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Special Issue "Materials, Design and Process Development for Additive Manufacturing"

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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: closed (28 February 2022) | Viewed by 25487

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Special Issue Editor

Dr. Vadim Sufiiarov

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Guest Editor

Peter the Great St. Petersburg Polytechnic University, 195251, Polytechnicheskaya, 29, St. Petersburg, Russia
Interests: additive manufacturing; rapid solidification; selective laser melting; microstructure; mechanical properties

Special Issue Information

Dear Colleagues,

Additive manufacturing is already actively used in various high-tech industries today. At the same time, there is a certain limitation and imperfection of known and widely used conventional materials when they are used in additive manufacturing.

In this regard, extensive research and development are aimed at the advancements of new materials by adjusting the chemical compositions of conventional alloys, new equipment with expanded functionality and the ability to work with a wide range of materials that were previously not available for additive manufacturing.

This issue will cover a wide scope of additive manufacturing processes, comprising investigation, characterization of materials and their properties, development and application of new materials, structures designed for additive manufacturing, as well as processes and techniques that will expand the potential applications of layer-by-layer synthesis.

Topics of particular interest include but are not limited to:

New biomaterials, including alloys with reduced Young modulus, and porous and biodegradable alloys;
New material formulations and composite materials adapted specially for additive manufacturing;
High-entropy alloys, ceramics, metal- and ceramic-matrix composites;
Metamaterials and alloys with shape memory effect;
Bulk metallic glasses and nanocrystalline alloys;
Difficult-to-weld materials (intermetallics, high carbon steels, etc.);
Processing of materials by additive manufacturing and for application in additive manufacturing (powder, wire, composites, slurry, filaments, etc.);
Multimaterial additive manufacturing;
Materials with graded properties such as microstructure, chemical composition, density, etc.;
Wire, filament, and slurry based additive manufacturing;
In situ synthesis and adjusting alloying with blending powders;
Characterization and performance of additively manufactured materials—mechanical, electrical, chemical, biological, etc.;
Computer methods for designing alloys, structures, and simulation of processes.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Vadim Sufiiarov
Guest Editor

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.

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-blind 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 2300 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
microstructure
properties
alloys development
3D printing
synthesis
computer modeling

Published Papers (14 papers)

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Editorial

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Open AccessEditorial

Special Issue: Materials, Design and Process Development for Additive Manufacturing

Vadim Sufiiarov

Materials 2022, 15(10), 3492; https://doi.org/10.3390/ma15103492 - 12 May 2022

Viewed by 661

Abstract

Additive manufacturing is a dynamically developed direction of modern digital manufacturing processes, which in some cases is already being used to create high-tech products, and in others there are active investigation on new materials and the design and development of technological processes [...] [...] Read more.

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

Research

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Open AccessArticle

Structure, Mechanical and Magnetic Properties of Selective Laser Melted Fe-Si-B Alloy

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Materials 2022, 15(12), 4121; https://doi.org/10.3390/ma15124121 - 09 Jun 2022

Cited by 1 | Viewed by 890

Abstract

Original 1CP powder was studied and it was founded that powder material partially consists of the amorphous phase, in which crystallization begins at 450 °C and ends at 575 °C. Selective laser melting parameters were investigated through the track study, and more suitable ones were found: laser power P = 90, 120 W; scanning speed V = 1200 mm/s. Crack-free columnar elements were obtained. The sample obtained with P = 90 W, contains a small amount of amorphous phase. X-ray diffraction of samples shows the presence of α-Fe(Si) and Fe₂B. SEM-image analysis shows the presence of ordered Fe₃Si in both samples. Annealed samples show 40% less microhardness; an annealed sample containing amorphous phase shows higher soft-magnetic properties: 2.5% higher saturation magnetization, 35% higher residual magnetization and 30% higher rectangularity coefficient. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Selective Electron Beam Melting (SEBM) of Pure Tungsten: Metallurgical Defects, Microstructure, Texture and Mechanical Properties

