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Progress and Challenges of Advanced Metallic Materials and Composites
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Progress and Challenges of Advanced Metallic Materials and Composites

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 30 December 2025 | Viewed by 2633

Special Issue Editor

Prof. Dr. Prashanth Konda Gokuldoss

E-Mail Website
Guest Editor
Department of Mechanical and Industrial Engineering, Tallinn University of Technology, Ehitajate tee 5, 19806 Tallinn, Estonia
Interests: circular economy; sustainable manufacturing; sustainable materials; metal matrix composites; powder metallurgy; metal foams; additive manufacturing/3D printing/solid free form fabrication (selective laser melting, binder jetting, electron beam melting); tribology and welding; light metals; Al and its alloys; nano-crystalline materials; solidification; meta-stable materials; bulk metallic glasses; high-pressure torsion (severe plastic deformation)
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue aims to present a series of featured articles and reviews exploring the latest advancements in the field of metallic materials and composites. Metallic materials and alloys have been traditionally used since the bronze age and have been constantly under development up to this age of semiconductors. They find applications in various industries, including, but not limited to, aerospace, automotive, biomedical, jewelry, tooling, and structural engineering. This Special Issue aims to compile key developments in the advancements of metallic materials and composites, especially their alloy strategy, processing, structure–property correlations, strengthening and failure mechanisms, sustainability and circular economy aspects, recycling, and modeling and simulation of materials and their properties. By combining theoretical insights and experimental observations with practical applications, this Special Issue aims to foster a deeper understanding of the potential of metallic materials and composites, guiding future research and development initiatives.

This Special Issue invites researchers, scholars, and industrialists to report on their recent findings on the development of metallic materials and composites. In addition, start-of-the-art reviews reflecting on specific aspects of the development of materials and composites are also welcome.

Prof. Dr. Prashanth Konda Gokuldoss
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. Materials 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 2600 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

  • metals and composites
  • alloy design
  • structure–property correlations
  • materials modeling
  • simulation
  • artificial intelligence
  • machine learning
  • sustainable materials
  • recycling

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Related Special Issue

Published Papers (4 papers)

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Research

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28 pages, 9743 KiB  
Article
Direct Reuse of Spent Nd–Fe–B Permanent Magnets
by Zara Cherkezova-Zheleva, Daniela Paneva, Sabina Andreea Fironda, Iskra Piroeva, Marian Burada, Maria Sabeva, Anna Vasileva, Kaloyan Ivanov, Bogdan Ranguelov and Radu Robert Piticescu
Materials 2025, 18(13), 2946; https://doi.org/10.3390/ma18132946 - 21 Jun 2025
Viewed by 862
Abstract
Nd–Fe–B permanent magnets are vital for numerous key technologies in strategic sectors such as renewable energy production, e-mobility, defense, and aerospace. Accordingly, the demand for rare earth elements (REEs) enormously increases in parallel to a significant uncertainty in their supply. Thus, research and [...] Read more.
Nd–Fe–B permanent magnets are vital for numerous key technologies in strategic sectors such as renewable energy production, e-mobility, defense, and aerospace. Accordingly, the demand for rare earth elements (REEs) enormously increases in parallel to a significant uncertainty in their supply. Thus, research and innovative studies are focus on the investigation of sustainable solutions to the problem and a closed-loop value chain. The present study is based on two benign-by-design approaches aimed at decreasing the recycling loop span by preparing standardized batches of EoL Nd–Fe–B materials to be treated separately depending on their properties, as well as using mechanochemical method for waste processing. The previously reported benefits of both direct recycling and mechanochemistry include significant improvements in processing metrics, such as energy use, ecological impact, technology simplification, and cost reduction. Waste-sintered Nd–Fe–B magnets from motorbikes were collected, precisely sorted, selected, and pre-treated. The study presents a protocol of resource-efficient recycling through mechanochemical processing of non-oxidized sintered EoL magnets, involving the extraction of Nd2Fe14B magnetic grains and refining the material’s microstructure and particle size after 120 min of high-energy ball milling in a zirconia reactor. The recycled material preserves the main Nd2Fe14B magnetic phase, while an anisotropic particle shape and formation of a thin Nd/REE-rich layer on the grain surface were achieved. Full article
(This article belongs to the Special Issue Progress and Challenges of Advanced Metallic Materials and Composites)
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13 pages, 6646 KiB  
Article
Prospect of Tellurium in High-Temperature Carburizing Gear Steels: An Industrial Study
by Jin Wang, Yun Bai, Wei Liu, Huiyu Xu, Qingsong Zhang, Guangwei Wang, Shufeng Yang and Jingshe Li
Materials 2025, 18(9), 2162; https://doi.org/10.3390/ma18092162 - 7 May 2025
Viewed by 367
Abstract
This work is a continuation of our previous research. We successfully produce low-carbon gear steel containing trace tellurium (Te) through industrial production line (EAF-LF-VD-CC), and we investigate the effects of a trace Te addition on the precipitation of MnS inclusions in sulfur-containing gear [...] Read more.
This work is a continuation of our previous research. We successfully produce low-carbon gear steel containing trace tellurium (Te) through industrial production line (EAF-LF-VD-CC), and we investigate the effects of a trace Te addition on the precipitation of MnS inclusions in sulfur-containing gear steel billets, the machinability of rods, and the high-temperature vacuum carburizing performance of rods. This study demonstrates that the addition of trace Te in steel can be achieved in industrial production without causing disruptions in the steelmaking process. The Te addition effectively induces spheroidization and refinement of MnS inclusions in industrial cast billets, showing good consistency with laboratory Te alloying experimental results. Furthermore, the Te addition reduces the deformation rate of MnS inclusions during industrial rolling processes. Benefiting from the spheroidization of MnS inclusions, the chip-breaking performance during the machining of Te-containing rods is significantly optimized, along with substantial improvement in machined surface roughness. The industrial rods exhibit excellent grain stability during 960 °C high-temperature vacuum carburizing, with carburizing rates significantly enhanced compared to conventional gear steels. This work comprehensively demonstrates the multifaceted effects of Te treatment on gear steel properties, particularly providing valuable references for developing high-temperature carburizing gear steels. Full article
(This article belongs to the Special Issue Progress and Challenges of Advanced Metallic Materials and Composites)
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Review

