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

Deadline for manuscript submissions: closed (20 September 2024) | Viewed by 21815

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Special Issue Editors

Prof. Dr. Hong Wu

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Guest Editor

State Key Laboratory of Powder Metallurgy, Central South University, Changsha, China
Interests: additive manufacturing; biomedical materials
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Dr. Yingtao Tian

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Guest Editor

School of Engineering, Lancaster University, Lancaster LA1 4YW, UK
Interests: laser welding, laser material processing in body-in-white and lithium-ion battery manufacturing; additive manufacturing; digital manufacturing; advanced material joining technologies
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Dr. Alberto Orozco Caballero

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Guest Editor

Department of Mechanical Engineering, Chemistry and Industrial Design, Universidad Politécnica de Madrid, Ronda de Valencia, 3, 28012 Madrid, Spain
Interests: deformation micromechanics; creep; additive manufacturing; light alloys; materials characterisation

Special Issue Information

Dear Colleagues,

Metal-powder-based additive manufacturing (AM) consists of a number of emerging technologies, such as powder bed fusion or the direct deposition of powders by lasers or electron beams. These enable us to produce load-bearing components or structures with extremely complex geometries, as well as providing unique opportunities for the tailored microstructure and design of new materials. In contrast to conventional manufacturing technologies, such as casting, forging and hot rolling, AM offers much greater degrees of freedom in manufacturing and can also significantly reduce the production steps and material waste. However, conventional materials may not be suitable for AM processes, and the lack of processable materials has hindered its wider adoption. Understanding the evolution of microstructure and the resulting material’s behavior is key for developing novel materials for AM processes.

This Special Issue welcomes original research and high-quality comprehensive reviews on recent advances in metal-powder-based additive manufacturing. The focus of this topic includes the design of new alloy compositions, developing the understanding of microstructure evolution and the impacts on mechanical properties. Material systems of interest include, but are not limited to, structural materials, different types of steels, aluminium, titanium, nickel, copper, cobalt-based alloys, refractory metals, shape-memory alloys, high-entropy alloys, and bulk metallic glasses.

Contributing papers are solicited in the following fields:

Novel alloy design tailored for AM;
Novel metal powder AM processes;
Multi-materials processing in AM;
Microstructural evolution during the AM processes;
Microstructure and property relationships of AM components;
Microstructural response of AM components to post-processing conditions.

Prof. Dr. Hong Wu
Dr. Yingtao Tian
Dr. Alberto Orozco Caballero
Guest Editors

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Keywords

metal powder materials
powder bed fusion
direct energy deposition
binder jetting
microstructures and properties
post-processing of AM components

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Published Papers (10 papers)

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Editorial

Jump to: Research

2 pages, 174 KiB

Open AccessEditorial

Recent Advances in Metal Powder-Based Additive Manufacturing

by Hong Wu, Yaojia Ren, Yingtao Tian and Alberto Orozco Caballero

Materials 2023, 16(11), 3975; https://doi.org/10.3390/ma16113975 - 26 May 2023

Viewed by 1657

Abstract

Over the past two decades, laser additive manufacturing technology has evolved rapidly and has been applied in many industrial sectors [...] Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

Research

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24 pages, 18811 KiB

Open AccessArticle

Microstructure and Mechanical Properties of As-Built Ti-6Al-4V and Ti-6Al-7Nb Alloys Produced by Selective Laser Melting Technology

by Dorota Laskowska, Błażej Bałasz and Wojciech Zawadka

Materials 2024, 17(18), 4604; https://doi.org/10.3390/ma17184604 - 19 Sep 2024

Cited by 1 | Viewed by 1410

Abstract

Additive manufacturing from metal powders using selective laser melting technology is gaining increasing interest in various industries. The purpose of this study was to determine the effect of changes in process parameter values on the relative density, microstructure and mechanical properties of Ti-6Al-4V and Ti-6Al-7Nb alloy samples. The experiment was conducted in response to a noticeable gap in the research on the manufacturability of the Ti-6Al-7Nb alloy in SLM technology. This topic is significant given the growing interest in this alloy for biomedical applications. The results of this study indicate that by properly selecting the volumetric energy density (VED), the relative density of the material produced and the surface roughness of the components can be effectively influenced. Microstructural analyses revealed similar patterns in both alloys manufactured under similar conditions, characterized by columnar β phase grains with needle-like α’ phases. Increasing the VED increased the tensile strength of the fabricated Ti-6Al-4V alloy components, while the opposite effect was observed for components fabricated from Ti-6Al-7Nb alloy. At the same time, Ti-6Al-7Nb alloy parts featured higher elongation values, which is desirable from the perspective of biomedical applications. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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19 pages, 16906 KiB

