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New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series)

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Powder Metallurgy".

Deadline for manuscript submissions: closed (31 December 2024) | Viewed by 15108

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Prof. Dr. Joan-Josep Suñol

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Department of Physics, Campus Montilivi s/n, University of Girona, 17003 Girona, Spain
Interests: powder metallurgy; structural analysis; thermal analysis; mechanical alloying; nanocrystalline
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Leszek Adam Dobrzański

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Medical and Dental Engineering Centre for Research, Design and Production ASKLEPIOS, 44-100 Gliwice, Poland
Interests: materials engineering; nanotechnology; biomaterials; medical; dental; manufacturing and surface engineering; machine building and automation; management and organization
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Special Issue Information

Dear Colleagues,

Powder metallurgy is a set of fabrication techniques related to three major processing steps. First, the precursor material is physically powdered (micro- or nanometric particles). Second, the powder is consolidated to obtain bulk specimens (traditionally by injection into a mould or passed through a dye). Third, pressure and/or temperature is applied. Powder metallurgy is now also applied in the production of composites. Furthermore, new topics have emerged, such as the circular economy or raw materials. In this Special Issue, we expect manuscripts related to new trends in materials (such as high-entropy alloys) and processes (additive manufacturing, unconventional sintering processes). Articles on a) mechanical properties: (fatigue, plasticity, creep), b) physical response (magnetic, electric) and/or c) oxidation–corrosion are welcome, as are review articles.

Prof. Dr. Joan-Josep Suñol
Prof. Dr. Leszek Adam Dobrzański
Guest Editors

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. Metals is an international peer-reviewed open access monthly 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 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

Powder metallurgy
Powder
Mechanical alloying
Sintering
Consolidation
Additive manufacturing
New processes and materials

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Published Papers (8 papers)

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Research

18 pages, 15215 KiB

Open AccessArticle

Correlation Between Morphology and Crystal Structure of Electrolytically Produced Zinc Dendritic Particles

by Nebojša D. Nikolić, Jelena D. Lović, Vesna M. Maksimović, Nikola S. Vuković, Nenad L. Ignjatović, Predrag M. Živković and Sanja I. Stevanović

Metals 2024, 14(12), 1468; https://doi.org/10.3390/met14121468 - 23 Dec 2024

Viewed by 837

Abstract

The correlation between the morphology and crystal structure of zinc dendritic particles produced by electrolysis from the alkaline electrolyte has been established. Morphology and crystal structure of Zn particles electrodeposited by the potentiostatic regime of electrolysis at overpotentials inside (−100 and −160 mV) and outside (−220, −280, and −340 mV) the plateau of the limiting diffusion current density were characterized by scanning electron microscope (SEM) and by X-ray diffraction (XRD), respectively. The particle size distribution (PSD) was performed in order to determine the dependency of the size of dendritic particles on applied electrolysis overpotential. With increasing the overpotential of electrolysis, the shape of particles changed from irregular forms denoted as precursors of dendrites to various forms of dendrites, while the size of the particles simultaneously decreased. All types of Zn dendrites exhibited the strong (002) preferred orientation, while the precursors of dendrites exhibited (101)(002) preferred orientation. The development of strong (002) preferred orientation was explained and discussed by making an analogy with the electrolytic production of lead dendrites from the concentrated nitrate electrolyte. Although zinc and lead belong to different types of crystal lattice (Pb-face-centered cubic type and Zn-hexagonal close-packed type), they have a common characteristic that is manifested by the strong preferred orientation in the crystal plane with the lowest surface energy. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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15 pages, 71765 KiB

Open AccessArticle

Study on Microstructure and High-Temperature Mechanical Properties of Al-Mg-Sc-Zr Alloy Processed by LPBF

by Zhihao Ren, Hao Zhang, Xuedao Shu, Haijie Xu, Siyuan Chen, Yaoyao Ding, Liwen Liang, Zixiang Qiu, Yang Yang and Yongjian Zheng

