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Numerical Simulation of Materials Processing

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

Deadline for manuscript submissions: 20 October 2025 | Viewed by 524

Special Issue Editors


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Guest Editor
Computational Mechanics and Materials, Idaho National Laboratory, Idaho Falls, ID 83415, USA
Interests: microstructural evolution; multiscale modeling; phase-field modeling; nuclear materials; advanced manufacturing

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Guest Editor
Department of Nuclear Engineering, North Carolina State University, Raleigh, NC, USA
Interests: additive manufacturing; process modeling; multiphysics modeling; fracture mechanics; finite element modeling

Special Issue Information

Dear Colleagues,

Material processing techniques govern the microstructure and properties of a material, which influences the material’s performance in engineering applications. Understanding the role of material processing conditions on the material behvaior is crucial for developing new materials and designing new components. Advanced manufacturing techniques have recently gained significant interest across various industries due to their ability to produce complex structures in a shorter time, facilitating faster material developments. These techniques have the potential to change the paradigm of new material and component designs for various engineering applications by producing new alloys and graded materials by facilitating innovative and hybrid component designs. Therefore, it is important to understand how the process conditions influence the material’s properties, and behavior. Numerical modeling approaches provide a cost-effective method to simulate different aspects of the manufacturing process and correlate the process conditions to the material’s microstructure, properties and performance. Recent advancements in numerical modeling techniques such as finite element, cellular automata, phase-field, computational fluid dynamics, level-set, finite volume, and GPU-based modeling have made the computational approaches more efficient.

This Special Issue will cover new findings on the numerical modeling of advanced material processing techniques and associated material evolution. Processes of interest include, but are not limited to, the directed energy deposition method, laser powder bed fusion method, advanced sintering techniques, diffusion bonding, joining of dissimilar materials, and laser welding. The goal is to present novel modeling approaches and new crucial findings to connect the role of material processing techniques to the final product. Manuscripts describing new modeling techniques for multiphysics and multiscale modeling simulating the manufacturing process at different length scales, microstructural evolution during the process, component builds, and new alloy development are highly welcome.

Dr. Sudipta Biswas
Dr. Wen Jiang
Guest Editors

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.

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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

  • modeling and simulation
  • advanced manufacturing
  • additive manufacturing
  • sintering
  • material evolution
  • process modeling
  • component modeling

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Published Papers (1 paper)

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Research

19 pages, 19709 KiB  
Article
Numerical Analysis of Aggregate Debonding in Asphalt Concrete
by Marek Klimczak and Marta Oleksy
Materials 2025, 18(10), 2297; https://doi.org/10.3390/ma18102297 - 15 May 2025
Viewed by 231
Abstract
The overall response of asphalt concrete under a subjected load is governed not only by the properties of its constituents but also by the interactions among them. In this paper, we focus on the numerical analysis of aggregate debonding, which is typically a [...] Read more.
The overall response of asphalt concrete under a subjected load is governed not only by the properties of its constituents but also by the interactions among them. In this paper, we focus on the numerical analysis of aggregate debonding, which is typically a phenomenon that precedes crack initiation. The interfacial transition zone plays a crucial role in the macroscopic performance of this material. Using image processing to reconstruct a specific sample microstructure, we carried out several finite element analyses to assess the impact of the debonding phenomenon on the general performance of asphalt concrete. Image segmentation algorithms were employed to accurately detect aggregate boundaries, followed by vectorization to describe their geometries. After applying a series of error-controlled geometry simplification procedures, the final microstructure was exported to the ABAQUS/Standard 2023 environment. A linear elastic solution for the reconstructed asphalt concrete sample was used as the reference solution. It was compared with linear viscoelastic solutions with a perfect bonding between constituents and, in the next step, with debonding allowed at aggregate–matrix interfaces. The latter phenomenon was analyzed by enforcing respective contact conditions between the aggregate and the bituminous matrix. It was found that introducing the viscoelastic material model for mastic resulted in a 142.72% increase in the vertical extreme displacement relative to the purely elastic solution. When debonding effects were additionally considered, this increase rose to 188.44%. The results confirm the necessity of debonding conditions to be introduced in reliable finite element analyses of asphalt concrete. Full article
(This article belongs to the Special Issue Numerical Simulation of Materials Processing)
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