Open AccessArticle

Microstructure, Mechanical, and Tribological Properties of Nb-Doped TiAl Alloys Fabricated via Laser Metal Deposition

by Kai Huang, Feng Xu, Xinyan Liu, Shiqiu Liu, Qingge Wang, Ian Baker, Min Song and Hong Wu

Materials 2024, 17(17), 4260; https://doi.org/10.3390/ma17174260 - 28 Aug 2024

Cited by 2 | Viewed by 1275

Abstract

TiAl alloys possess excellent properties, such as low density, high specific strength, high elastic modulus, and high-temperature creep resistance, which allows their use to replace Ni-based superalloys in some high-temperature applications. In this work, the traditional TiAl alloy Ti-48Al-2Nb-2Cr (Ti4822) was alloyed with additional Nb and fabricated using laser metal deposition (LMD), and the impacts of this additional Nb on the microstructure and mechanical and tribological properties of the as-fabricated alloys were investigated. The resulting alloys mainly consisted of the γ phase, trace β₀ and α₂ phases. Nb was well distributed throughout the alloys, while Cr segregation resulted in the residual β₀ phase. Increasing the amount of Nb content increased the amount of the γ phase and reduced the amount of the β₀ phase. The alloy Ti4822-2Nb exhibited a room-temperature (RT) fracture strength under a tensile of 568 ± 7.8 MPa, which was nearly 100 MPa higher than that of the Ti4822-1Nb alloy. A further increase in Nb to an additional 4 at.% Nb had little effect on the fracture strength. Both the friction coefficient and the wear rate increased with the increasing Nb content. The wear mechanisms for all samples were abrasive wear with local plastic deformation and oxidative wear, resulting in the formation of metal oxide particles. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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12 pages, 5072 KiB

Open AccessArticle

Tailored Time–Temperature Transformation Diagram for IN718 Alloy Obtained via Powder Bed Fusion Additive Manufacturing: Phase Behavior and Precipitation Dynamic

by Julio Cesar Franco-Correa, Enrique Martínez-Franco, Celso Eduardo Cruz-González, Juan Manuel Salgado-López and Jhon Alexander Villada-Villalobos

Materials 2023, 16(23), 7280; https://doi.org/10.3390/ma16237280 - 22 Nov 2023

Cited by 2 | Viewed by 2778

Abstract

Experimental and computational approaches were used to study the microstructure of IN718 produced via powder bed fusion additive manufacturing (PBF-AM). The presence, chemical composition, and distribution of stable and metastable phases (γ′′, δ, MC, and Laves) were also analyzed. The information obtained from the microstructural study was used to construct a tailored time–temperature transformation (TTT) diagram customized for additive manufacturing of IN718. Experimental techniques, including differential scanning calorimetry (DSC), scanning electron microscopy, energy dispersive X-ray spectroscopy, and electron backscatter diffraction (EBSD), were employed to establish the morphological, chemical, and structural characteristics of the microstructure. The Thermo-Calc software and a Scheil–Gulliver model were used to analyze the presence and behavior of phase transformations during heating and cooling processes under non-thermodynamic equilibrium conditions, typical of AM processes. Unlike conventional TTT diagrams of this alloy, the diagram presented here reveals that the precipitation of γ′′ and δ phases occurs at lower temperatures and shorter times in AM-manufactured parts. Significantly, the superposition of γ′′ and δ phase curves in the proposed diagram underscores the interdependence between these phases. This TTT diagram is a valuable insight that can help in the development of heat treatment processes and quality control for IN718 produced via PBF-AM. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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10 pages, 4194 KiB

Open AccessCommunication

Fabricating Inner Channels in Laser Additive Manufacturing Process via Thin-Plate-Preplacing Method

by Junke Jiao, Shengyuan Sun, Zifa Xu, Jiale Wang, Liyuan Sheng and Jicheng Gao

Materials 2023, 16(19), 6406; https://doi.org/10.3390/ma16196406 - 26 Sep 2023

Viewed by 1303

Abstract

This paper presents a hybrid manufacturing process for the preparation of complex cavity structure parts with high surface quality. Firstly, laser precision packaging technology is utilized to accurately connect a thin plate to a substrate with microchannel. Secondly, Direct Metal Laser-Sintering (DMLS) technology is utilized to completely shape the part. The morphology and microstructure of laser encapsulated specimens and DMLS molded parts were investigated. The results show that the thin plate and the substrate can form a good metallurgical bond. The lowest surface roughness of the DMLS molded parts was 1.18 μm. The perpendicularity between the top of the microchannel and the side wall was optimal when the laser power was 240 W. Consequently, the hybrid manufacturing process effectively solves the problems of poor surface quality and powder sticking of closed inner cavities. The method effectively eliminates the defects of adhesive powder in the inner cavity of the DMLS microchannel, improves the finish, and solves the problem that mechanical tools cannot be processed inside the microchannel, which lays the foundation for the research of DMLS high-quality microchannel process. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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21 pages, 8716 KiB

