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Additive Manufacturing of Metals and Alloys: Microstructure and Mechanical Properties—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 November 2026 | Viewed by 1339

Special Issue Editors


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Guest Editor
ARM Laboratory, Department of Innovative Technologies, University of Applied Sciences and Arts of Southern Switzerland (SUPSI), CH-6962 Lugano-Viganello, Switzerland
Interests: metal additive manufacturing; design for additive manufacturing; process optimization and engineering; functionally graded materials; high-entropy alloys
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Guest Editor
Institute of Systems Engineering, School of Engineering, HES-SO Valais-Wallis, Rue de l’Industrie 23, Sion, Switzerland
Interests: additive manufacturing; powder metallurgy; shape memory alloys; functional materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Over the past decade, metal additive manufacturing (AM) technologies have been demonstrated to be fabrication processes enabling innovative engineering solutions which exhibit unprecedented performance advantages not achievable through more conventional manufacturing methods. AM metal structures and alloys, such as functionally graded materials, shape memory alloys, and high-entropy alloys, exhibit innovative performance properties such as self-healing, excellent mechanical strength at high temperatures, shape memory effect, improved corrosion and wear resistance, and enhanced biocompatibility, increasing industrial impact in sectors such as aerospace, automotive, biomedical, and power generation, outperforming the current engineering solutions.

This Special Issue will compile recent and innovative developments in the field of additive manufacturing of metal alloys and structures. The articles published in this collection will cover topics including, but not limited to, AM high-entropy alloy optimization and characterization, AM functionally graded materials, AM advanced metal design and development, process and microstructural simulation, AM property analysis and assessment, and enabling advanced functionalities through metal AM techniques. The topics are open to both basic and applied research with strong industrial interest, as well as for the development of applications.

Dr. Federico Mazzucato
Prof. Dr. Samuel Rey-Mermet
Guest Editors

Manuscript Submission Information

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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

  • metal additive manufacturing
  • high-entropy alloys
  • functionally graded materials
  • microstructure analysis
  • advanced functionalities
  • process simulation
  • process engineering
  • advanced metal alloys
  • mechanical properties

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Published Papers (2 papers)

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Research

19 pages, 6946 KB  
Article
Hot Forging of DIN 8555 E6-UM-60 Alloy Produced by Directed Energy Deposition: Understanding the Metallurgical Effects
by Carlos Antônio Ferreira, Lirio Schaeffer, Anderson Daleffe, Henrique Cechinel Casagrande, Gilson de March and Joélson Vieira da Silva
Materials 2026, 19(2), 373; https://doi.org/10.3390/ma19020373 - 16 Jan 2026
Viewed by 344
Abstract
This study investigates a hybrid processing route that integrates localized fusion-based additive manufacturing and hot forging for the production of complex-shaped components, with emphasis on metallurgical integrity and mechanical performance. The DIN 8555 E6-UM-60 alloy, traditionally classified as martensitic and applied under severe [...] Read more.
This study investigates a hybrid processing route that integrates localized fusion-based additive manufacturing and hot forging for the production of complex-shaped components, with emphasis on metallurgical integrity and mechanical performance. The DIN 8555 E6-UM-60 alloy, traditionally classified as martensitic and applied under severe wear conditions, exhibited atypical metallurgical behavior during hybrid processing, notably the consistent formation of chromium carbides under specific thermomechanical conditions. Metallographic analyses, microhardness measurements, thermographic monitoring, hot tensile tests, and room-temperature tensile tests were performed to establish correlations between microstructure, thermal history, and mechanical response. Specimens produced by additive manufacturing and subsequently hot forged showed a significant reduction in porosity, improved microstructural homogeneity, and partial retention of hardening phases, enabling discussion of recrystallization mechanisms, phase stabilization, and precipitation phenomena in martensitic alloys processed by additive manufacturing. Hot tensile tests revealed limited hot workability of the alloy, while room-temperature tensile tests led to premature fracture, with failure consistently initiating at pre-existing microcracks formed during the forging stage. Although detrimental, these microcracks provide valuable insight into critical processing conditions and ductility limits of the material. Overall, the hybrid route demonstrates strong potential for industrial applications, highlighting the importance of precise thermomechanical cycle control to mitigate defects and enhance structural reliability. Full article
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18 pages, 5679 KB  
Article
Effect of Fe and Si Content on Microstructure, Mechanical Properties, and Corrosion Resistance of 7050 Alloy
by Changlin Li, Wei Zhao, Tingrui Zhang, Xiwu Li, Zhicheng Liu, Ying Li, Lizhen Yan, Pengfei Xu, Kai Wen, Yongan Zhang, Zhihui Li and Baiqing Xiong
Materials 2026, 19(1), 135; https://doi.org/10.3390/ma19010135 - 30 Dec 2025
Cited by 2 | Viewed by 604
Abstract
In this work, the effect of Fe and Si content on microstructure, mechanical properties, and corrosion resistance of 7050 alloy was systematically investigated by room temperature tensile, fracture toughness, and exfoliation corrosion tests, complemented by microstructural characterization through SEM and TEM. The results [...] Read more.
In this work, the effect of Fe and Si content on microstructure, mechanical properties, and corrosion resistance of 7050 alloy was systematically investigated by room temperature tensile, fracture toughness, and exfoliation corrosion tests, complemented by microstructural characterization through SEM and TEM. The results demonstrate that the impurity elements Fe and Si induce the formation of insoluble Fe-rich phases and Mg2Si phases in the alloy, respectively. The coexistence of Fe and Si leads to a severe synergistic deterioration effect on mechanical properties. Furthermore, the study reveals that Si has a more profound negative impact on mechanical properties than Fe. While Fe primarily reduces ductility and fracture toughness by initiating microcracks through Fe-rich phases with minimal effect on strength, Si not only forms brittle Mg2Si phases that impair toughness but also significantly depletes the Mg content in the matrix, thereby reducing the quantity of strengthening phases. This results in a comprehensive and severe decline in strength, plasticity, and toughness. In addition, Fe and Si impurities markedly degrade the exfoliation corrosion resistance of the alloy. Full article
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