Advances in Additive Manufacturing of Metal Alloys: Microstructure, Mechanical Behavior, and Surface Performance

Special Issue Editor


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Guest Editor
Materials Science and Metallurgical Engineering Department, University of Oviedo, Asturias, Spain
Interests: materials; microstructure mechanical properties; material characterization metals heat treatment failure analysis

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) of metal alloys has emerged as a transformative approach to materials processing, enabling the design and fabrication of complex geometries with tailored properties. This special issue aims to highlight recent advances in metal AM, with particular emphasis on the relationships between processing parameters, microstructural evolution, mechanical performance, and surface-related properties such as wear and corrosion resistance.

We invite original research contributions that explore the influence of manufacturing parameters, alloy composition, post-processing treatments (e.g., heat treatment, surface modification, among others), and microstructure on the in-service performance of metallic components. Topics of interest include mechanical behaviour, tribological performance, corrosion mechanisms, and related phenomena.

This special issue seeks to gather high-quality evidence to support the optimisation of manufacturing and post-processing strategies, with the goal of enhancing the reliability and functional performance of metal parts produced by AM. Ultimately, the initiative aims to advance AM technologies to meet the demands of increasingly challenging service environments.

We look forward to receiving your contributions.

Dr. Alejandro González-Pociño
Guest Editor

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Keywords

  • additive manufacturing
  • metal alloys
  • microstructure
  • mechanical properties
  • corrosion resistance
  • wear behavior
  • heat treatment
  • alloy design
  • service performance

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Published Papers (3 papers)

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Research

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23 pages, 3596 KB  
Article
Analysis and Characterization of Axially Joined Friction-Welded Ti6Al4V Alloy Rods
by Mthobisi Zulu, Peter Madindwa Mashinini, Tshepo Ntsoane, Andrew Venter, Ryno van der Merwe and Deon Marais
J. Manuf. Mater. Process. 2026, 10(3), 79; https://doi.org/10.3390/jmmp10030079 - 26 Feb 2026
Viewed by 532
Abstract
The effect of process inputs in the friction welding of Ti6Al4V alloy rods was investigated through the analysis of residual stresses, microstructure, chemical phases and hardness testing of the weld joints. The rods were welded using different combinations of process inputs. The results [...] Read more.
The effect of process inputs in the friction welding of Ti6Al4V alloy rods was investigated through the analysis of residual stresses, microstructure, chemical phases and hardness testing of the weld joints. The rods were welded using different combinations of process inputs. The results revealed variations in residual stresses, hardness and microstructure of the weld joints when weld inputs were varied. Peak compressive residual stresses were obtained at the centre of the weld interface, where the grains were very fine. The joints with a greater volume fraction of martensitic grains had elevated residual stress values. The maximum compressive residual stress values were obtained at the weld interface, with high hardness results. A further investigation was conducted to study the relationship between the residual stresses, microstructure and mechanical properties of the weld joint. Full article
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17 pages, 6482 KB  
Article
Effect of Post-Build Annealing on the Microstructure and Mechanical Properties of LPBF-Processed AlSn10Pb10 Alloy
by Kirill O. Akimov, Alexander L. Skorentsev, Nikolay M. Rusin, Vadim E. Likharev, Dmitry P. Il’yashchenko and Andrey I. Dmitriev
J. Manuf. Mater. Process. 2026, 10(3), 77; https://doi.org/10.3390/jmmp10030077 - 24 Feb 2026
Viewed by 604
Abstract
The work studied the effect of high-temperature annealing on the phase composition, microstructure, and mechanical properties of an AlSn10Pb10 vol.% alloy obtained by laser powder bed fusion (LPBF). For this purpose, a series of anneals was carried out in the temperature range of [...] Read more.
The work studied the effect of high-temperature annealing on the phase composition, microstructure, and mechanical properties of an AlSn10Pb10 vol.% alloy obtained by laser powder bed fusion (LPBF). For this purpose, a series of anneals was carried out in the temperature range of 200–500 °C with a duration of 30 min. Using X-ray diffraction, it was determined that the annealed samples had a three-phase structure consisting of Al, β-Sn, and α-Pb phases, with a gradual decrease in their lattice elastic strain and dislocation density as the heating temperature increased. Analysis of the obtained SEM images revealed that these changes were accompanied by the coarsening of Sn and Pb inclusions and growth of the pure aluminum areas. As a result of the described structural changes with increasing annealing temperature, the ultimate compressive strength of the alloy monotonically decreased from 108 MPa (in the as-built state) to 75 MPa after annealing at 500 °C. The alloy’s ductility (strain at peak stress) also improved and reached a maximum of 26% after annealing at 400 °C. Compression test results showed that the optimal combination of ductility and strength of the LPBF-processed AlSn10Pb10 alloy was observed after annealing at 400 °C. Full article
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Review

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45 pages, 6271 KB  
Review
Progresses and Challenges in Additive Manufacturing of Bulk Metallic Glasses
by Md Mahbubur Rahman, Raju Ahammad, Asif Karim Neon, Mukitur Rhaman, Md Jonaet Ansari, Md Nizam Uddin, Md Mainul Islam and Muhammad Altaf Nazir
J. Manuf. Mater. Process. 2026, 10(4), 121; https://doi.org/10.3390/jmmp10040121 - 30 Mar 2026
Cited by 1 | Viewed by 1173
Abstract
Bulk metallic glasses (BMGs) are a type of amorphous metal with a high degree of mechanical strength, elasticity and corrosion resistance, properties that are highly influenced by composition and the processing of the material. BMGs can be applied in advanced engineering fields, such [...] Read more.
Bulk metallic glasses (BMGs) are a type of amorphous metal with a high degree of mechanical strength, elasticity and corrosion resistance, properties that are highly influenced by composition and the processing of the material. BMGs can be applied in advanced engineering fields, such as aerospace, biomedical, MEMS, and industrial applications. Additive manufacturing (AM) is revolutionary in producing intricate BMG parts whilst maintaining the amorphous structure. The current review critically evaluates the recent development in AM of BMGs, such as the development of selective laser melting, electron beam melting, and directed energy deposition, and new classes of hybrid strategies. Enhancements in dimensional accuracy, amorphous retention, microstructural tailoring and functional performance are emphasized along with computational and real-time process optimization strategies to improve overall manufacturing efficiency and material quality. Subsequently, the challenges that still exist are addressed in the review, including crystallization during printing, the buildup of stress, printable thickness, complicated geometries, oxidation, contamination, and heterogeneous amorphous fractions. Lastly, multi-material printing, scalable AM approaches, and AI-assisted design solutions are key features of future perspectives to solve existing restrictions. The review provides an excellent guidance for the researcher and engineer interested in advancing additive manufacturing of BMGs with the best structure–property relations. Full article
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