Applications of Additive Manufacturing and Numerical Simulation in High-Performance Metallic Materials

A special issue of Crystals (ISSN 2073-4352). This special issue belongs to the section "Crystalline Metals and Alloys".

Deadline for manuscript submissions: 20 October 2026 | Viewed by 749

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School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China
Interests: additive manufacturing; machine learning; superalloys; microstructural control; severe plastic deformation
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Special Issue Information

Dear Colleagues,

Additive Manufacturing (AM) has revolutionized the production of complex, lightweight, and customized components across aerospace, biomedical, and automotive industries. However, ensuring the reliability and repeatability of AM processes, particularly for high-performance metals, remains a significant challenge. This Special Issue, ‘Applications of Additive Manufacturing and Numerical Simulation in High-Performance Metallic Materials’, is dedicated to the pivotal role of computational modeling and its essential integration with experimental validation. We seek contributions that explore the synergy between advanced numerical techniques and AM technologies, with a special interest in studies combining simulation with experimental data for high-performance metallic materials (e.g., nickel-based superalloys, titanium alloys, high-strength steels). Topics of interest include multi-scale and multi-physics simulations of melting, solidification, and thermal stress; microstructure evolution and mechanical properties; topology optimization for design-for-AM; and digital twin frameworks. By bridging the gap between digital models and physical processes, this Special Issue aims to showcase cutting-edge research that accelerates process qualification, enhances final part quality, and unlocks the full design freedom offered by Additive Manufacturing.

Dr. Yunwei Gui
Prof. Dr. Umberto Prisco
Guest Editors

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Keywords

  • additive manufacturing
  • numerical simulation
  • high-performance metals
  • multi-physics modeling
  • experimental validation
  • process-microstructure-property relationships
  • topology optimization
  • residual stress
  • digital twin
  • powder bed fusion

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Published Papers (1 paper)

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Research

10 pages, 1959 KB  
Article
In Situ Synchrotron Radiation Computed Tomography Study on Fatigue Damage Evolution of Additively Manufactured Ti-6Al-4V Alloy
by Hui Wang, Guangcheng Fan and Yu Xiao
Crystals 2026, 16(3), 195; https://doi.org/10.3390/cryst16030195 - 11 Mar 2026
Viewed by 479
Abstract
Additive manufacturing (AM) of Ti-6Al-4V alloy is widely used in aerospace and medical fields due to its excellent strength and corrosion resistance. However, the microstructural heterogeneity induced by the AM process often results in fatigue properties inferior to those of their forged counterparts. [...] Read more.
Additive manufacturing (AM) of Ti-6Al-4V alloy is widely used in aerospace and medical fields due to its excellent strength and corrosion resistance. However, the microstructural heterogeneity induced by the AM process often results in fatigue properties inferior to those of their forged counterparts. Synchrotron Radiation Computed Tomography (SR-CT) was employed to conduct an in situ three-dimensional investigation of fatigue damage evolution in Ti-6Al-4V alloy fabricated via laser powder bed fusion (LPBF). Experimental results revealed phenomena of crack bridging and deflection, accompanied by the consistent presence of local high-density zones (LHDZs) throughout the fatigue damage progression. Combined with quantitative analysis of crack propagation rates, the influence of LHDZs on fatigue damage evolution was analyzed, and the relationship between AM processes, LHDZs, and fatigue damage was discussed. The results indicate that the basket-weave α-phase microstructure in Ti-6Al-4V prepared by LPBF exhibits a high correlation with the distribution of LHDZs, and the orientation of LHDZs aligns with the crack propagation direction. By adjusting process parameters such as cooling rate and temperature gradient, the formation of LHDZs can be modified, thereby influencing the fatigue properties of the material. This provides theoretical support for achieving process optimization of the fatigue properties of Ti-6Al-4V alloy prepared via LPBF. Full article
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