Advanced Welding and Additive Manufacturing Technologies of Metallic Materials

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

Deadline for manuscript submissions: 31 December 2026 | Viewed by 904

Special Issue Editor


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Guest Editor
School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan 430070, China
Interests: welding; additive manufacturing; modeling and simulation; machine learning
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Special Issue Information

Dear Colleagues,

Advanced welding and additive manufacturing technologies constitute the scientific and industrial foundation for fabricating and joining high-performance metallic materials. Both disciplines are governed by common physical principles, including highly localized energy–matter interactions, rapid solidification phenomena, and complex thermo-mechanical cycles. These principles dictate the resulting microstructures, defect populations, and mechanical performance of the final components. A deeper understanding of these fundamentals is critical to overcoming persistent technological barriers and unlocking the full potential of next-generation metallic systems.

This Special Issue on “Advanced Welding and Additive Manufacturing Technologies of Metallic Materials” will consolidate state-of-the-art research that advances the fundamental understanding and technological application of welding and additive manufacturing for metallic materials. The scope is comprehensive, covering innovations in processes such as high-energy-density beam welding and additive manufacturing, the underlying physics of melt-pool dynamics and solidification, and the processing–microstructure–property relationships in advanced alloys such as high-entropy alloys and superalloys. Further focus will be placed on computational modeling, digital twins, machine learning, advanced in situ monitoring and control, the mechanisms and mitigation of defects and residual stress, and synergistic hybrid manufacturing methods. The collection aims to chronicle the latest breakthroughs and establish a benchmark for the current state of advanced metal manufacturing, pushing the boundaries of process capability, material performance, and scientific understanding.

Dr. Wenchao Ke
Guest Editor

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Keywords

  • welding and joining
  • additive manufacturing
  • metallic materials
  • microstructure
  • mechanical properties
  • modeling and simulation
  • machine learning
  • monitoring and process control
  • residual stress
  • defects

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Published Papers (2 papers)

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Research

21 pages, 5046 KB  
Article
Study on the Modification of TiC/440C Composite Coatings Fabricated by Plasma Surfacing
by Rongxin Lan, Zhengbing Meng, Meiqiao Wu, Jiangbo Deng and Dinghua Feng
Metals 2026, 16(5), 505; https://doi.org/10.3390/met16050505 - 7 May 2026
Viewed by 281
Abstract
S136 mold steel is widely used in the injection molding industry due to its excellent properties. However, during actual production, the mold is inevitably exposed to harsh service conditions involving high temperature, high pressure, chemical corrosion, and mechanical wear, leading to risks of [...] Read more.
S136 mold steel is widely used in the injection molding industry due to its excellent properties. However, during actual production, the mold is inevitably exposed to harsh service conditions involving high temperature, high pressure, chemical corrosion, and mechanical wear, leading to risks of failure caused by pitting corrosion, intergranular corrosion, electrochemical corrosion, selective dissolution, and surface fatigue wear. To enhance the surface protection performance of the mold, a TiC-reinforced 440C stainless steel composite coating was fabricated on the S136 substrate using plasma spray welding technology. Composite powders with different TiC contents (wt.%) were prepared via mechanical mixing. The phase composition, microstructure, microhardness, corrosion resistance, and wear resistance of the coatings were characterized by XRD, SEM, Vickers microhardness tester, electrochemical workstation, and vertical universal friction and wear tester. Furthermore, the corresponding strengthening mechanisms were elucidated. The results show that the incorporation of TiC refines the microstructure and synergistically enhances both corrosion and wear resistance. Among the tested coatings, the one with 1.0 wt.% TiC exhibits the best overall performance, with a significantly increased microhardness of 858.85 HV (approximately 1.5 times that of the substrate), an Ecorr of –0.286 ± 0.002 V, an Icorr of 4.51 × 10−7 A·cm−2, and a friction coefficient of 0.591. This study provides important theoretical and technological insights for the surface strengthening of S136 mold steel using plasma spray welding of TiC/440C composite coatings to improve corrosion and wear resistance and extend service life. Full article
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16 pages, 2588 KB  
Article
Prediction of Activity of Au-Sn-Based Lead-Free Solder Using Modified Molecular Interaction Volume Model
by Hai Wu, Liangliang Chen, Liguo Zhu, Lingxin Kong, Ganggang Liu, Bin Yang and Yong Deng
Metals 2026, 16(3), 330; https://doi.org/10.3390/met16030330 - 16 Mar 2026
Viewed by 312
Abstract
Controlling thermodynamic properties is critical for the rational design and development of advanced lead-free solders, especially in high-temperature applications. Au–Sn-based alloys have emerged as promising candidates for high-performance electronic packaging, yet reliable thermodynamic descriptions of their multicomponent systems remain limited. The Modified Molecular [...] Read more.
Controlling thermodynamic properties is critical for the rational design and development of advanced lead-free solders, especially in high-temperature applications. Au–Sn-based alloys have emerged as promising candidates for high-performance electronic packaging, yet reliable thermodynamic descriptions of their multicomponent systems remain limited. The Modified Molecular Interaction Volume Model (M-MIVM) provides a effective approach for characterizing strongly asymmetric liquid alloys that are typical in Au–Sn-based systems. This work focuses on the thermodynamic modeling of Au–Sn-containing ternary and quaternary solder systems within a physically consistent and computationally efficient framework. The study aims to support the database development, composition design, and optimization of next-generation high-temperature lead-free solders. Full article
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