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Design, Process and Adoption of New Materials for Additive Manufacturing

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 August 2025 | Viewed by 2606

Special Issue Editor

Department of Mechanical Engineering, University of Texas at Dallas, Richardson, TX 75080, USA
Interests: cryogenic directed energy deposition (DED); wire arc additive manufacturing; ultrasonic nanocrystal surface modification; multi-material DED studied with experimental and modeling approaches; sustainable manufacturing; in-space manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The potential of additive manufacturing (AM) to revolutionize the production process across various platforms, from aerospace to biomedical engineering, continues to reach new heights. It further reshapes the modern industry’s transformative approach to designing and developing new materials. The development of these materials for AM is expected to enhance its various application-oriented performance, sustainability, and cost-effectiveness.

We encourage researchers to submit manuscripts that focus on, but are not limited to, the following areas:

  • Novel material formulations and their unique properties;
  • Functional gradient materials;
  • Biomaterials;
  • High-entropy alloys;
  • Theoretical and computational models that predict material behavior;
  • Sustainable and eco-friendly materials and practices;
  • High-performance polymers;
  • Composite materials.

This Special Issue aims to be a comprehensive resource, fostering collaboration and knowledge sharing among researchers, engineers, industry, and academic professionals. It seeks to explore the design, synthesis, and processing of new materials tailored for AM, including metals, polymers, ceramics, and composites.

Join us in shaping the future of additive manufacturing by contributing to this Special Issue, a collection of works that will inspire the next wave of technological advancements and industry transformations in the field of AM.

Dr. Wei Li
Guest Editor

MysoreNagaraja Kishore (kishore.mysorenagaraja@utdallas.edu)
Guest Editor Assistant

Manuscript Submission Information

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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

  • additive manufacturing
  • novel materials
  • functional gradient materials
  • biomaterials
  • high-entropy alloys
  • experimental and modeling
  • sustainable materials
  • high-performance polymers
  • composite materials

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Published Papers (2 papers)

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Research

20 pages, 5218 KiB  
Article
Toward Stabilizing the Keyhole in Laser Spot Welding of Aluminum: Numerical Analysis
by Saeid SaediArdahaei and Xuan-Tan Pham
Materials 2024, 17(19), 4741; https://doi.org/10.3390/ma17194741 - 27 Sep 2024
Viewed by 963
Abstract
The inherent instability of laser welding, particularly keyhole instability, poses significant challenges in industrial applications, leading to defects such as porosities that compromise weld quality. Various forces act on the keyhole and molten pool during laser welding, influencing process stability. These forces are [...] Read more.
The inherent instability of laser welding, particularly keyhole instability, poses significant challenges in industrial applications, leading to defects such as porosities that compromise weld quality. Various forces act on the keyhole and molten pool during laser welding, influencing process stability. These forces are categorized into those promoting keyhole opening and penetration (e.g., recoil pressure) and those promoting keyhole collapse (e.g., surface tension, Darcy’s damping forces), increasing instability and defect likelihood. This paper provides a comprehensive instability analysis to uncover key factors affecting keyhole and process instability, presenting future avenues for improving laser welding stability. Using a novel numerical method for simulating laser spot welding on aluminum with COMSOL Multiphysics 5.6, we investigated the effect of laser pulse shaping on keyhole and process instability. Our analysis focused on keyhole morphology, fluid flow behaviour, and force analysis. The results indicated that the curvature effect, Marangoni effect, and Darcy’s damping force are primary contributors to instability, with the curvature effect and Darcy’s damping force being the most dominant. Additionally, erratic and high-velocity magnitudes induce intense fluid flow behaviour, exacerbating keyhole instability. Moreover, single/quadruple peak triangular and variant rectangular ramp-down pulse shapes produced the least instability, while multi-pulse rectangular shapes exhibited intense instability. It was found that combining triangular/rectangular pulse shapes can reduce force and keyhole instability by smoothing spontaneous force spikes, resulting in a more stabilized welding process. Controlling fluid flow and abrupt force changes with appropriate pulse shaping is key to defect-free welded products. Full article
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16 pages, 9986 KiB  
Article
Microstructure and Shape Memory Properties of Gas Tungsten Arc Welded Fe-17Mn-5Si-10Cr-4Ni-(V, C) Shape Memory Alloy
by Dohyung Kim, Taeyoon Kim, Changwook Ji, Sangwon Ji, Wookjin Lee and Wangryeol Kim
Materials 2024, 17(18), 4547; https://doi.org/10.3390/ma17184547 - 16 Sep 2024
Cited by 2 | Viewed by 1220
Abstract
In this study, microstructure, mechanical, and shape memory properties of the welded Fe-based shape memory alloy (Fe-SMA) plates with a nominal composition of Fe-17Mn-5Si-10Cr-4Ni-(V, C) (wt.%) by gas tungsten arc welding were investigated. The optimal heat input to ensure full penetration of the [...] Read more.
In this study, microstructure, mechanical, and shape memory properties of the welded Fe-based shape memory alloy (Fe-SMA) plates with a nominal composition of Fe-17Mn-5Si-10Cr-4Ni-(V, C) (wt.%) by gas tungsten arc welding were investigated. The optimal heat input to ensure full penetration of the Fe-SMA plate with a thickness of 2 mm was found to be 0.12 kJ. The solidified grain morphology adjacent to the partially melted zone was columnar, whereas the equiaxed morphology emerged as solidification proceeded. The ultimate tensile decreased after welding owing to the much larger grain size of the fusion zone (FZ) and heat-affected zone (HAZ) than that of the base material (BM). Weldment showed lower pseudoelastic (PE) recovery strain and higher shape memory effect (SME) than those of the plate, which could be ascribed to the large grain size of the FZ and HAZ. Recovery stress (RS) slightly decreased after welding owing to lower mechanical properties of weldment. On the other hand, aging treatment significantly improved all PE recovery, SME, and RS via carbide precipitation. Digital image correlation analysis revealed that HAZ showed the lowest SME after heating and cooling, implying that the improved SME of FZ compensated for the low SME of the HAZ. Full article
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