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Additive Manufacturing and Nondestructive Testing of Metals

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

Deadline for manuscript submissions: 20 June 2025 | Viewed by 9803

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Special Issue Editors

Dr. Yu Zhan

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Guest Editor

College of Sciences, Northeastern University, Shenyang, China
Interests: laser ultrasonic nondestructive testing; laser additive manufacturing; mechanical behavior of materials

Prof. Dr. Changsheng Liu

E-Mail Website
Guest Editor

Key Laboratory of Ministry of Education for Anisotropy and Texture of Materials, School of Materials Science and Engineering, Northeastern University, Shenyang, China
Interests: laser application technology; laser cladding; laser ultrasound; laser additive manufacturing

Dr. Zhiyong Hu

E-Mail Website
Guest Editor Assistant

School of Mechanical Engineering and Automation, Northeastern University, Shenyang, China
Interests: product reliability modeling and evaluation; intelligent diagnosis and maintenance; prognostics and health management

Special Issue Information

Dear Colleagues,

The additive manufacturing and non-destructive testing technologies of metal materials are widely used in aerospace, biomedical, petrochemical, and weapon equipment fields, among others. The great potential of these technologies and their advantages over traditional metal components (associated with preparation and performance testing methods) have attracted the attention of researchers in various fields of knowledge.

The proposed Special Issue will cover all areas related to theory and methodology, science, technology, and applications of additive manufacturing and non-destructive testing technologies of metal materials. Papers on the application of non-destructive testing technology in the field of additive manufacturing, as well as the testing and simulation of residual stress, will be particularly very popular.

Additive manufacturing is a promising technology used for the fabrication of metal components. It can realize the direct forming of high-performanceand compact metal parts with complex structures. However, defects and residual stresses that occur during the manufacturing process are inevitable. Therefore, monitoring the additive manufacturing process and detecting the final state of components are very important, and this urgent demand also presents new opportunities and challenges for non-destructive testing technology.

Dr. Yu Zhan
Prof. Dr. Changsheng Liu
Guest Editors
Dr. Zhiyong Hu
Guest Editor Assistant

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Keywords

structural design and modeling analysis
additive manufacturing processes and process enhancements
mechanical properties and characterization methods
non-destructive testing of residual stress and defects (ultrasonic, X-ray)

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Published Papers (6 papers)

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Research

16 pages, 9470 KiB

Open AccessArticle

Influence of Process Parameter and Build Rate Variations on Defect Formation in Laser Powder Bed Fusion SS316L

by Tasrif Ul Anwar, Patrick Merighe, Rahul Reddy Kancharla, Boopathy Kombaiah and Nadia Kouraytem

Materials 2025, 18(2), 435; https://doi.org/10.3390/ma18020435 - 18 Jan 2025

Viewed by 1054

Abstract

Laser powder bed fusion (LPBF) is an additive manufacturing process that has gained interest for its material fabrication due to multiple advantages, such as the ability to print parts with small feature sizes, good mechanical properties, reduced material waste, etc. However, variations in the key process parameters in LPBF may result in the instantiation of porosity defects and variation in build rate. Particularly, volumetric energy density (VED) is a variable that encapsulates a number of those parameters and represents the amount of energy input from the laser source to the feedstock. VED has been traditionally used to inform the quality of the printed part but different values of VED are presented as optimal values for certain material systems. An optimal VED value can be maintained by changing the key process parameters so that various combinations yield a constant value. In this study, an optimal constant VED value is maintained while printing SS316L with variable key processing parameters. Porosity analysis is performed using optical microscopy, as well as X-ray computed tomography, to reveal the volume density and distribution of those pores. Two primary defect categories are identified, namely lack of fusion and porosity induced by balling defects. The findings indicate that, even at optimal VED, variations in process parameters can significantly influence defect type, underscoring the sensitivity of defect formation to the variation of these parameters. Furthermore, a minor change in the build rate, driven by adjustments in process parameters, was found to influence defect categories. These findings emphasize that fine tuning the process parameters and build rate is essential to minimize defects. Finally, fiducial marks have been identified as a source of unintentional porosity defects. These results enable the refinement of process parameters, ultimately optimizing LPBF to achieve enhanced material density and expedite the printing. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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32 pages, 73644 KiB