and

Materials 2022, 15(3), 1172; https://doi.org/10.3390/ma15031172 - 03 Feb 2022

Cited by 9 | Viewed by 1366

Abstract

Effects of processing parameters on the metallurgical defects, microstructure, texture, and mechanical properties of pure tungsten samples fabricated by selective electron beam melting are investigated. SEBM-fabricated bulk tungsten samples with features of lack of fusion, sufficient fusion, and over-melting are examined. For samples upon sufficient fusion, an ultimate compressive strength of 1.76 GPa is achieved at the volumetric energy density of 900 J/mm³–1000 J/mm³. The excellent compressive strength is higher and the associated volumetric energy density is significantly lower than corresponding reported values in the literature. The average relative density of SEBM-fabricated samples is 98.93%. No microcracks, but only pores with diameters of few tens of micrometers, are found in SEBM-ed tungsten samples of sufficient fusion. Properties of samples by SEBM and selective laser melting (SLM) have also been compared. It is found that SLM-fabricated samples exhibit inevitable microcracks, and have a significantly lower ultimate compressive strength and a slightly lower relative density of 98.51% in comparison with SEBM-ed samples. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Effect of Elevated Temperatures on the Mechanical Properties of a Direct Laser Deposited Ti-6Al-4V

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Materials 2021, 14(21), 6432; https://doi.org/10.3390/ma14216432 - 27 Oct 2021

Cited by 6 | Viewed by 1579

Abstract

In the present work, the mechanical properties of the DLD-processed Ti-6Al-4V alloy were obtained by tensile tests performed at different temperatures, ranging from 20 °C to 800 °C. Thereby, the process conditions were close to the conditions used to produce large-sized structures using the DLD method, resulting in specimens having the same initial martensitic microstructure. According to the obtained stress curves, the yield strength decreases gradually by 40% when the temperature is increased to 500 °C. Similar behavior is observed for the tensile strength. However, further heating above 500 °C leads to a significant increase in the softening rate. It was found that the DLD-processed Ti-6Al-4V alloy had a Young’s modulus with higher thermal stability than conventionally processed alloys. At 500 °C, the Young’s modulus of the DLD alloy was 46% higher than that of the wrought alloy. The influence of the thermal history on the stress relaxation for the cases where 500 °C and 700 °C were the maximum temperatures was studied. It was revealed that stress relaxation processes are decisive for the formation of residual stresses at temperatures above 700 °C, which is especially important for small-sized parts produced by the DLD method. The coefficient of thermal expansion was investigated up to 1050 °C. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Structure and Properties of Ti/Ti64 Graded Material Manufactured by Laser Powder Bed Fusion

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Materials 2021, 14(20), 6140; https://doi.org/10.3390/ma14206140 - 16 Oct 2021

Cited by 7 | Viewed by 1406

Abstract

Multimaterial additive manufacturing is an attractive way of producing parts with improved functional properties by combining materials with different properties within a single part. Pure Ti provides a high ductility and an improved corrosion resistance, while the Ti64 alloy has a higher strength. The combination of these alloys within a single part using additive manufacturing can be used to produce advanced multimaterial components. This work explores the multimaterial Laser Powder Bed Fusion (L-PBF) of Ti/Ti64 graded material. The microstructure and mechanical properties of Ti/Ti64-graded samples fabricated by L-PBF with different geometries of the graded zones, as well as different effects of heat treatment and hot isostatic pressing on the microstructure of the bimetallic Ti/Ti64 samples, were investigated. The transition zone microstructure has a distinct character and does not undergo significant changes during heat treatment and hot isostatic pressing. The tensile tests of Ti/Ti64 samples showed that when the Ti64 zones were located along the sample, the ratio of cross-sections has a greater influence on the mechanical properties than their shape and location. The presented results of the investigation of the graded Ti/Ti64 samples allow tailoring properties for the possible applications of multimaterial parts. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Structure and Properties of Barium Titanate Lead-Free Piezoceramic Manufactured by Binder Jetting Process

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Materials 2021, 14(16), 4419; https://doi.org/10.3390/ma14164419 - 06 Aug 2021

Cited by 10 | Viewed by 1774

Abstract

This article presents the results of manufacturing samples from barium titanate (BaTiO₃) lead-free piezoceramics by using the binder jetting additive manufacturing process. An investigation of the manufacturing process steps for two initial powders with different particle size distributions was carried. The influence of the sintering and the particle size distribution of the starting materials on grain size and functional properties was evaluated. Samples from fine unimodal powder compared to coarse multimodal one have 3–4% higher relative density values, as well as a piezoelectric coefficient of 1.55 times higher values (d₃₃ = 183 pC/N and 118 pC/N correspondingly). The influence of binder saturation on sintering modes was demonstrated. Binder jetting with 100% saturation for both powders enables printing samples without delamination and cracking. Sintering at 1400 °C with a dwell time of 6 h forms the highest density samples. The microstructure of sintered samples was characterized with scanning electron microscopy. The possibility of manufacturing parts from functional ceramics using additive manufacturing was demonstrated. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Preparation of W-C-Co Composite Micropowder with Spherical Shaped Particles Using Plasma Technologies

