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Metals
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Additive Manufacturing and Processing of Metallic Alloys and Composites
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Additive Manufacturing and Processing of Metallic Alloys and Composites

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (30 May 2025) | Viewed by 1865

Special Issue Editors

Dr. Zahabul Islam

E-Mail Website
Guest Editor
Mechanical and Manufacturing Engineering, School of Engineering, Bowling Green State University, Bowling Green, OH 43403, USA
Interests: additive manufacturing; characterizations; computer modeling and design; mechanical testing
Special Issues, Collections and Topics in MDPI journals
Dr. Daudi Waryoba

E-Mail Website
Guest Editor
Engineering, Penn State University, DuBois, PA 15801, USA
Interests: physical & powder metallurgy; thermomechanical; material characterization; structure-property-processing optimization
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are pleased to invite you to contribute to a Special Issue titled “Additive Manufacturing and Processing of Metallic Alloys and Composites,” in collaboration with Metals, an open access journal published by MDPI. Additive manufacturing (AM) continues to revolutionize the way we design, manufacture, and process metallic alloys and composite materials, opening new possibilities in industries such as the aerospace, automotive, biomedical, and energy sectors. This Special Issue seeks to bring together cutting-edge research and developments in this exciting area.

Scope of this Special Issue: This Special Issue aims to provide a comprehensive overview of the latest advancements and breakthroughs in the field of additive manufacturing and processing of metallic alloys and composites. We encourage contributions that address fundamental challenges, innovative solutions, and emerging trends that have the potential to significantly impact the way metallic materials are designed and processed via AM technologies.

Topics of interest include but are not limited to the following:

  1. Additive manufacturing techniques: innovations in LPBF, DED, binder jetting, cold spray, EBM, and WAAM.
  2. Materials for additive manufacturing: design and processing of metallic alloys (e.g., titanium, steels, superalloys), composites, and multi-material AM.
  3. Processing–structure–property relationships: microstructural evolution, mechanical properties, residual stress, and defect mitigation in AM parts.
  4. Computational modeling and simulation: modeling thermomechanical behavior, microstructure evolution, and multi-physics simulations of AM materials.

Researchers and practitioners are invited to submit original research articles, comprehensive review articles, and short communications that contribute to the broad field of additive manufacturing and metallic/composite processing. Each submission will undergo a peer-review process to ensure the quality and impact.

Dr. Zahabul Islam
Dr. Daudi Waryoba
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

  • additive manufacturing
  • metallic alloys and composites
  • processing
  • microstructures
  • mechanical properties
  • computational modeling

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  • External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
  • Reprint: MDPI Books provides the opportunity to republish successful Special Issues in book format, both online and in print.

Further information on MDPI's Special Issue policies can be found here.

Published Papers (3 papers)