Open AccessArticle

Influence of Loading Mode on the Biaxial Stress–Strain Curve at Hydraulic Bulge Test

by Jiří Sobotka, Pavel Solfronk, Martin Švec and David Koreček

Materials 2024, 17(23), 5762; https://doi.org/10.3390/ma17235762 - 25 Nov 2024

Viewed by 796

Abstract

Stress–strain curves are generally a very important material characteristic. For example, in numerical simulations, especially in sheet metal forming, stress–strain curves represent one of the most important data inputs. However, there is quite a wide range of parameters that influence their outline under the chosen technological conditions and, therefore, must always be taken into account. Among them, the influence of stress state and loading history is also relevant. In addition to that, to properly define the advanced yield conditions used in numerical simulations, it is also necessary to perform material tests under multi-axial stress states. For the above reasons, the present paper deals with the influence of the loading mode on the resulting outline of stress–strain curves under the equi-biaxial stress state at hydraulic bulge test (HBT). In light of the different loading modes, the classical continuous increase in pressure in accordance with ISO 16808 was compared with the so-called ramp test, where holding times for a duration of 90 s were applied. Two materials were selected for experiments, namely, a dual-phase steel (DP steel) with UTS of 500 MPa and an interstitial-free steel (IF steel) with a yield strength of 150 MPa. The results revealed totally different deformation behaviour of the tested materials depending on the used loading mode. Moreover, an evaluation of the microstructure was performed as well to clarify the measured results. The contactless optical system GOM Correlate Pro was used to evaluate the results of the HBT. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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22 pages, 28763 KiB

Open AccessArticle

Comparative Analysis of Mechanical Properties: Conventional vs. Additive Manufacturing for Stainless Steel 316L

by Constantin Alex Sumanariu, Cătălin Gheorghe Amza, Florin Baciu, Mihai Ion Vasile and Adrian Ionut Nicoara

Materials 2024, 17(19), 4808; https://doi.org/10.3390/ma17194808 - 29 Sep 2024

Cited by 2 | Viewed by 2381

Abstract

This research investigates the tensile strength and microstructural properties of stainless steel 316L, comparing samples fabricated using additive manufacturing (AM) to those produced via conventional manufacturing techniques such as forging and casting using stainless steel 316L for its mechanical performance and corrosion resistance. Tensile tests revealed that AM samples had an ultimate tensile strength (UTS) of 650 MPa, a yield strength of 550 MPa and an elongation at break of 20%, and conventionally manufactured samples achieved a UTS of 580 MPa, a yield strength of 450 MPa and a higher elongation at break of 35%. The reduced ductility of AM samples is offset by their higher strength. Scanning electron microscopy (SEM) analysis showed that AM samples had a refined grain structure, with grain sizes ranging from 1 to 5 µm, whereas conventionally produced samples exhibited larger grain sizes of 10 to 20 µm, contributing to their increased ductility. This shows that while AM processes can give a rather high strength, the ductility property is simpler to attain with casting. Further work is needed to investigate post-processing techniques like hot isotropic pressing (HIP) and heat treatments for enhancing the ductility of AM parts as well as mechanical properties. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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17 pages, 2613 KiB

Open AccessArticle

Statistical Reliability Analysis of Ultrasonic Velocity Method for Predicting Residual Strength of High-Strength Concrete under High-Temperature Conditions

