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Designs
Special Issues
Post-manufacturing Testing and Characterization of Materials
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Post-manufacturing Testing and Characterization of Materials

A special issue of Designs (ISSN 2411-9660).

Deadline for manuscript submissions: 31 May 2025 | Viewed by 5158

Special Issue Editor

Dr. Obeidi Muhannad

E-Mail Website
Guest Editor
School of Mechanical & Manufacturing Engineering, Dublin City University, Dublin, Ireland
Interests: additive manufacturing; laser surface processing; metal surface modification
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Materials science is witnessing a paradigm shift with the advent of advanced manufacturing techniques such as additive manufacturing, precision machining, forging, flow forming, and deep drawing. While these processes bestow unprecedented flexibility and efficiency, they also introduce a myriad of challenges in ensuring the integrity and performance of materials. Post-manufacturing, materials often undergo intricate microstructural and chemical composition changes, including phase transformation and grain size alteration, propelled by diverse cooling rates and mechanical stresses. For this reason, subsequent processing might be necessary in order to mitigate this problem and produce parts with more consistent properties.

These intrinsic alterations to materials post-production necessitate meticulous scrutiny to accurately discern the structural evolution and functional attributes of the materials. Understanding these transformations is pivotal for engineers and researchers to optimize material design and fabrication processes, ensuring superior performance and reliability across diverse applications. However, the journey towards comprehensive material characterization post-manufacturing is riddled with challenges. The multifaceted nature of these transformations demands a multifaceted approach towards testing and analysis. Traditional methods often fall short in capturing the nuances of these changes, necessitating the development and integration of advanced analytical techniques and methodologies. Moreover, the time-sensitive nature of modern manufacturing necessitates expeditious yet precise characterization protocols to facilitate rapid decision-making and process optimization. This urgency underscores the imperative of leveraging cutting-edge technologies, such as advanced microscopy, spectroscopy, and computational modelling, to unravel the intricacies of post-manufacturing material behaviour efficiently. Furthermore, the interdisciplinary nature of materials science underscores the need for collaboration and knowledge exchange across diverse domains. Collaborative efforts between materials scientists, engineers, and manufacturing experts are indispensable in navigating the complexities of post-manufacturing material testing and characterization, fostering innovation and driving progress in materials science and engineering.

In conclusion, the pursuit of excellence in material performance mandates a holistic approach towards post-manufacturing testing and characterization. By embracing innovation, collaboration, and advanced analytical techniques, we can unravel the enigma of material behaviour, paving the way for transformative advancements in manufacturing, engineering, and beyond.

In this Special Issue (SI), we delve into the critical significance of post-manufacturing testing and characterization of materials when trying to comprehend and delineate material properties. We invite authors to publish their original and review articles in this SI and share the results achieved in material properties and inspection.

Dr. Obeidi Muhannad
Guest Editor

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. Designs 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 1600 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
  • 3D printing
  • defect evaluation
  • mechanical stresses
  • deformation
  • simulation
  • material characterization
  • process control
  • post-manufacturing

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Published Papers (5 papers)