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32 pages, 5566 KiB  
Review
Additive Manufacturing of Metals Using the MEX Method: Process Characteristics and Performance Properties—A Review
by Katarzyna Jasik, Lucjan Śnieżek and Janusz Kluczyński
Materials 2025, 18(12), 2744; https://doi.org/10.3390/ma18122744 - 11 Jun 2025
Viewed by 490
Abstract
Compared to traditional manufacturing methods, additive manufacturing (AM) enables the production of parts with arbitrary structures, effectively addressing the challenges faced when fabricating complex geometries using conventional techniques. The dynamic development of this technology has led to the emergence of increasingly advanced materials. [...] Read more.
Compared to traditional manufacturing methods, additive manufacturing (AM) enables the production of parts with arbitrary structures, effectively addressing the challenges faced when fabricating complex geometries using conventional techniques. The dynamic development of this technology has led to the emergence of increasingly advanced materials. One of the best examples is metal–polymer composites, which allow the manufacturing of fully dense components consisting of stainless steel and titanium alloys, employing the widely available AM technology based on material extrusion (MEX). Metallic materials intended for this type of 3D printing may serve as an alternative to currently prevalent techniques including techniques like selective laser melting (SLM), owing to significantly lower equipment and material costs. Particularly applicable in low-volume production, where total costs and manufacturing time are critical factors, MEX technology of polymer–metallic composites offer relatively fast and economical AM of metal components, proving beneficial during the design of geometrically complex, and low-cost equipment. Due to the significant advancements in AM technology, this review focuses on the latest developments in the additive manufacturing of metallic components using the MEX approach. The discussion encompasses the printing process characteristics, materials tailored to this technology, and post-processing steps (debinding and sintering) necessary for obtaining fully metallic MEX components. Additionally, the article characterizes the printing process parameters and their influence on the functional characteristics of the resulting components. Finally, it presents the drawbacks of the process, identifies gaps in existing research, and outlines challenges in refining the technology. Full article
(This article belongs to the Special Issue Progress and Challenges of Advanced Metallic Materials and Composites)
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47 pages, 4349 KiB  
Review
Metal Nanocomposites as Biosensors for Biological Fluids Analysis
by Dan Chicea and Alexandra Nicolae-Maranciuc
Materials 2025, 18(8), 1809; https://doi.org/10.3390/ma18081809 - 15 Apr 2025
Viewed by 544
Abstract
Metal nanocomposites are rapidly emerging as a powerful platform for biosensing applications, particularly in the analysis of biological fluids. This review paper examines the recent advancements in the development and application of metal nanocomposites as biosensors for detecting various analytes in complex biological [...] Read more.
Metal nanocomposites are rapidly emerging as a powerful platform for biosensing applications, particularly in the analysis of biological fluids. This review paper examines the recent advancements in the development and application of metal nanocomposites as biosensors for detecting various analytes in complex biological matrices such as blood, serum, urine, and saliva. We discuss the unique physicochemical properties of metal nanocomposites, including their high surface area, enhanced conductivity, and tunable optical and electrochemical characteristics, which contribute to their superior sensing capabilities. The review will cover various fabrication techniques, focusing on their impact on the sensitivity, selectivity, and stability of the resulting biosensors. Furthermore, we will analyze the diverse applications of these biosensors in the detection of disease biomarkers, environmental toxins, and therapeutic drugs within biological fluids. Finally, we will address the current challenges and future perspectives of this field, highlighting the potential for improved diagnostic tools and personalized medicine through the continued development of advanced metal nanocomposite-based biosensors. Full article
(This article belongs to the Special Issue Progress and Challenges of Advanced Metallic Materials and Composites)
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