Open AccessArticle

Mechanical and Surface Characteristics of Selective Laser Melting-Manufactured Dental Prostheses in Different Processing Stages

by Edgar Moraru, Alina-Maria Stoica, Octavian Donțu, Sorin Cănănău, Nicolae-Alexandru Stoica, Victor Constantin, Daniela-Doina Cioboată and Liliana-Laura Bădiță-Voicu

Materials 2023, 16(18), 6141; https://doi.org/10.3390/ma16186141 - 9 Sep 2023

Cited by 5 | Viewed by 2104

Abstract

Due to the expansion of the use of powder bed fusion metal additive technologies in the medical field, especially for the realization of dental prostheses, in this paper, the authors propose a comparative experimental study of the mechanical characteristics and the state of their microscale surfaces. The comparison was made from material considerations starting from two dental alloys commonly used to realize dental prostheses: Ni-Cr and Co-Cr, but also technologies for obtaining selective laser melting (SLM) and conventional casting. In addition, to compare the performances with the classical casting technology, for the dental prostheses obtained through SLM, the post-processing stage in which they are in a preliminary finishing and polished state was considered. Therefore, for the determination of important mechanical characteristics and the comparative study of dental prostheses, the indentation test was used, after which the hardness, penetration depths (maximum, permanent, and contact depth), contact stiffness, and contact surface were established, and for the determination of the microtopography of the surfaces, atomic force microscopy (AFM) was used, obtaining the local areal roughness parameters at the miniaturized scale—surface average roughness, root-mean-square roughness (RMS), and peak-to-peak values. Following the research carried out, several interesting conclusions were drawn, and the superiority of the SLM technology over the classic casting method for the production of dental prostheses in terms of some mechanical properties was highlighted. At the same time, the degree of finishing of dental prostheses made by SLM has a significant impact on the mechanical characteristics and especially the local roughness parameters on a miniaturized scale, and if we consider the same degree of finishing, no major differences are observed in the roughness parameters of the surfaces of the prostheses produced by different technologies. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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16 pages, 6735 KiB

Open AccessArticle

Microstructural Evolution, Mechanical Properties and Tribological Behavior of B₄C-Reinforced Ti In Situ Composites Produced by Laser Powder Bed Fusion

by Jingguang Du, Yaojia Ren, Xinyan Liu, Feng Xu, Xiaoteng Wang, Runhua Zhou, Ian Baker and Hong Wu

Materials 2023, 16(13), 4890; https://doi.org/10.3390/ma16134890 - 7 Jul 2023

Cited by 4 | Viewed by 2086

Abstract

Based on the advantage of rapid net-shape fabrication, laser powder bed fusion (LPBF) is utilized to process B₄C-reinforced Ti composites. The effect of volumetric energy density (VED) on the relative density, microstructural evolution, tensile properties and wear behaviors of B₄C-reinforced Ti composites were systematically investigated. The LPBF-ed samples with high relative density (>99%) can be achieved, while the pores and un-melted powders can be observed in the sample owing to the low energy input (33 J/mm³). The additive particulates B₄C were transformed into needle-like TiB whiskers with nano-scale while C dissolved in the Ti matrix. Fine-scale grains (<10 μm) with random crystallographic orientation can be achieved and the residual stress shows a downtrend as the VED increases. Through the analysis of the tensile and wear tests, the sample at 61 J/mm³VED showed a good combination of strength and wear performance, with an ultimate tensile strength of 951 MPa and a wear rate of 3.91 × 10⁻⁴ mm³·N⁻¹m⁻¹. The microstructural evolution in VED changes and the corresponding underlying strengthening mechanisms of LPBF-ed Ti + B₄C composites are conducted in detail. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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20 pages, 8487 KiB

Open AccessArticle

The Effects of Co on the Microstructure and Mechanical Properties of Ni-Based Superalloys Prepared via Selective Laser Melting

by Xiaoqiong Ouyang, Feng Liu, Lan Huang, Lin Ye, Heng Dong, Liming Tan, Li Wang, Xiaochao Jin and Yong Liu

