Recent Advances in Multi-Material Metal Additive Manufacturing

Special Issue Editor

Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA 94550, USA
Interests: additive manufacturing; fracture mechanics; synchrotron X-rays; process monitoring; data analytics; particle dynamics

Special Issue Information

Dear Colleagues,

As the Guest Editor for the Journal of Manufacturing and Materials Processing, I am pleased to announce a Special Issue on the Recent Advances in Multi-Material Metal Additive Manufacturing (AM). Over the past 30 years, metal AM has evolved rapidly in various aspects, e.g., productivity and part quality. Many industrial sectors have started to adopt AM due to the unique capabilities that AM can offer. But almost with no exception, the application space of the metal AM technologies has been limited to single-material components. On the one hand, it is the technical difficulties, e.g., deposition method and material compatibility, that have slowed down the advancement of multi-material AM; on the other hand, the lack of known applications resulted in less investments. This problem will be solved as multi-material AM becomes more accessible and the meso-scale design starts to be incorporated into the design philosophy.

For this Special Issue, researchers are encouraged to submit their novel studies which address the challenges specifically in multi-material metal AM, including but not limited to:

  1. Design optimization;
  2. Feedstock delivery methods;
  3. Machine and laser control;
  4. Scan strategy optimization;
  5. Printing parameter optimization;
  6. Process monitoring;
  7. Characteristics of the multi-material interface;
  8. Defect formation mechanisms;
  9. Material compatibility;
  10. Alloy discovery;
  11. Post-processing treatments;
  12. Microstructural characteristics;
  13. Mechanical performance;
  14. Novel multi-material testing methods.

Dr. Ziheng Wu
Guest Editor

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Keywords

  • multi-material
  • metal additive manufacturing
  • powder bed fusion
  • graded material
  • defect formation mechanisms
  • solidification
  • microstructural characteristics
  • mechanical performance
  • alloy discovery
  • process and design optimization

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Published Papers (2 papers)

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Research

28 pages, 18753 KiB  
Article
Photopolymerization of Stainless Steel 420 Metal Suspension: Printing System and Process Development of Additive Manufacturing Technology toward High-Volume Production
by Hoa Xuan Nguyen, Bibek Poudel, Zhiyuan Qu, Patrick Kwon and Haseung Chung
J. Manuf. Mater. Process. 2024, 8(5), 191; https://doi.org/10.3390/jmmp8050191 - 1 Sep 2024
Viewed by 817
Abstract
As the metal additive manufacturing (AM) field evolves with an increasing demand for highly complex and customizable products, there is a critical need to close the gap in productivity between metal AM and traditional manufacturing (TM) processes such as continuous casting, machining, etc., [...] Read more.
As the metal additive manufacturing (AM) field evolves with an increasing demand for highly complex and customizable products, there is a critical need to close the gap in productivity between metal AM and traditional manufacturing (TM) processes such as continuous casting, machining, etc., designed for mass production. This paper presents the development of the scalable and expeditious additive manufacturing (SEAM) process, which hybridizes binder jet printing and stereolithography principles, and capitalizes on their advantages to improve productivity. The proposed SEAM process was applied to stainless steel 420 (SS420) and the processing conditions (green part printing, debinding, and sintering) were optimized. Finally, an SS420 turbine fabricated using these conditions successfully reached a relative density of 99.7%. The SEAM process is not only suitable for a high-volume production environment but is also capable of fabricating components with excellent accuracy and resolution. Once fully developed, the process is well-suited to bridge the productivity gap between metal AM and TM processes, making it an attractive candidate for further development and future commercialization as a feasible solution to high-volume production AM. Full article
(This article belongs to the Special Issue Recent Advances in Multi-Material Metal Additive Manufacturing)
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23 pages, 6841 KiB  
Article
Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers
by Nickolay S. Lubimyi, Mihail Chepchurov, Andrey A. Polshin, Michael D. Gerasimov, Boris S. Chetverikov, Anastasia Chetverikova, Alexander A. Tikhonov and Ardalion Maltsev
J. Manuf. Mater. Process. 2024, 8(2), 44; https://doi.org/10.3390/jmmp8020044 - 21 Feb 2024
Cited by 1 | Viewed by 2260
Abstract
This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation [...] Read more.
This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation and justification of the selected loads on the drill body arising from metal-cutting forces. The described methodology for designing a digital model of a metal-cutting tool for the purpose of its further production using SLM 3D metal printing methods facilitates the procurement of a digital model characterized by a reduced weight and volume of material. The described design technology involves the production of a thin-walled outer shell that forms the external technological surfaces necessary for the drill body, as well as internal structural elements formed as a result of topological optimization of the product shape. Much attention in this article is paid to the description of the technology for filling internal cavities with a viscous metal polymer, formed as a result of the topological optimization of the original model. Due to this design approach, it is possible to reduce the volume of 3D metal printing by 32%, which amounts to more than USD 135 in value terms. Full article
(This article belongs to the Special Issue Recent Advances in Multi-Material Metal Additive Manufacturing)
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