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Research

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13 pages, 3203 KiB  
Article
Effect of Curvature Shape on the Impact Strength of Additively Manufactured Acrylonitrile Butadiene Styrene Parts Produced via Fused Deposition Modeling
by Muhammad Fahad, Waseem Raja, Muhammad Naveed Iqbal and Abdul Waheed Awan
Designs 2024, 8(6), 132; https://doi.org/10.3390/designs8060132 - 8 Dec 2024
Viewed by 538
Abstract
Additive manufacturing (AM) has greatly revolutionized manufacturing due to its ability to manufacture complex shapes without the need for additional tooling. Most AM applications are based on geometries comprising curved shapes subjected to impact loads. The main focus of this study was on [...] Read more.
Additive manufacturing (AM) has greatly revolutionized manufacturing due to its ability to manufacture complex shapes without the need for additional tooling. Most AM applications are based on geometries comprising curved shapes subjected to impact loads. The main focus of this study was on investigating the influence of infill density and the radius of curvature on the impact strength of parts manufactured via an FDM process. Standard geometrical specimens with varying part infill densities and radii of curvature were produced and subjected to Charpy impact tests to evaluate their impact strength. The results suggest that the impact strength increases with the increased density caused by higher amounts of material as well as by the changing cross-sectional areas of the beads. Also, the radius of curvature of the parts shows a clear inverse relationship with the impact energy absorbed by the specimens (i.e., increasing the radius decreased the impact energy of the parts) produced via an FDM process, which can be explained using the beam theory of structural mechanics. The maximum value of impact strength obtained was 287 KJ/m2, and this was achieved at the highest infill density (i.e., solid) and for the smallest radius of curvature. Full article
(This article belongs to the Special Issue Post-manufacturing Testing and Characterization of Materials)
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16 pages, 5548 KiB  
Article
Optimizing Selective Laser Melting of Inconel 625 Superalloy through Statistical Analysis of Surface and Volumetric Defects
by Ali Shahrjerdi, Mojtaba Karamimoghadam, Reza Shahrjerdi, Giuseppe Casalino and Mahdi Bodaghi
Designs 2024, 8(5), 87; https://doi.org/10.3390/designs8050087 - 28 Aug 2024
Viewed by 1016
Abstract
This article delves into optimizing and modeling the input parameters for the selective laser melting (SLM) process on Inconel 625. The primary aim is to investigate the microstructure within the interlayer regions post-process optimization. For this study, 100 layers with a thickness of [...] Read more.
This article delves into optimizing and modeling the input parameters for the selective laser melting (SLM) process on Inconel 625. The primary aim is to investigate the microstructure within the interlayer regions post-process optimization. For this study, 100 layers with a thickness of 40 µm each were produced. Utilizing the design of experiments (DOE) methodology and employing the Response Surface Method (RSM), the SLM process was optimized. Input parameters such as laser power (LP) and hatch distance (HD) were considered, while changes in microhardness and roughness, Ra, were taken as the responses. Sample microstructure and surface alterations were assessed via scanning electron microscopy (SEM) analysis to ascertain how many defects and properties of Inconel 625 can be controlled using DOE. Porosity and lack of fusion, which were due to rapid post-powder melting solidification, prompted detailed analysis of the flaws both on the surfaces of and in terms of the internal aspects of the samples. An understanding of the formation of these imperfections can help refine the process for enhanced integrity and performance of Inconel 625 printed material. Even slight directional changes in the columnar dendrite structures are discernible within the layers. The microstructural characteristics observed in these samples are directly related to the parameters of the SLM process. In this study, the bulk samples achieved a microhardness of 452 HV, with the minimum surface roughness recorded at 9.9 µm. The objective of this research was to use the Response Surface Method (RSM) to optimize the parameters to result in the minimum surface roughness and maximum microhardness of the samples. Full article
(This article belongs to the Special Issue Post-manufacturing Testing and Characterization of Materials)
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15 pages, 8322 KiB  
Article
Computational Investigation of the Fluidic Properties of Triply Periodic Minimal Surface (TPMS) Structures in Tissue Engineering
by Muhammad Noman Shahid, Muhammad Usman Shahid, Shummaila Rasheed, Muhammad Irfan and Muhannad Ahmed Obeidi
Designs 2024, 8(4), 69; https://doi.org/10.3390/designs8040069 - 10 Jul 2024
Cited by 1 | Viewed by 1331
Abstract
Tissue engineering, a rapidly advancing field in medicine, has made significant strides with the development of artificial tissue substitutes to meet the growing need for organ transplants. Three-dimensional (3D) porous scaffolds are widely utilized in tissue engineering, especially in orthopedic surgery. This study [...] Read more.
Tissue engineering, a rapidly advancing field in medicine, has made significant strides with the development of artificial tissue substitutes to meet the growing need for organ transplants. Three-dimensional (3D) porous scaffolds are widely utilized in tissue engineering, especially in orthopedic surgery. This study investigated the fluidic properties of diamond and gyroid structures with varying porosity levels (50–80%) using Computational Fluid Dynamics (CFD) analysis. The pressure and velocity distributions were analyzed, and it was observed that the pressure decreased gradually, whereas the velocity increased in the central area of the surface structures. Specifically, the pressure drop ranged from 2.079 to 0.984 Pa for the diamond structure and from 1.669 to 0.943 Pa for the gyroid structure as the porosity increased from 50% to 80%. It was also found that the permeability increased as the porosity level increased, with values ranging from 2.424×10−9 to 5.122×10−9 m2 for the diamond structure and from 2.966×10−9 to 5.344×10−9 m2 for the gyroid structure. The wall shear stress (WSS) was also analyzed, showing a consistent decrease with increased porosity for both types of structures, with WSS values ranging from 9.903×10−2 to 9.840×10−1 Pa for the diamond structure and from 1.150×10−1 to 7.717×10−2 Pa for the gyroid structure. Overall, this study provides insights into the fluidic properties of diamond and gyroid structures, which can be useful in various applications such as tissue engineering. Full article
(This article belongs to the Special Issue Post-manufacturing Testing and Characterization of Materials)
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15 pages, 16558 KiB  
Article
Investigation on the Microstructure and Micro-Mechanical Properties of Thermal-Sprayed NiCoCrAlY High Entropy Alloy Coating
by Animesh Kumar Basak, Nachimuthu Radhika, Chander Prakash and Alokesh Pramanik
Designs 2024, 8(2), 37; https://doi.org/10.3390/designs8020037 - 20 Apr 2024
Cited by 4 | Viewed by 1249
Abstract
NiCoCrAlY high entropy alloy (HEA) coating (47.1 wt.% Ni, 23 wt.% Co, 17 wt.% Cr, 12.5 wt.% Al, and 0.4 wt.% Y) was deposited on a stainless steel subtract by atmospheric plasma spraying (APS). The as-deposited coating was about 300 μm thickness with [...] Read more.
NiCoCrAlY high entropy alloy (HEA) coating (47.1 wt.% Ni, 23 wt.% Co, 17 wt.% Cr, 12.5 wt.% Al, and 0.4 wt.% Y) was deposited on a stainless steel subtract by atmospheric plasma spraying (APS). The as-deposited coating was about 300 μm thickness with <1% porosity. The microstructure of the coating consisted of dispersed secondary phases/intermetallics in the solid solution. The stress–strain behaviour of this coating was investigated in micro-scale with the help of in situ micro-pillar compression. The experimental results show that yield and compressive stress in the cross-section of the coating was higher (1.27 ± 0.10 MPa and 2.19 ± 0.10 GPa, respectively) than that of the planar direction (0.85 ± 0.09 MPa and 1.20 ± 0.08 GPa, respectively). The various secondary/intermetallic phases (γ′–Ni3Al, β–NiAl) that were present in the coating microstructure hinder the lattice movement during compression, according to Orowan mechanism. In addition to that, the direction of the loading to that of the orientation of the phase/splat boundaries dictate the crack propagation architecture, which results in difference in the micro-mechanical properties. Full article
(This article belongs to the Special Issue Post-manufacturing Testing and Characterization of Materials)
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Review