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Materials 2021, 14(15), 4258; https://doi.org/10.3390/ma14154258 - 30 Jul 2021

Cited by 6 | Viewed by 1163

Abstract

The possibility of obtaining composite micropowders of the W-C-Co system with a spherical particle shape having a submicron/nanoscale internal structure was experimentally confirmed. In the course of work carried out, W-C-Co system nanopowders with the average particle size of approximately 50 nm were produced by plasma-chemical synthesis. This method resulted in the uniform distribution of W, Co and C among the nanoparticles of the powder in the nanometer scale range. Dense microgranules with an average size of 40 microns were obtained from the nanopowders by spray drying. The spherical micropowders with an average particle size of 20 microns were received as a result of plasma treatment of 25.36 microns microgranule fraction. The spherical particles obtained in the experiments had a predominantly dense microstructure and had no internal cavities. The influence of plasma treatment process parameters on dispersity, phase, and chemical composition of spherical micropowders and powder particles microstructure has been established. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Features of Heat Treatment the Ti-6Al-4V GTD Blades Manufactured by DLD Additive Technology

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Materials 2021, 14(15), 4159; https://doi.org/10.3390/ma14154159 - 27 Jul 2021

Cited by 8 | Viewed by 1173

Abstract

Additive manufacturing of titanium alloys is one of the fastest growing areas of 3D metal printing. The use of AM methods for parts production in the aviation industry is especially promising. During the deposition of products with differently sized cross-sections, the thermal history changes, which leads to non-uniformity of the structure and properties. Such heterogeneity can lead to failure of the product during operation. The structure of deposited parts, depending on the thermal cycle, may consist of α’, α + α’ + β’, and α + β in different ratios. This problem can be solved by using heat treatment (HT). This paper presents research aimed towards the determination of optimal heat treatment parameters that allows the reception of the uniform formation of properties in the after-treatment state, regardless of the initial structure and properties, using the example of a deposited Ti-6Al-4V gas turbine blade. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Computer Simulation of Hydrodynamic and Thermal Processes in DLD Technology

Gleb A. Turichin

Ekaterina A. Valdaytseva

Stanislav L. Stankevich

and

Ilya N. Udin

Materials 2021, 14(15), 4141; https://doi.org/10.3390/ma14154141 - 25 Jul 2021

Cited by 2 | Viewed by 1252

Abstract

This article deals with the theoretical issues of the formation of a melt pool during the process of direct laser deposition. The shape and size of the pool depends on many parameters, such as the speed and power of the process, the optical and physical properties of the material, and the powder consumption. On the other hand, the influence of the physical processes occurring in the material on one another is significant: for instance, the heating of the powder and the substrate by laser radiation, or the formation of the free surface of the melt, taking into account the Marangoni effect. This paper proposes a model for determining the size of the melt bath, developed in a one-dimensional approximation of the boundary layer flow. The dimensions and profile of the surface and bottom of the melt pool are obtained by solving the problem of convective heat transfer. The influence of the residual temperature from the previous track, as well as the heat from the heated powder of the gas–powder jet, taking into account its spatial distribution, is considered. The simulation of the size and shape of the melt pool, as well as its free surface profile for different alloys, is performed with 316 L steel, Inconel 718 nickel alloy, and VT6 titanium alloy Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessEditor’s ChoiceArticle

Microstructure and Mechanical Properties of NiTi-Based Eutectic Shape Memory Alloy Produced via Selective Laser Melting In-Situ Alloying by Nb

Igor Polozov

and

Anatoly Popovich

Materials 2021, 14(10), 2696; https://doi.org/10.3390/ma14102696 - 20 May 2021

Cited by 6 | Viewed by 1791

Abstract

This paper presents the results of selective laser melting (SLM) process of a nitinol-based NiTiNb shape memory alloy. The eutectic alloy Ni₄₅Ti₄₅Nb₁₀ with a shape memory effect was obtained by SLM in-situ alloying using a powder mixture of NiTi and Nb powder particles. Samples with a high relative density (>99%) were obtained using optimized process parameters. Microstructure, phase composition, tensile properties, as well as martensitic phase transformations temperatures of the produced alloy were investigated in as-fabricated and heat-treated conditions. The NiTiNb alloy fabricated using the SLM in-situ alloying featured the microstructure consisting of the NiTi matrix, fine NiTi+β-Nb eutectics, as well as residual unmelted Nb particles. The mechanical tests showed that the obtained alloy has a yield strength up to 436 MPa and the tensile strength up to 706 MPa. At the same time, in-situ alloying with Nb allowed increasing the hysteresis of martensitic transformation as compared to the alloy without Nb addition from 22 to 50 °C with an increase in A_f temperature from −5 to 22 °C. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Additive Manufacturing of Ti-48Al-2Cr-2Nb Alloy Using Gas Atomized and Mechanically Alloyed Plasma Spheroidized Powders

