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Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys
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Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys

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

Deadline for manuscript submissions: 20 February 2026 | Viewed by 4318

Special Issue Editor

Dr. Ehsan Farabi

E-Mail Website
Guest Editor
School of Materials Science & Engineering, UNSW Sydney, Sydney, NSW 2052, Australia
Interests: physical metallurgy; additive manufacturing; Ti-alloys; phase transformation; interfaces; grain boundaries; microstructure

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (AM) has transformed the field of engineering by offering unparalleled flexibility in fabricating complex components using a wide range of metals and alloys with minimum waste and short lead times. Nevertheless, other enquiries persist, such as how the specific characteristics of metal additive manufacturing (AM) components are attained and, in connection, whether and how they might be intentionally devised. Acquiring this type of expertise is essential for enhancing the performance of AM parts, which is a crucial requirement for enabling their use in new and challenging applications. Conversely, the prevailing body of physical metallurgy textbook knowledge focuses on microstructural evolution under the assumption of equilibrium conditions. However, this assumption frequently proves to be incorrect in the context of AM, necessitating a reconsideration of this knowledge within the framework of AM. To uncover local processing–structure–property relationships, one area of emphasis in methodological research has been the advancement of microstructural analyses, facilitated by recent developments in characterization techniques that enable the acquisition of large three-dimensional structural datasets. This provides an outstanding opportunity for intentional microstructural manipulation to enhance the mechanical performance and overall functionality of AM builds.

The Special Issue, titled "Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys", is dedicated to publishing studies focused on the in-depth exploration of the additive manufacturing process applied to metallic materials, with a specific focus on investigating the microstructure and mechanical properties of the resulting materials. We extend an invitation to you to participate in this Special Issue by submitting papers that explore the strategic design of microstructures and defects, multi-scale materials characterization, in situ monitoring of AM processes, and a re-evaluation of physical metallurgy to develop the desired mechanical properties in manufactured products for various industrial applications.

Dr. Ehsan Farabi
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

  • metal additive manufacturing
  • fusion and solid-state metal additive manufacturing
  • wire and powder-based additive manufacturing
  • microstructure
  • mechanical properties
  • alloys
  • advanced materials design

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Published Papers (5 papers)

