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Laser Additive Manufacturing and Precision Joining of Structural Materials
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Laser Additive Manufacturing and Precision Joining of Structural Materials

A Special Issue of Materials (ISSN 1996-1944) belonging to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 December 2026 | Viewed by 1006

Editors

Dr. Danyang Lin

E-Mail Website
Guest Editor
School of Materials Science and Technology, Harbin Institute of Technology at Weihai, Weihai 264209, China
Interests: additive manufacturing; laser welding; nano-manufacturing; alloys and its composites; shape memory alloys
Special Issues, Collections and Topics in MDPI journals
Dr. Zubin Chen

E-Mail Website
Guest Editor
Yantai Research Institute and Graduate School of Harbin Engineering University, Yantai 264006, China
Interests: microstructure and properties regulation of metal additive manufacturing; ultrasonic field assisted additive manufacturing; brazing; titanium alloy and titanium matrix composites; high-entropy alloy
Special Issues, Collections and Topics in MDPI journals
Dr. Qiang Chen

E-Mail Website
Guest Editor Assistant
School of Materials Science and Technology, Harbin Institute of Technology at Weihai, Weihai 264209, China
Interests: additive manufacturing; laser welding; nano-manufacturing; alloys and its composites; shape memory alloys

Special Issue Information

Dear Colleagues,

In recent years, metal laser additive manufacturing has emerged as a transformative technology for producing complex, high-performance metallic components in industries such as aerospace, biomedical, automotive, and energy. By enabling near‑net shaping with reduced material waste and design freedom beyond conventional methods, techniques such as laser powder bed fusion and laser directed energy deposition have attracted extensive research interest. However, challenges persist regarding process stability, microstructure control, defect formation (e.g., porosity, cracking), and the resulting mechanical anisotropy. Furthermore, the relationship between laser processing parameters, solidification behavior, and final component performance remains insufficiently understood, especially for new alloys and hybrid manufacturing routes.

Therefore, this Special Issue focuses on recent advances in metal laser additive manufacturing, covering (but not limited to) the following topics: development of novel alloys specifically designed for laser‑based processes; in‑situ monitoring and process control to minimize defects; post‑processing treatments (e.g., heat treatment, surface finishing, hot isostatic pressing) to tailor microstructures and improve mechanical properties; and multi‑material or functionally graded structures. Special attention will be paid to studies that elucidate the interconnections between laser processing conditions, microstructural evolution, and the resulting mechanical, corrosion, or fatigue performance. Both original research articles and critical reviews are welcome to push forward the understanding and industrial adoption of metal laser additive manufacturing.

Dr. Danyang Lin
Dr. Zubin Chen
Guest Editors

Dr. Qiang Chen
Guest Editor Assistant

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 250 words) can be sent to the Editorial Office for assessment.

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-anonymized 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
  • hybrid manufacturing
  • laser welding
  • nano-manufacturing
  • repair and remanufacturing
  • alloys and their composites
  • shape memory alloys

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Published Papers (2 papers)

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Research

19 pages, 6484 KB  
Article
Influence of Ni Contents and Local Hydrogen Concentration on Crack Propagation in FCC Fe-Ni Alloy Models: A Molecular Dynamics Study
by Kaimeng Wang, Yingli Li, Molin Su, Hongqiao Yan, Yue Zhao and Lei Zhao
Materials 2026, 19(15), 3304; https://doi.org/10.3390/ma19153304 - 4 Aug 2026
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Abstract
This study investigates the atomic-scale effects of hydrogen concentration and Ni content on crack propagation in Fe-Ni alloy models using molecular dynamics methods. A Mode I crack model with a (001)[100] orientation was constructed, and hydrogen atoms were locally introduced at the crack [...] Read more.
This study investigates the atomic-scale effects of hydrogen concentration and Ni content on crack propagation in Fe-Ni alloy models using molecular dynamics methods. A Mode I crack model with a (001)[100] orientation was constructed, and hydrogen atoms were locally introduced at the crack tip with concentrations of 5.3 at.% and 14.3 at.%. Fe-Ni alloy models with 5%, 10%, 15%, and 20% Ni were compared in terms of crack growth, dislocation evolution, stacking fault energy, and hydrogen diffusion. The results show that local hydrogen introduction has a limited effect on the peak stress–strain response, while hydrogen clearly accelerates crack propagation in the middle stage, especially at high concentrations. For the 10% Ni model, the middle-stage crack growth rate increases to 0.36 Å/ps under 14.3 at.% crack-tip hydrogen. Crack growth in all models shows three stages. The 15% Ni model exhibits a clear plateau in the second stage and the shortest final crack length. Further analysis shows that Ni content regulates dislocation behavior through stacking fault energy. At 15% Ni, sustained dislocation entanglement and high-density dislocation multiplication occur near the crack tip, which helps dissipate local stress. Hydrogen diffusion analysis indicates that hydrogen mobility is lower in the 15% Ni model, which may be related to hydrogen retention near dislocation-rich regions. A normalized comparison based on hydrogen diffusion and middle-stage crack growth rate further identifies 15% Ni as the lowest crack propagation tendency composition among the studied models. These results provide atomic-scale data for Ni-content optimization in hydrogen-resistant alloys, although the direct engineering transfer of the findings is limited by the length and time scales of molecular dynamics simulations. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing and Precision Joining of Structural Materials)
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23 pages, 14324 KB  
Article
Weldability Improvement of Additively Manufactured Nickel-Based Superalloy by Controlling W and Si Migration at Solidification Front
by Rui Ma, Xin Xi, Zhaoyang Lin, Wenrui Luo, Yanhao Hou, Wenjun Zhao, Zhifeng Shi, Xiaoguo Song, Qiang Chen and Danyang Lin
Materials 2026, 19(15), 3210; https://doi.org/10.3390/ma19153210 - 27 Jul 2026
Viewed by 489
Abstract
Nickel-based superalloy components prepared by laser powder bed fusion (LPBF) are increasingly being used in the hot ends of aeroengines, which still need to be laser-welded to realize the assembly connection of large closed structures. However, the unique microstructural characteristics of LPBFed parts [...] Read more.
Nickel-based superalloy components prepared by laser powder bed fusion (LPBF) are increasingly being used in the hot ends of aeroengines, which still need to be laser-welded to realize the assembly connection of large closed structures. However, the unique microstructural characteristics of LPBFed parts render them more poorly weldable than casts and wroughts, especially in cracking-sensitive superalloys. In this study, cracking mechanisms were analyzed by performing laser deep fusion welding on an LPBFed Haynes 230 alloy. The key factors leading to weld cracking were strongly correlated with the low-melting-point TCP phases enriched with W, Si, Al, and silicides, both of which tended to be distributed in the boron(B)-rich region and exhibited poor coherence with the matrix. In addition, the flow behavior of the molten pool affected the solidification rate of the weld, resulting in large solidification shrinkage stresses in the cracking-sensitive zone (CZ) part of the weld. In order to minimize the development conditions of the cracking-sensitive phases, reducing the content of W (from 14.96 to 13.56 wt.%) and Si (from 0.47 to 0.25 wt.%) was chosen to alleviate the segregation of W, Si and C elements in the solid phase at the end of solidification. Thus, TCP phase and silicides were transformed into carbides, which successfully suppressed weld cracking, reducing the crack depth ratio from 0.70 ± 0.08 to zero. New insights into the weldability improvement and crack inhibition mechanism of laser-welded additively manufactured cracking-sensitive superalloys are provided, accelerating the rapid application of large assemblies. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing and Precision Joining of Structural Materials)
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