Metals 2024, 14(8), 890; https://doi.org/10.3390/met14080890 - 4 Aug 2024

Cited by 1 | Viewed by 1880

Abstract

Al-Mg-Sc-Zr alloy processed via laser powder bed fusion (LPBF) is poised for significant application in aerospace, where its high-temperature capabilities are paramount for the safety and longevity of engineered structures. This study offers a systematic examination of the alloy’s high-temperature tensile properties in relation to its microstructure and precipitate phases, utilizing experimental approaches. The LPBF-processed Al-Mg-Sc-Zr alloy features a bimodal microstructure, with columnar grains in the melt pool’s interior and equiaxed grains along its boundary, conferring exceptional properties. The application of well-calibrated processing parameters has yielded an alloy with an impressive relative density of 99.8%, nearly fully dense. Following a thermal treatment of 350 °C for 4 h, the specimens were subjected to tensile tests at both room and elevated temperatures. The data reveal that the specimens exhibit a tensile strength of 560.6 MPa and an elongation of 11.1% at room temperature. A predictable decline in tensile strength with rising temperature is observed: at 100 °C, 150 °C, 200 °C, and 250 °C; the respective strengths and elongations are 435.1 MPa and 25.8%, 269.4 MPa and 20.1%, 102.8 MPa and 47.9%, 54.0 MPa and 72.2%. These findings underpin the technical rationale for employing LPBF-processed Al-Mg-Sc-Zr alloy in aerospace applications. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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15 pages, 6674 KiB

Open AccessArticle

Ultrafine Grain 316L Stainless Steel Manufactured by Ball Milling and Spark Plasma Sintering: Consequences on the Corrosion Resistance in Chloride Media

by Eric Hug, Clément Keller, Cendrine Folton, Jade Papin, Kostiantyn Tabalaiev and Gaël Marnier

Metals 2024, 14(8), 864; https://doi.org/10.3390/met14080864 - 27 Jul 2024

Viewed by 1321

Abstract

This paper reports experimental results concerning the corrosion of 316L austenitic stainless steels produced by ball milling and spark plasma sintering in NaCl electrolyte. Specimens with grain sizes ranging from 0.3 µm to 3 µm, without crystallographic texture, were obtained and compared with a cast that is 110 µm in grain size and an annealed reference. The potentiodynamic experiments showed that the reduction in grain size leads to a degradation of the electrochemical passivation behavior. This detrimental effect can be overcome by appropriate passivation in a HNO₃ concentrated solution before consolidation. The Mott–Schottky measurements showed that the semiconducting properties of the passive layer do not vary significantly on the grain size, especially the donor density, which is responsible for the chemical passivation breakdown by chloride anions. The total electrical resistance of the layer, measured by impedance spectroscopy is always lower than the one of a cast and annealed 316L, but it slightly increases with a reduction in grain size in the ultrafine grain range. This is followed by a slight increase in the thickness of the oxide layer. The effect of chloride ions is very pronounced in terms of passivation breakdown if the powder is not passivated prior to sintering. This leads to the nucleation and growth of subsurface main pits and the formation of secondary satellite pits, especially for the smallest grain sizes. Passivation of the 316L powder before sintering has been found to be an effective way to prevent this phenomenon. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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21 pages, 9613 KiB

Open AccessArticle

Processing, Microstructure, and Properties of Bimetallic Steel-Ni Alloy Powder HIP