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Research

17 pages, 9468 KiB  
Article
Characterization of 3D-Printed Ti-6Al-4V Alloy Behavior During Cold Deformation
by Tin Brlić, Stoja Rešković, Sonja Kraljević Šimunković, Ljerka Slokar Benić and Samir Čimić
Materials 2025, 18(8), 1832; https://doi.org/10.3390/ma18081832 - 16 Apr 2025
Viewed by 259
Abstract
In this paper, the characterization of the deformation behavior of additively manufactured 3D-printed Ti-6Al-4V alloys during elastic and plastic deformation was carried out on the test samples deformation zone during cold deformation at room temperature. The additive manufacturing process direct metal laser sintering [...] Read more.
In this paper, the characterization of the deformation behavior of additively manufactured 3D-printed Ti-6Al-4V alloys during elastic and plastic deformation was carried out on the test samples deformation zone during cold deformation at room temperature. The additive manufacturing process direct metal laser sintering (DMLS) was used to 3D print the Ti-6Al-4V test samples. The temperature, i.e., stress, changes, strain, and strain rate distribution in the deformation zone of the 3D-printed Ti-6Al-4V alloy during elastic and plastic deformation were compared using static tensile tests, thermography, and digital image correlation (DIC) simultaneously. Periodic oscillations of the maximum temperature changes during elastic and plastic deformation were observed in the deformation zone. The thermoelastic effect with the lowest temperature drop between −0.47 °C and −0.54 °C was observed in the deformation zone of the 3D-printed Ti-6Al-4V testing samples during elastic deformation. A significant difference between strain and strain rate localization in the deformation zone was found immediately before fracture of the test sample. Maximum strain amounts in the range of 0.078–0.080 and strain rates of 0.025–0.027 s−1 were determined. Static tensile tests, thermography, and digital image correlation were proved to be valid methods for determining the localization of stress, strain, and strain rate in the deformation zone of 3D-printed Ti-6Al-4V test samples. Full article
(This article belongs to the Special Issue Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys)
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19 pages, 7054 KiB  
Article
Effect of Gradient Transition Layer on the Cracking Behavior of Ni60B (NiCrBSi) Coatings by Laser Cladding
by Qi Sun, Weiming Bi, Shan Yao, Wenxu Zhu, Wenjian Ma, Bing Hu, Cuimin Bao, Yong Zhang and Fangyong Niu
Materials 2025, 18(2), 419; https://doi.org/10.3390/ma18020419 - 17 Jan 2025
Cited by 2 | Viewed by 528
Abstract
Laser cladding technology is an effective method for producing wear-resistant coatings on damaged substrates, improving both wear and corrosion resistance, which extends the service life of components. However, the fabrication of hard and brittle materials is highly susceptible to the problem of cracking. [...] Read more.
Laser cladding technology is an effective method for producing wear-resistant coatings on damaged substrates, improving both wear and corrosion resistance, which extends the service life of components. However, the fabrication of hard and brittle materials is highly susceptible to the problem of cracking. Using gradient transition layers is an effective strategy to mitigate the challenge of achieving crack-free laser-melted wear-resistant coatings. This study presents the cracking issue of laser cladding Ni60B (NiCrBSi) coatings on 38CrMoAl (18CrNiMo7-6) steel by designing a gradient transition layer infused with varying amounts of Ni powder. We examine how different levels of Ni doping in the transition layer influence the fabrication of the Ni60B coating. The results indicate that the cracking mechanism of Ni60B is primarily due to the brittleness and hardness of the fusion cladding layer, which can result in cold cracks under residual tensile stress. Increasing the nickel content in the transition layer reduces the difference in thermal expansion coefficients between the cladding layer and the substrate. Additionally, the nickel in the transition layer permeates the cladding layer due to the laser remelting effect. The physical phase within the cladding layer transitions from the initial CrB, M7C3, and γ-Ni solid solution to γ-Ni solid solution and Ni-B-Si eutectic, with a small amount of boride and carbide hard phases. As the nickel doping in the transition layer increases, the proportion of the toughness phase dominated by Ni elements significantly rises, leading to a decrease in the hardness of the fused cladding layer. However, the average hardness of the fusion cladding layer in crack-free samples was measured at 397.5 ± 5.7 HV0.2, which is 91% higher than that of the substrate. Full article
(This article belongs to the Special Issue Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys)
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16 pages, 8792 KiB  
Article
Application of a 3D-Printed Part with Conformal Cooling in High-Pressure Die Casting Mould and Evaluation of Stress State During Exploitation
by Marcin Małysza, Robert Żuczek, Dorota Wilk-Kołodziejczyk, Krzysztof Jaśkowiec, Adam Bitka, Mirosław Głowacki, Łukasz Zięba and Stanisław Pysz
Materials 2024, 17(23), 5988; https://doi.org/10.3390/ma17235988 - 6 Dec 2024
Viewed by 879
Abstract
The article addresses stress formation in the structural 3D-printed elements of a high-pressure die casting die mould used for production of aluminum castings. The 3D-printed elements with conformal cooling are manufactured of 18Ni300 powder. Initial numerical calculations were performed on a test die [...] Read more.
