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Crystals
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Advanced Welding and Additive Manufacturing
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Advanced Welding and Additive Manufacturing

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

Deadline for manuscript submissions: 29 August 2025 | Viewed by 1195

Special Issue Editors

Dr. Chao Chen

E-Mail Website
Guest Editor
Key Laboratory of Automobile Materials, School of Materials Science and Engineering, Jilin University, Changchun 130025, China
Interests: welding; microstructures; additive manufacturing; welded joints; droplet transfer
Special Issues, Collections and Topics in MDPI journals
Dr. Guorui Sun

E-Mail Website
Guest Editor
Key Laboratory of Automobile Materials, School of Materials Science and Engineering, Jilin University, Changchun 130025, China
Interests: laser arc composite welding/additive manufacturing; intelligent and efficient repair and remanufacturing; integrated treatment of welding/additive manufacturing processes and component surfaces

Special Issue Information

Dear Colleagues,

With the advancement of Industry 4.0, metal-joining technologies and additive manufacturing (3D printing) are gradually becoming the core drivers of modern manufacturing. These technologies not only revolutionize traditional product design and production methods but also demonstrate significant application potential across various sectors such as aerospace, automotive manufacturing, medical devices, and energy. To foster academic exchange and technological progress in this field, our journal has established a Special Issue on "Advanced Welding and Additive Manufacturing", soliciting high-quality research papers, review articles, and technical reports from around the globe. This Special Issue will focus on, but is not limited to, the following research directions:

Metal-joining technologies：

1. Innovations in welding processes (such as laser welding, electron beam welding, friction stir welding, etc.);

2. The development and application of new joining materials;

3. Analysis of microstructure evolution and mechanical properties during the joining process;

4. Methods for joining multi-material composite structures and their reliability evaluation.

Additive Manufacturing Technologies：

1. The current status and future trends of mainstream additive manufacturing processes like metal powder bed fusion (PBF) and directed energy deposition (DED);

2. Optimization strategies for material characteristics, forming accuracy, and surface quality in additive manufacturing;

3. Case studies of additive manufacturing applications in complex structural components with a lightweight design;

4. The exploration of additive manufacturing processes for new metallic materials (such as ultra-high-strength steels, titanium alloys, nickel-based superalloys, etc.).

Dr. Chao Chen
Dr. Guorui Sun
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. Crystals 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 2100 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

  • welding
  • additive manufacturing
  • microstructure
  • mechanical properties

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

Published Papers (2 papers)

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Research

18 pages, 7231 KiB  
Article
Electron Beam Welding of Dissimilar Ti6Al4V and Al6082-T6 Alloys Using Magnetron-Sputtered Cu Interlayers
by Georgi Kotlarski, Darina Kaisheva, Maria Ormanova, Milka Atanasova, Angel Anchev, Vladimir Dunchev, Borislav Stoyanov and Stefan Valkov
Crystals 2025, 15(4), 373; https://doi.org/10.3390/cryst15040373 - 18 Apr 2025
Viewed by 289
Abstract
In the present work, the influence of a magnetron-sputtered copper interlayer on the process of electron beam welding of Ti6Al4V and Al6082-T6 plates was investigated. A sample without a filler was also prepared as a control. The microstructure, microhardness, and tensile properties of [...] Read more.
In the present work, the influence of a magnetron-sputtered copper interlayer on the process of electron beam welding of Ti6Al4V and Al6082-T6 plates was investigated. A sample without a filler was also prepared as a control. The microstructure, microhardness, and tensile properties of both samples were determined. Applying a copper interlayer resulted in the formation of an additional CuAl2 intermetallic compound in the form of a eutectic structure along the boundary of the aluminum crystal grains. A noticeable shift in the preferred crystallographic orientation of the aluminum phase from the denser {111} family of crystallographic planes in the case of the sample prepared without a filler towards less-dense ones such as {110}, {100}, and {311} in the case of applying a copper filler was observed. This was most probably caused by the lower free surface energy of the crystals oriented towards the {111} family of crystal planes, which favored the chemical bonding between the aluminum solid solution and the CuAl2 intermetallics. As a result of applying the copper interlayer, a noticeable increase in the microhardness of the weld seam was observed from 78 ± 2 HV0.05 to 136 ± 3 HV0.05. Applying a copper interlayer also led to an improved energy absorption capacity of the weld seam, as suggested by the increase in the UTS/YS ratio from 1.03 to 1.44. This could be explained by the smooth transition between the highly dissimilar Ti6Al4V and Al6082-T6 alloys. The UTS of the sample with the copper filler reached 208 MPa, which was about 60% of that of the base Al6082-T6 alloy. Full article
(This article belongs to the Special Issue Advanced Welding and Additive Manufacturing)
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22 pages, 8797 KiB  
Article
Distortion and Residual Stress Reduction Using Asynchronous Heating Sources for Multi-Robot Coordinated Wire-Arc Directed Energy Deposition
by Yongzhe Li, Chenxiao Zhang, Caowei Huang, Xiaoyu Wang, Guangjun Zhang and Yijun Zhou
Crystals 2025, 15(2), 155; https://doi.org/10.3390/cryst15020155 - 2 Feb 2025
Viewed by 716
Abstract
Multi-robot coordinated wire-arc directed energy deposition (MRC-WA-DED) has proliferated in recent decades, employing asynchronous independent heating sources to deposit material simultaneously. Beyond enhancing efficiency, MRC-WA-DED introduces a synergic effect between the heating sources, resulting in a controllable thermal field on the deposit component. [...] Read more.
Multi-robot coordinated wire-arc directed energy deposition (MRC-WA-DED) has proliferated in recent decades, employing asynchronous independent heating sources to deposit material simultaneously. Beyond enhancing efficiency, MRC-WA-DED introduces a synergic effect between the heating sources, resulting in a controllable thermal field on the deposit component. This research aims to investigate if the synergic effect is beneficial for residual stress and distortion reduction and how it can be applied to enhance the quality of MRC-WA-DEDed parts. A finite element model was developed to compare the thermodynamic response of WA-DED when both coordinated heating sources (CHSs) and a single heating source (SHS) are applied. Simulation and deposition experiments were carried out to clarify the influence of different coordination strategies on the fabricated component’s thermal behavior, stress distribution, and distortion conditions. The results indicate that the synergic effect of CHSs leads to a smoother temperature gradient than that accomplished by a SHS, reducing the maximum distortion of a single layer by 49.1%. As validated by actual depositions, the residual stress, maximum distortion, and hardness of a ten-layer component were reduced by 6.5%, 11.2%, and 18.6%, respectively. Full article
(This article belongs to the Special Issue Advanced Welding and Additive Manufacturing)
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