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Additive Manufacturing of Aluminum Alloys and Aluminum Matrix Composites (Second Edition)

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

Deadline for manuscript submissions: 20 August 2025 | Viewed by 4265

Special Issue Editor

Dr. Hongze Wang

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Shanghai JiaoTong University, Shanghai 200240, China
Interests: additive manufacturing; biomimetic 3D printed structures
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With significant advantages in specific strength and stiffness, aluminum alloys and aluminum matrix composites have been widely used in transportation, aerospace, and other applications. Additive manufacturing (AM) has great potential for the rapid customization and repairment of parts. At present, various additive manufacturing methods have been developed that could be generally categorized into fusion, solid-state, and binder jetting AM. The heat source in fusion AM includes laser, electron beam, and electric arc. The style of providing the supplementary material in fusion AM includes powder bed, deposited powder, and deposited wire. Solid-state AM generally includes cold spray, ultrasonic AM, and friction AM. Because of the diversity of the manufacturing methods and the unique properties of materials, it is important to perform comprehensive and comparative studies on the AM of aluminum alloys and aluminum matrix composites, which could provide a guide for selecting the most suitable AM method for industrial application. For this Special Issue, we invite our colleagues to submit papers in the areas of additive manufacturing of aluminum alloys and aluminum matrix composites. The topics of interest include but are not limited to fusion and solid-state additive manufacturing processes, advanced characterization, modeling and simulation, optimization of the manufacturing process, topological optimization, in situ observation, monitoring control, post-treatment, and hybrid manufacturing. Review papers and short communications are also of interest for this Special Issue. 

Dr. Hongze Wang
Guest Editor

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Keywords

  • additive manufacturing
  • aluminum alloy
  • aluminum composite
  • selective melting
  • powder deposition
  • wire deposition
  • cold spray
  • post-treatment
  • hybrid manufacturing
  • advanced characterization

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Published Papers (3 papers)

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Research

15 pages, 12430 KiB  
Article
Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy
by Jie Huang, Xiaolin Zhang, Zijue Tang, Qianglong Wei, Kaiming Hu, Ming Lou, Li Yan, Yawei Hu, Guoshuang Cai, Huan Qi, Yi Wu, Haowei Wang and Hongze Wang
Materials 2024, 17(22), 5496; https://doi.org/10.3390/ma17225496 - 11 Nov 2024
Viewed by 987
Abstract
The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive [...] Read more.
The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a “turning point temperature” in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C. Full article
(This article belongs to the Special Issue Additive Manufacturing of Aluminum Alloys and Aluminum Matrix Composites (Second Edition))
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16 pages, 13663 KiB  
Article
Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion
by Zhiheng Shu and Yunzhong Liu
Materials 2024, 17(3), 686; https://doi.org/10.3390/ma17030686 - 31 Jan 2024
Cited by 3 | Viewed by 1340
Abstract
(TiH2 + ScH3)/Al-Mg composite powders with different Ti contents were produced by ball milling. These composite powders were fabricated to cube and cuboid shape samples via a laser powder bed fusion process with optimal processing parameters. The TiH2 and [...] Read more.
(TiH2 + ScH3)/Al-Mg composite powders with different Ti contents were produced by ball milling. These composite powders were fabricated to cube and cuboid shape samples via a laser powder bed fusion process with optimal processing parameters. The TiH2 and ScH3 particles underwent dehydrogenation during the laser powder bed fusion process, and these composite powders ultimately formed Al-Mg-Sc-Ti alloys. The relative density, printability, microstructure, hardness and tensile properties of these alloy samples were investigated. The results show that these Al-Mg-Sc-Ti alloys have lower hot-crack sensitivity, having fine equiaxed grains. An Al18Mg3(Ti,Sc)2 intermetallic phase and in situ L12-Al3(Sc,Ti) precipitations formed during the laser powder bed fusion process, which is beneficial for nucleation and dispersion strengthening. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti alloy was 313.6 MPa with an elongation of 6.6%. During the hot isostatic pressing treatment, most of the Mg element precipitated from the matrix and changed the Al3(Sc,Ti) into a Al18Mg3(Ti,Sc)2 precipitate completely. The Al-Mg-Sc-Ti alloys were nearly fully dense after the hot isostatic pressing treatment and exhibited better mechanical properties. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti was 475 MPa with an elongation of 8.5%. Full article
(This article belongs to the Special Issue Additive Manufacturing of Aluminum Alloys and Aluminum Matrix Composites (Second Edition))
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23 pages, 8584 KiB  
Article
Experimental and Statistical Analysis of the Effect of Heat Treatment on Surface Roughness and Mechanical Properties of Thin-Walled Samples Obtained by Selective Laser Melting from the Material AlSi10Mg
by Sergey N. Grigoriev, Nikita Nikitin, Oleg Yanushevich, Natella Kriheli, Olga Kramar, Roman Khmyrov, Idarmach Idarmachev and Pavel Peretyagin
Materials 2023, 16(23), 7326; https://doi.org/10.3390/ma16237326 - 24 Nov 2023
Cited by 5 | Viewed by 1364
Abstract
Statistical analysis of mechanical properties of thin-walled samples (~500 microns) obtained by selective laser melting from AlSi10Mg material and subjected to heat treatment for 1 h at temperatures from 260 °C to 440 °C (step of aging temperature change 30 °C) has shown [...] Read more.
Statistical analysis of mechanical properties of thin-walled samples (~500 microns) obtained by selective laser melting from AlSi10Mg material and subjected to heat treatment for 1 h at temperatures from 260 °C to 440 °C (step of aging temperature change 30 °C) has shown that the maximum strain hardening in the stretching diagram section from yield strength to tensile strength is achieved at the heat treatment temperature equal to 290 °C. At carrying out of correlation analysis, a statistically significant positive correlation between deformation corresponding to yield strength and the sum of heights of the largest protrusions and depths of the largest depressions of the surface roughness profile within the basic length of the sample (Rz) and the full height of the surface roughness profile (Rmax) was established. It was found that the reason for the correlation is the presence of cohesive states between the extreme values of the surface roughness profile that persist along the entire length of the specimen. Full article
(This article belongs to the Special Issue Additive Manufacturing of Aluminum Alloys and Aluminum Matrix Composites (Second Edition))
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