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Materials 2020, 13(18), 3952; https://doi.org/10.3390/ma13183952 - 07 Sep 2020

Cited by 16 | Viewed by 2463

Abstract

In this paper, laser powder-bed fusion (L-PBF) additive manufacturing (AM) with a high-temperature inductive platform preheating was used to fabricate intermetallic TiAl-alloy samples. The gas atomized (GA) and mechanically alloyed plasma spheroidized (MAPS) powders of the Ti-48Al-2Cr-2Nb (at. %) alloy were used as the feedstock material. The effects of L-PBF process parameters—platform preheating temperature—on the relative density, microstructure, phase composition, and mechanical properties of printed material were evaluated. Crack-free intermetallic samples with a high relative density of 99.9% were fabricated using 900 °C preheating temperature. Scanning electron microscopy and X-Ray diffraction analyses revealed a very fine microstructure consisting of lamellar α₂/γ colonies, equiaxed γ grains, and retained β phase. Compressive tests showed superior properties of AM material as compared to the conventional TiAl-alloy. However, increased oxygen content was detected in MAPS powder compared to GA powder (~1.1 wt. % and ~0.1 wt. %, respectively), which resulted in lower compressive strength and strain, but higher microhardness compared to the samples produced from GA powder. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Heat Treatment of Corrosion Resistant Steel for Water Propellers Fabricated by Direct Laser Deposition

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Andrey Olisov

Materials 2020, 13(12), 2738; https://doi.org/10.3390/ma13122738 - 17 Jun 2020

Cited by 13 | Viewed by 1624

Abstract

The urgency of heat treatment of samples of maraging steel obtained by direct laser deposition from steel powder 06Cr15Ni4CuMo is considered. The structural features and properties of 06Cr15Ni4CuMo steel samples after direct laser deposition and heat treatment are studied. The work is devoted to research into the influence of thermal processing on the formation of structure and the mechanical properties of deposit samples. Features of formation of microstructural components by means of optical microscopy are investigated. Tests for tension and impact toughness are conducted. As a result, it was established that the material obtained by the direct laser deposition method in its initial state significantly exceeds the strength characteristics of heat treatment castings of similar chemical composition, but is inferior to it in terms of impact toughness and relative elongation. The increase in relative elongation and impact toughness up to the level of cast material in the deposit samples is achieved at the subsequent heat treatment, which leads to the formation of the structure of tempered martensite and reduction in its content at two-stage tempering in the structure of the metal. The strength of the material is also reduced to the level of cast metal. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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Open AccessArticle

Fabrication of Silicon Carbide Fiber-Reinforced Silicon Carbide Matrix Composites Using Binder Jetting Additive Manufacturing from Irregularly-Shaped and Spherical Powders

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Materials 2020, 13(7), 1766; https://doi.org/10.3390/ma13071766 - 09 Apr 2020

Cited by 21 | Viewed by 5251

Abstract

In this paper, silicon carbide fiber-reinforced silicon carbide (SiC_f/SiC) composites were fabricated using binder jetting additive manufacturing followed by polymer infiltration and pyrolysis. Spherical SiC powders were produced using milling, spray drying, and thermal plasma treatment, and were characterized using SEM and XRD methods. Irregularly shaped and spherical SiC powders were used to obtain SiC_f/SiC blends for the application in binder jetting. The effect of SiC powder shape on densification behavior, microstructure, and mechanical properties of binder jetted SiC_f/SiC composites was evaluated. The highest density of 2.52 g/cm³ was obtained after six polymer infiltration and pyrolysis cycles. The microstructure and mechanical properties of the fabricated SiC_f/SiC composites were characterized. Using the spherical SiC powder resulted in higher fracture toughness and hardness, but lower flexural strength compared to the irregularly shaped powder. It was shown that it is feasible to fabricate dense SiC_f/SiC composites using binder jetting followed by polymer infiltration and pyrolysis. Full article

(This article belongs to the Special Issue Materials, Design and Process Development for Additive Manufacturing)

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