by Shenyan Huang, Chen Shen and Victor Samarov

Metals 2024, 14(1), 118; https://doi.org/10.3390/met14010118 - 19 Jan 2024

Cited by 1 | Viewed by 1610

Abstract

This work explores technical feasibility in hot isostatic pressing (HIP) manufacturing of an integral bimetallic component using steel and Ni alloy powder for supercritical carbon dioxide (sCO₂) turbomachinery. Lab-scale bimetallic HIP specimens using HAYNES^® 282^® and SS316L or SS415 powder are investigated in powder configuration, heat treatment, microstructure, and tensile properties up to 400 °C. Interdiffusion profiles at dissimilar alloy interfaces caused by HIP cycle is predicted by DICTRA simulations and validated by electron probe microanalysis (EPMA). The interdiffusion distance of most elements is around 100 μm, while C and N have a higher interdiffusion distance. Dense distribution of Ti-rich carbonitrides and alumina particles are found to decorate prior particle boundaries near joining interface on the 282 side, affecting tensile strength across interface as well as tensile failure location. A higher amount of excessive carbonitride formation near interface is observed in SS316L/282 than in SS415/282, which is consistent with the predicted greater degree of interdiffusion effect in SS316L/282. Typical HAYNES^® 282^® heat treatment condition is applicable to 282/SS316L and 282/SS415 combinations, resulting in a higher strength than cast CF8M and CA6NM. A pilot-scale bimetallic SS415/282 pipe is then demonstrated to show the promise of scaleup. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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13 pages, 4198 KiB

Open AccessArticle

Deciphering Microstructures and Phases of Gas-Atomised Novel Al-Fe-Si-Cr-Ni Alloys

by Bhaskaranand Bhatt, Alessandra Martucci, Enrico Virgillito, Federico Gobber, Federica Bondioli, Diego Manfredi, Mariangela Lombardi and Paolo Fino

Metals 2024, 14(1), 17; https://doi.org/10.3390/met14010017 - 22 Dec 2023

Cited by 1 | Viewed by 2141

Abstract

Rapid solidification techniques, such as gas atomisation, have been widely implemented in metallic alloys/composites to increase solid solubility, avoid or mitigate segregation phenomena, and favour metastable phase formation to enhance performance. Particularly, gas atomisation can enhance the solid solubility of low diffusion coefficient elements like Fe, Ni, Mn, Zr, and Cr in the α-Al matrix, yielding metastable phases. As a result, Al alloys exhibit excellent strength at high temperatures. In this study, the AISI 304L alloy was employed to introduce Fe, Ni, and Cr elements into the AlSi10Mg alloy through gas atomisation, resulting in the formation of two distinct hypereutectic AlFe-based alloys: AlFe9Si8Cr2Ni and AlFe18Si8Cr5Ni2. Gas-atomised alloy powders were separated into different size fractions by sieving and characterised using X-ray diffraction, differential scanning calorimetry, optical microscopy, and scanning electron microscopy. Microstructural analyses revealed dendritic patterns with distinct phases, highlighting the influence of the alloying element content on the solidification processes. Furthermore, a synergic evaluation of the XRD and EDS analysis results allowed the identification of intermetallic phases and their distribution in the two systems. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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16 pages, 3240 KiB

Open AccessFeature PaperArticle

Study on Debinding and Sintering Conditions in Extrusion-Based Additive Manufacturing of 316L and 316L + Cu

by Jean-François Silvain, Daniel Lincoln Gifford, Sébastien Fourcade, Laurent Cuzacq, Jean-Luc Grosseau-Poussard, Catherine Debiemme-Chouvy, Nicolas Tessier Doyen and Yongfeng Lu

Metals 2023, 13(11), 1858; https://doi.org/10.3390/met13111858 - 7 Nov 2023

Cited by 1 | Viewed by 1979

Abstract

This study investigates the use of a methylcellulose binder in extrusion additive manufacturing of 316L as an alternative to common wax-based binders. Various quantities of copper (Cu) powder were also added in the paste composition to attempt to reduce the sintering temperature by promoting persistent liquid phase sintering. Debinding experiments were conducted under different temperatures and dwell times using argon (Ar), Ar/5%H₂, and Ar/1%O₂ atmospheres. Debinding reduced carbon (C) content to 0.032 wt.% by using a two-step debinding process of Ar/5%H₂ and Ar/1%O₂ thermal treatments. Using this debinding process, sintering was conducted at 1200 °C under Ar/5%H₂ atmosphere with the presence of 0, 10, and 20 vol.% Cu in the paste. Microstructure, mechanical, and corrosion properties were studied. Cu additions allowed the improvement of the densification when sintering at 1200 °C was performed. A 20 vol.% Cu addition yielded 88% relative density after sintering for 10 h, while pure 316L powder sintered under the same conditions had 70%. Mechanical properties were inferior to fully dense stainless steel, but it is not clear if this is due to the Cu additions or insufficient densification. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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14 pages, 36423 KiB

