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Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition
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Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 January 2026 | Viewed by 2562

Special Issue Editor

Dr. Hui Huang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: welding mechanics; FEA simulation; additive manufacturing; engineering software
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and additive manufacturing are key technologies in the modern manufacturing industry that increasingly require high-quality products, high-volume deposition, and high-temperature application. New types of materials and structures, such as functionally graded materials and lattice structures, can be fabricated by additive manufacturing, which is superior to traditional processes. Advanced welding processes and additive manufacturing, as well as their digital twins, will significantly contribute to manufacturing technology and the process development of materials.

This Special Issue aims to highlight the latest progress on the welding process and additive manufacturing development towards the fabrication of new structures, the innovation of functional materials, and the optimization of manufacturing processes. Full-length research articles on welding technology development, weld consumables, powder material, the additive manufacturing process, numerical modeling, and process monitoring and control, among other topics, are welcome. The world’s leading experts in the field of welding and additive manufacturing will be invited to submit their findings. Accepted papers will be available via open access for the whole research community in order to increase the visibility of the authors’ innovative research findings.

Dr. Hui Huang
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. Journal of Manufacturing and Materials Processing 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 1800 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
  • process monitoring
  • modeling

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Related Special Issue

Published Papers (4 papers)

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Research

18 pages, 2473 KiB  
Article
Experimental Investigations on Microstructure and Mechanical Properties of L-Shaped Structure Fabricated by WAAM Process of NiTi SMA
by Vatsal Vaghasia, Rakesh Chaudhari, Sakshum Khanna, Jash Modi and Jay Vora
J. Manuf. Mater. Process. 2025, 9(7), 239; https://doi.org/10.3390/jmmp9070239 - 11 Jul 2025
Viewed by 461
Abstract
In the present study, an L-shaped multi-walled structure of NiTi shape memory alloy (SMA) was fabricated by using the wire arc additive manufacturing (WAAM) method on a titanium substrate. The present study aims to investigate the fabricated structure for microstructure, macrostructure, and mechanical [...] Read more.
In the present study, an L-shaped multi-walled structure of NiTi shape memory alloy (SMA) was fabricated by using the wire arc additive manufacturing (WAAM) method on a titanium substrate. The present study aims to investigate the fabricated structure for microstructure, macrostructure, and mechanical properties. The 40 layers of L-shaped structure were successfully fabricated at optimized parameters of wire feed speed at 6 m/min, travel speed at 12 mm/s, and voltage at 20 V. The macrographs demonstrated the continuous bonding among the layers with complete fusion. The microstructure in the area between the two middle layers has exhibited a mixture of columnar grains (both coarse and fine), interspersed with dendritic colonies. The microstructure in the topmost layers has exhibited finer colonial structures in relatively greater numbers. The microhardness (MH) test has shown the average values of 283.2 ± 3.67 HV and 371.1 ± 5.81 HV at the bottom and topmost layers, respectively. A tensile test was conducted for specimens extracted from deposition and build directions, which showed consistent mechanical behavior. For the deposition direction, the average ultimate tensile strength (UTS) and elongation (EL) were obtained as 831 ± 22.91 MPa and 14.32 ± 0.55%, respectively, while the build direction has shown average UTS and EL values of 774 ± 6.56 MPa and 14.16 ± 0.21%, respectively. The elongation exceeding 10% in all samples suggests that the fabricated structure demonstrates properties comparable to those of wrought metal. Fractography of all tensile specimens has shown good ductility and toughness. Lastly, a differential scanning calorimetry test was carried out to assess the retention of shape memory effect for the fabricated structure. The authors believe that the findings of this work will be valuable for various industrial applications. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)
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21 pages, 3031 KiB  
Article
Influence and Potential of Additive Manufactured Reference Geometries for Ultrasonic Testing
by Stefan Keuler, Anne Jüngert, Martin Werz and Stefan Weihe
J. Manuf. Mater. Process. 2025, 9(7), 224; https://doi.org/10.3390/jmmp9070224 - 1 Jul 2025
Viewed by 513
Abstract
This study researches and discusses the impact of different manufacturing-induced effects of additive manufacturing (AM), such as anisotropy on sound propagation and attenuation, on the production of test specimens for ultrasonic testing (UT). It was shown that a linear, alternating hatching pattern led [...] Read more.