The article addresses stress formation in the structural 3D-printed elements of a high-pressure die casting die mould used for production of aluminum castings. The 3D-printed elements with conformal cooling are manufactured of 18Ni300 powder. Initial numerical calculations were performed on a test die mould made of standard steel X40CrMoV5 to determine temperature distribution and stress state, providing a baseline for comparing 3D-printed 18Ni300 parts. A database for 18Ni300 material was developed, including optimal heat treatment parameters: aged at 560 °C for 8 h. The resulting tensile strength of approximately ~1600 MPa, yield strength 1550 MPa, and elongation 6–7%, with properties temperature-dependent from 20 °C to 600 °C. Results show that conformal cooling increases stress gradients, highlighting the demands on fatigue strength at elevated temperatures. The study revealed that the heat treatment significantly influences the final properties, with tensile strengths of 1400–2000 MPa and elongation from 1 to 8%. While the heat treatment has a greater impact on the mechanical properties than the printing parameters, optimizing the printing settings remains crucial for ensuring density and quality in the die moulds under cyclic loads. Full article
(This article belongs to the Special Issue Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys)
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14 pages, 9231 KiB  
Article
Hot Deformation Behavior of Free-Al 2.43 wt.% Si Electrical Steel Strip Produced by Twin-Roll Strip Casting and Its Effect on Microstructure and Texture
by Huihui Wang, Wanlin Wang, Peisheng Lyu and Shengjie Wu
Materials 2024, 17(13), 3152; https://doi.org/10.3390/ma17133152 - 27 Jun 2024
Viewed by 810
Abstract
Twin-roll strip casting (TRSC) technology has unique advantages in the production of non-oriented electrical steel. However, the hot deformation behavior of high-grade electrical steel produced by TRSC has hardly been reported. This work systematically studied the hot deformation behavior of free-Al 2.43 wt.% [...] Read more.
Twin-roll strip casting (TRSC) technology has unique advantages in the production of non-oriented electrical steel. However, the hot deformation behavior of high-grade electrical steel produced by TRSC has hardly been reported. This work systematically studied the hot deformation behavior of free-Al 2.43 wt.% Si electrical steel strip produced by twin-roll strip casting. During the simulated hot rolling test, deformation reduction was set as 30%, and the ranges of deformation temperature and strain rate were 750~950 °C and 0.01~5 s−1, respectively. The obtained true stress–strain curves show that the peak true stress decreased with an increase in the deformation temperature and with a decrease in the strain rate. Then, the effect of hot deformation parameters on microstructure and texture was analyzed using optical microstructure observation, X-ray diffraction, and electron backscattered diffraction examination. In addition, based on the obtained true stress–strain curves of the strip cast during hot deformation, the constitutive equation for the studied silicon steel strip was established, from which it can be found that the deformation activation energy of the studied steel strip is 83.367 kJ/mol. Finally, the kinetics model of dynamic recrystallization for predicting the recrystallization volume percent was established and was verified by a hot rolling experiment conducted on a rolling mill. Full article
(This article belongs to the Special Issue Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys)
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16 pages, 3811 KiB  
Article
The Effects of Heat Treatment on the Microstructure and Mechanical Properties of a Selective Laser Melted AlCoFeNi Medium-Entropy Alloy
by Xinyang Han, Xiangwei Li, Bokai Liao, Youzhao Zhang, Lei Xu, Xingpeng Guo and Shuyan Zhang
Materials 2024, 17(7), 1582; https://doi.org/10.3390/ma17071582 - 29 Mar 2024
Cited by 1 | Viewed by 1145
Abstract
A single body-centered cubic (BCC)-structured AlCoFeNi medium-entropy alloy (MEA) was prepared by the selective laser melting (SLM) technique. The hardness of the as-built sample was around 32.5 HRC. The ultimate tensile strength (UTS) was around 1211 MPa, the yield strength (YS) was around [...] Read more.
A single body-centered cubic (BCC)-structured AlCoFeNi medium-entropy alloy (MEA) was prepared by the selective laser melting (SLM) technique. The hardness of the as-built sample was around 32.5 HRC. The ultimate tensile strength (UTS) was around 1211 MPa, the yield strength (YS) was around 1023 MPa, and the elongation (El) was around 10.8%. A novel BCC + B2 + face-centered cubic (FCC) structure was formed after aging. With an increase in aging temperature and duration, the number of fine grains increased, and more precipitates were observed. After aging at 450 °C for 4 h, the formed complex polyphase structure significantly improved the mechanical properties. Its hardness, UTS, YS, and El were around 45.7 HRC, 1535 MPa, 1489 MPa, and 8.5%, respectively. The improvement in mechanical properties was mainly due to Hall–Petch strengthening, which was caused by fine grains, and precipitation strengthening, which was caused by an increase in precipitates after aging. Meanwhile, the FCC precipitates made the alloy have good toughness. The complex interaction of multiple strengthening mechanisms leads to a good combination of strength, hardness, and toughness. Full article
(This article belongs to the Special Issue Advances in Thermomechanical Processing and Additive Manufacturing of Engineering Alloys)
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