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19 pages, 2448 KiB  
Review
A Systematic Evaluation of Design Freedoms and Restrictions of Lattice Structures Used as Interlock Bonds
by Raphael Freund, Karl Hilbig and Thomas Vietor
Designs 2024, 8(5), 97; https://doi.org/10.3390/designs8050097 - 29 Sep 2024
Viewed by 576
Abstract
Additive manufacturing provides new possibilities in product design compared to traditional manufacturing processes. Particularly additive material extrusion offers the freedom to combine multiple materials in a single component without additional steps. However, combining multiple materials often leads to reduced adhesion, which can hinder [...] Read more.
Additive manufacturing provides new possibilities in product design compared to traditional manufacturing processes. Particularly additive material extrusion offers the freedom to combine multiple materials in a single component without additional steps. However, combining multiple materials often leads to reduced adhesion, which can hinder the creation of high-strength designs. This issue can be largely mitigated using the geometric freedom of additive manufacturing to produce interlocking structures. This publication investigates the use of lattice structures as interlocking bonds in multi-material applications. The aim is to aid the design of suitable lattice structures by collecting geometric freedoms of lattices, application requirements, and manufacturing constraints, for this information to be used in suitable designs in the future. Initially, the general design freedoms of lattice structures are compiled and explained. Subsequently, these design freedoms are narrowed down based on the specific requirements for interlocking bonds and the limitations imposed by geometry and material combinations during manufacturing. The publication concludes with design recommendations that can be used as the basis for interlock bonds. Suitable lattice designs should aim for high interconnectivity, interconnected porosity, and a high number of similar strut structures, all the while maintaining low dimensions in the interface direction. Full article
(This article belongs to the Special Issue Post-manufacturing Testing and Characterization of Materials)
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