innovations in this rapidly evolving field.

Dr. Nikša Čatipović
Dr. Massimo Rogante 
Dr. Anatoly Viktorovych Zavdoveev 
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-anonymized 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.