This study researches and discusses the impact of different manufacturing-induced effects of additive manufacturing (AM), such as anisotropy on sound propagation and attenuation, on the production of test specimens for ultrasonic testing (UT). It was shown that a linear, alternating hatching pattern led to strong anisotropy in sound velocity and attenuation, with a deviation in sound velocity and gain of over 840 m/s and 9 dB, depending on the measuring direction. Furthermore, it was demonstrated that the build direction exhibits distinct acoustic properties. The influence of surface roughness on both the reflector and coupling surfaces was analyzed. It was demonstrated that post-processing of the reflector surface is not necessary, as varying roughness levels did not significantly change the signal amplitude. However, for high frequencies, pre-treatment of the coupling surface can improve sound transmission up to 6 dB at 20 MHz. Finally, the reflection properties of flat bottom holes (FBH) in reference blocks produced by AM and electrical discharge machining (EDM) were compared. The equivalent reflector size (ERS) of the FBH, which refers to the size of an idealized defect with the same ultrasonic reflection behavior as the measured defect, was determined using the distance gain size (DGS) method—a method that uses the relationship between reflector size, scanning depth, and echo amplitude to evaluate defects. The findings suggest that printed FBHs achieve an improved match between the ERS and the actual manufactured reflector size with a deviation of less than 13%, thereby demonstrating the potential for producing standardized test blocks through additive manufacturing. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)
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16 pages, 5105 KiB  
Article
On the Effect of the Cell Size and Beam Radius on the Compressive Strength and Residual Stresses of Ti-6Al-4V BCC Lattice Sandwich Structures Manufactured by L-PBF
by Gaetano Pollara, Dina Palmeri, Roberto Licari and Antonio Barcellona
J. Manuf. Mater. Process. 2025, 9(6), 192; https://doi.org/10.3390/jmmp9060192 - 10 Jun 2025
Viewed by 553
Abstract
Lattice structures offer the possibility to obtain lightweight components with additional functionalities, improving their shock absorption and thermal exchange properties. Recently, a body-centered cubic (BCC) lattice structure has been used to fabricate metal lattice sandwich panels (MLSPs) for aerospace applications. MLSPs are made [...] Read more.
Lattice structures offer the possibility to obtain lightweight components with additional functionalities, improving their shock absorption and thermal exchange properties. Recently, a body-centered cubic (BCC) lattice structure has been used to fabricate metal lattice sandwich panels (MLSPs) for aerospace applications. MLSPs are made of two external skins and a lattice core and can be produced thanks to laser powder bed fusion technology (LPBF), which is characterized by its superior printing accuracy with respect to other additive manufacturing processes for metals. Since few studies can be found in the literature on Ti-6Al-4V MLSPs, further work is needed to evaluate the mechanical response of these panels. Moreover, due to their design complexity and to avoid a costly experimental campaign, numerical simulation could be used to encourage the industrial application of these structures. In this paper, different cell configurations were printed and tested in compression to study the influence of the cell’s geometrical parameters, i.e., the cell size and beam radius, on the mechanical response of MLSPs. Numerical simulations of the LPBF of these geometries were also carried out to understand how the residual stresses can be varied by varying the cell configuration. A geometrical evaluation was carried out to quantitatively express the influence of the beam radius and cell size on the resulting volume fraction, which strongly influences the mechanical behavior and residual stress profiles of MLSPs. From the analysis, we found that the C2-R0.35 sample resulted in the configuration with the highest compressive strength, while C3-R0.25 showed the lowest and most uniform residual stress profile. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)
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17 pages, 22554 KiB  
Article
Static and Fatigue Strength of Graphene Nanoplatelet-Reinforced AA6061-T6 Friction Stir Spot-Welded Lap Joints
by Amir Alkhafaji, Daniel Camas and Hayder Al-Asadi
J. Manuf. Mater. Process. 2025, 9(3), 98; https://doi.org/10.3390/jmmp9030098 - 18 Mar 2025
Viewed by 562
Abstract
Despite the significant economic and environmental advantages of friction stir spot welding (FSSW) and its amazing results in welding similar and dissimilar metals and alloys, some of which were known as unweldable, it has some structural and characteristic defects such as keyhole formation, [...] Read more.
Despite the significant economic and environmental advantages of friction stir spot welding (FSSW) and its amazing results in welding similar and dissimilar metals and alloys, some of which were known as unweldable, it has some structural and characteristic defects such as keyhole formation, hook defects, and bond line oxidation. This has prompted researchers to focus on these defects and propose and investigate techniques to treat or compensate for their deteriorating effects on microstructural and mechanical properties under different loading conditions. In this experimental study, sheets of AA6061-T6 aluminum alloy with a thickness of 1.8 mm were employed to investigate the influence of reinforcement by graphene nanoplatelets (GNPs) with lateral sizes of 1–10 µm and thicknesses of 3–9 nm on the static and fatigue behavior of FSSW lap joints. The welding process was carried out with constant, predetermined welding parameters and a constant amount of nanofiller throughout the experiment. Cross-sections of as-welded specimens were tested by optical microscope (OM) and energy-dispersive spectroscopy (EDS) to ensure the incorporation of the nanographene into the matrix of the base alloy by measuring the weight percentage (wt.%) of carbon. Microhardness and tensile tests revealed a significant improvement in both tensile shear strength and micro-Vickers hardness due to the reinforcement process. The fatigue behavior of the GNP-reinforced FSSW specimens was evaluated under low and high cycle fatigue conditions. The reinforcement process had a detrimental effect on the fatigue life of the joints under cyclic loading conditions. The microstructural analysis and examinations conducted during this study revealed that this reduction in fatigue strength is attributed to the agglomeration of GNPs at the grain boundaries of the aluminum matrix, leading to porosity in the stir zone (SZ), the formation of continuous brittle phases, and a transition in the fracture mechanism from ductile to brittle. The experimental results, including fracture modes, are presented and thoroughly discussed. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models: 2nd Edition)
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