Open AccessArticle

A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

by Andrea Angelastro, Paolo Posa, Vito Errico and Sabina Luisa Campanelli

Metals 2023, 13(9), 1588; https://doi.org/10.3390/met13091588 - 13 Sep 2023

Cited by 7 | Viewed by 1541

Abstract

In this work, a systematic study was conducted on the fabrication of multi-material components obtained employing Laser-Powder Bed Fusion (L-PBF) technology. The idea of making multi-material components is a winning capability of additive technologies because it allows for the fabrication of Functionally Graded Materials (FGMs) with the customization of parts according to different required properties. This study aims to determine the ability of an inexpensive system, adaptable to the L-PBF machines already on the market, with a powder-spreading technique based on coaters or rollers, to produce parts with continuously variable properties in each layer. Also, the correlation between certain selectable factors in the production design and the result obtained in terms of metallurgical and mechanical properties and chemical composition was investigated. The factors studied were the relative position of the different materials within the powder chamber and the geometry of the equipment designed to produce the cFGMs components. The performed tests involved the use of two materials, a nickel-based superalloy, and a stainless steel, having different chemical, physical, and mechanical properties to obtain gradual property variations in the manufactured samples. Based on the results of post-process characterization obtained via metallographic, chemical, and mechanical analysis, the relative positions of the materials and the geometry of the developed equipment have a limited effect on the sample’s manufactured properties. The characteristics of the FGM zone depend on the nature of the employed powders, and its extent coincides with that defined during the design of the divider. Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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13 pages, 10873 KiB

Open AccessArticle

Research on the Microstructure and Mechanical Properties of Repaired 7N01 Aluminum Alloy by Laser-Directed Energy Deposition with Sc Modified Al-Zn-Mg

by Jibing Chen, Shanji Yu, Junsheng Yang, Rong Xu, Ruidi Li, Shisen Huang, Hongbin Zhu and Xinyan Liu

Metals 2023, 13(5), 829; https://doi.org/10.3390/met13050829 - 23 Apr 2023

Cited by 6 | Viewed by 2220

Abstract

Aluminum alloy is an important material used in railway train structures. It is of great significance to repair aluminum alloy through directional energy deposition to reduce cost and improve the performance of the aluminum alloy. In this study, 7N01 aluminum alloy was repaired by means of laser-directed energy deposition (DED) with the powder of Sc-modified Al-Zn-Mg aluminum alloy as raw material. The microstructure and mechanical properties of the repaired specimens were studied through the metallographic microscope, scanning electron microscope, electron backscatter diffraction, universal tensile test, and Vickers hardness test in combination. The results show that the bonding interface of the repaired aluminum alloy is satisfactory, and the porosity is 2.8%. The grains in the repaired area are the columnar crystals growing vertically along the boundary of the melt pool with an obvious temperature gradient. Fine equiaxed crystals are distributed along the boundary of the melt pool, and Al₃(Sc,Zr) particles play a role in grain refinement. The average grain size of the fine grain area in the repair zone next to the fusion zone is 9.1 μm, and the average grain size of the coarse grain area is 20 μm. The average tensile strength in the area of repair approaches 349 MPa, which is 91% that of the base material, and the elongation rate is 10.9%, which is 53.2% that of the base material. The hardness ranges between 122 HV and 131 HV, which is comparable to the base material. However, there is a significant decrease in the tensile strength and hardness of the base material (heat-affected zone). Full article

(This article belongs to the Special Issue New Trends of Powder Engineering and Additive Manufacturing (Editorial Board Members’ Collection Series))

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