Materials 2023, 16(7), 2926; https://doi.org/10.3390/ma16072926 - 6 Apr 2023

Cited by 3 | Viewed by 2407

Abstract

In this work, two Ni-based superalloys with 13 wt.% and 35 wt.% Co were prepared via selective laser melting (SLM), and the effects of Co on the microstructure and mechanical properties of the additively manufactured superalloys were investigated. As the Co fraction increased from 13 wt.% to 35 wt.%, the average grain size decreased from 25.69 μm to 17.57 μm, and the size of the nano-phases significantly increased from 80.54 nm to 230 nm. Moreover, the morphology of the γ′ phase changed from that of a cuboid to a sphere, since Co decreased the γ/γ′ lattice mismatch from 0.64% to 0.19%. At room temperature, the yield strength and ultimate tensile strength of the 13Co alloy reached 1379 MPa and 1487.34 MPa, and those of the 35Co alloy were reduced to 1231 MPa and 1350 MPa, while the elongation increased by 52%. The theoretical calculation indicated that the precipitation strengthening derived from the γ′ precipitates made the greatest contribution to the strength. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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15 pages, 8773 KiB

Open AccessArticle

Structure and Mechanical Properties of Cu–Al–Mn Alloys Fabricated by Electron Beam Additive Manufacturing

by Evgeny Moskvichev, Nikolay Shamarin and Alexey Smolin

Materials 2023, 16(1), 123; https://doi.org/10.3390/ma16010123 - 22 Dec 2022

Cited by 4 | Viewed by 2233

Abstract

In this work, the method of electron beam additive manufacturing (EBAM) was used to fabricate a Cu-based alloy possessing a shape memory effect. Electron beam additive technology is especially relevant for copper and its alloys since the process is carried out in a vacuum, which makes it possible to circumvent oxidation. The main purpose of the study was to establish the influence of the printing parameters on the structure of the obtained products, their phase composition, mechanical properties, dry friction behavior, and the structure-phase gradient that formed in Cu–Al–Mn alloy samples during electron beam layer-by-layer printing. The results of the study allowed us to reveal that the structure-phase composition, the mechanical properties, and the tribological performance of the fabricated material are mainly affected by the magnitude of heat input during electron beam additive printing of Cu–Al–Mn alloy. High heat input values led to the formation of the β1′ + α decomposed structure. Low heat input values enabled the suppression of decomposition and the formation of an ordered 1 structure. The microhardness values were distributed on a gradient from 2.0 to 2.75 GPa. Fabricated samples demonstrated different behaviors in friction and wear depending on their composition and structure, with the value of the friction coefficient lying in the range between 0.1 and 0.175. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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20 pages, 4546 KiB

Open AccessEditor’s ChoiceArticle

Programmable Density of Laser Additive Manufactured Parts by Considering an Inverse Problem

by Mika León Altmann, Stefan Bosse, Christian Werner, Rainer Fechte-Heinen and Anastasiya Toenjes

Materials 2022, 15(20), 7090; https://doi.org/10.3390/ma15207090 - 12 Oct 2022

Cited by 1 | Viewed by 2356

Abstract

In this Article, the targeted adjustment of the relative density of laser additive manufactured components made of AlSi10Mg is considered. The interest in demand-oriented process parameters is steadily increasing. Thus, shorter process times and lower unit costs can be achieved with decreasing component densities. Especially when hot isostatic pressing is considered as a post-processing step. In order to be able to generate process parameters automatically, a model hypothesis is learned via artificial neural networks (ANN) for a density range from 70% to almost 100%, based on a synthetic dataset with equally distributed process parameters and a statistical test series with 256 full factorial combined instances. This allows the achievable relative density to be predicted from given process parameters. Based on the best model, a database approach and supervised training of concatenated ANNs are developed to solve the inverse parameter prediction problem for a target density. In this way, it is possible to generate a parameter prediction model for the high-dimensional result space through constraints that are shown with synthetic test data sets. The presented concatenated ANN model is able to reproduce the origin distribution. The relative density of synthetic data can be predicted with an R²-value of 0.98. The mean build rate can be increased by 12% with the formulation of a hint during the backward model training. The application of the experimental data shows increased fuzziness related to the big data gaps and a small number of instances. For practical use, this algorithm could be trained on increased data sets and can be expanded by properties such as surface quality, residual stress, or mechanical strength. With knowledge of the necessary (mechanical) properties of the components, the model can be used to generate appropriate process parameters. This way, the processing time and the amount of scrap parts can be reduced. Full article

(This article belongs to the Special Issue Recent Advances in Metal Powder Based Additive Manufacturing)

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