by Wonchang Kim, Keesin Jeong and Taegyu Lee

Materials 2024, 17(6), 1406; https://doi.org/10.3390/ma17061406 - 19 Mar 2024

Cited by 2 | Viewed by 1148

Abstract

Herein, we conducted a comprehensive statistical assessment of the ultrasonic pulse velocity (UPV) method’s effectiveness in predicting concrete strength under diverse conditions, specifically early age, middle age, and high-temperature exposure. The concrete mixtures, with water-to-cement (W/C) ratios of 0.33 and 0.28, were classified as granite aggregate or coal-ash aggregate mixes. Compressive strength and UPV measurements were performed under these conditions, and subsequent statistical analyses treated the identified factors as distinct groups. The results revealed a substantial difference in compressive strength between specimens at early age (average of 13.01) and those at middle age (average of 41.96) and after high-temperature exposure (average of 48.08). Conversely, UPV analysis showed an insignificant difference between the early-age specimens and those after high-temperature exposure. The analysis of the W/C ratio and coarse aggregate demonstrated significant differences (p-value < 0.05) in compressive strength between specimens in middle age and those exposed to high temperatures, excluding the early-age specimens. However, UPV analysis revealed insignificant differences, with p-values of 0.67 and 0.38 between specimens at an early age and post-high-temperature exposure, respectively. Regression analysis identified suitable functions for each scenario, emphasizing the importance of a strength prediction model for concrete after high-temperature exposure, particularly considering the W/C ratio. Since concrete showed statistically different compressive strength, UPV, and strength prediction models in three conditions (early age, middle age, and high temperature), different strength prediction models must be used for the purpose of accurately predicting the strength of concrete. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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17 pages, 7247 KiB

Open AccessArticle

Effect of Scanning Strategy on the Manufacturing Quality and Performance of Printed 316L Stainless Steel Using SLM Process

by Zhijun Zheng, Bing Sun and Lingyan Mao

Materials 2024, 17(5), 1189; https://doi.org/10.3390/ma17051189 - 4 Mar 2024

Cited by 10 | Viewed by 1902

Abstract

In this study, the effects of Z-0°, Z-67°, Z-90°, I-67°, and S-67° scanning strategies on the surface morphology, microstructure, and corrosion resistance of the specimens in SLM316L were systematically studied. The results show that the partition scanning path can effectively improve the manufacturing quality of the specimen, reduce the cumulative roughness layer by layer, and increase the density of the specimen. The scan path of the island partition of the fine partition is better than that of the strip partition; moreover, the 67° rotation between each layer reduces the accumulation of the height difference of the melt pool, fills the scanning gap of the previous layer, and improves the molding quality of the sample. Electrochemical tests were performed in an aqueous solution of NaCl (3.5 wt%), including open-circuit potential (OCP), dynamic potential polarization, and electrochemical impedance spectroscopy (EIS). The results show that the specimen with a 67° rotation between each layer achieves stability of the surface potential in a short time, and the I-67° specimen exhibits good corrosion performance, while the Z-0° specimen has the worst corrosion resistance. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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13 pages, 6199 KiB

Open AccessArticle

Investigating the Impact of Substrate Preheating on the Thermal Flow and Microstructure of Laser Cladding of Nickel-Based Superalloy

by Zhibo Jin, Xiangwei Kong and Liang Ma

Materials 2024, 17(2), 399; https://doi.org/10.3390/ma17020399 - 12 Jan 2024

Cited by 10 | Viewed by 1627

Abstract

The preheating of the substrate in laser additive superalloys can reduce residual stress and minimize cracking. However, this preheating process can lead to changes in the heat transfer conditions, ultimately affecting the resulting microstructure and mechanical properties. In order to explore the influence of substrate preheating on the formation of laser cladding, this research focuses on investigating the characteristics of Inconel 718, a nickel-based superalloy, as the subject of study. To simulate the temperature and flow field of laser cladding, a 3D computational fluid dynamics (CFD) model is employed. By varying the initial preheating conditions, an investigation is conducted into the distribution of the temperature field under different parameters. This leads to the acquisition of varying temperature gradients, G, and solidification speeds, R. Subsequently, an analysis is carried out on both the flow field and solidification microstructure in the melt pool. The results demonstrate that the preheating of the substrate results in a slower cooling rate, ultimately leading to the formation of a coarser microstructure. Full article

(This article belongs to the Special Issue Additive Manufacturing and Nondestructive Testing of Metals)

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