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Research

14 pages, 2626 KiB  
Article
Warpage Prediction in Wire Arc Additive Manufacturing: A Comparative Study of Isotropic and Johnson–Cook Plasticity Models
by Saeed Behseresht and Young Ho Park
Metals 2025, 15(6), 665; https://doi.org/10.3390/met15060665 - 15 Jun 2025
Viewed by 338
Abstract
Wire Arc Additive Manufacturing (WAAM), a specific type of Directed Energy Deposition (DED) additive manufacturing, has recently gained widespread attention for manufacturing industrial components. WAAM has many advantages compared to other metal AM processes such as powder bed fusion. It is not only [...] Read more.
Wire Arc Additive Manufacturing (WAAM), a specific type of Directed Energy Deposition (DED) additive manufacturing, has recently gained widespread attention for manufacturing industrial components. WAAM has many advantages compared to other metal AM processes such as powder bed fusion. It is not only cost-efficient and easily accessible, but also capable of manufacturing large-scale industrial components in a short period of time. However, due to the inherent layered nature of the process and significant heat accumulation, parts can experience severe warping, often leading to part rejection. Predicting these anomalies prior to manufacturing would allow for process parameter adjustments to reduce or eliminate residual stresses and large deformations. In this study, we develop a simulation-based model capable of accurately predicting final deformations and unintended warpages. A Johnson–Cook plasticity model with isotropic hardening is implemented through a UMAT user subroutine in Abaqus. The proposed model is then utilized to predict the residual stresses and deformations in WAAM-fabricated parts. Simple wall geometries with 4, 8, and 20 layers deposited on build plates of varying thicknesses, are tested to assess the performance of the model. Combined Johnson–Cook plasticity and isotropic hardening for the WAAM process were implemented for the first time in this study, and the model was validated against experimental data, showing a maximum deviation of 4%. Thermal analysis of a four-layer-high wall took 12 min, while structural analysis using the proposed model took 1 h and 40 min. In comparison, thermo-mechanical analysis of the same geometry reported in the literature takes 14 h. The results demonstrate that the proposed model is not only highly accurate in predicting warpage but also significantly faster than other methodologies reported in the literature. Full article
(This article belongs to the Special Issue Additive Manufacturing and Processing of Metallic Alloys and Composites)
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14 pages, 4905 KiB  
Article
Experimental Study of Process Parameter Effects on Internal Defects in Titanium Coaxial Wire-Based Laser Metal Deposition
by Remy Mathenia, Braden McLain, Todd Sparks and Frank Liou
Metals 2025, 15(5), 499; https://doi.org/10.3390/met15050499 - 30 Apr 2025
Viewed by 485
Abstract
Wire-based laser metal deposition is an additive manufacturing process that can be used in the efficient manufacturing of complex structures. This paper utilizes a three-beam coaxial laser wire system to explore the effect of process parameters on the resultant deposition density. The reduction [...] Read more.
Wire-based laser metal deposition is an additive manufacturing process that can be used in the efficient manufacturing of complex structures. This paper utilizes a three-beam coaxial laser wire system to explore the effect of process parameters on the resultant deposition density. The reduction in or elimination of defects is important to the mechanical properties of the additively manufactured material and the widespread adoption of additive manufacturing processes. In this work, two-bead-wide walls were deposited under varying experimental conditions, including the traverse feed rate and workpiece illumination proportion. A method for calculating the bead pitch and layer height increment based on the geometry of the deposited material was developed. The deposited samples were micro-CT-scanned to characterize internal defects at a high resolution. The volume of the detected defects was measured and compared to the total sample volume to calculate a defect rate for each run of the experiment. The traverse feed rate and defocusing level were found to have a significant impact on the output defect rate. As these process parameters were increased, the defect rate decreased. Across the experimental levels, the defect volume percentage was reduced from 1.021% to 0.062%. This reduction in internal defect size enhances the material’s mechanical performance and ensures its suitability for aerospace applications. Full article
(This article belongs to the Special Issue Additive Manufacturing and Processing of Metallic Alloys and Composites)
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18 pages, 10739 KiB  
Article
Unveiling Temperature Distribution and Residual Stress Evolution of Additively Manufactured Ti6Al4V Alloy: A Thermomechanical Finite Element Simulation
by Qihong Fang, Pei Zhao, Jia Li, Hong Wu and Jing Peng
Metals 2025, 15(1), 83; https://doi.org/10.3390/met15010083 - 17 Jan 2025
Cited by 1 | Viewed by 733
Abstract
The performance of the selective electron beam melting (SEBM) products depends on the SEBM-induced temperature and stress. Here, the thermomechanical finite element simulations are conducted to investigate the dynamic evolution of temperature and the thermal stress of melt pool during the SEBM process [...] Read more.
The performance of the selective electron beam melting (SEBM) products depends on the SEBM-induced temperature and stress. Here, the thermomechanical finite element simulations are conducted to investigate the dynamic evolution of temperature and the thermal stress of melt pool during the SEBM process of Ti6Al4V alloys under various processing parameters and scanning strategies. The results show that the melt pool undergoes three stages of preheating, melting, and remelting under the influence of adjacent scanning tracks. This complex thermal history drives significant changes in thermal stress within the melt pool. After adjusting the processing parameters, it is found that a low scanning speed and high electron beam energy result in a high temperature gradient and stress in the molten pool. Compared to the electron beam energy, the scanning speed has a more significant impact on temperature and residual stress. For the dual-electron-beam scanning strategy, the coupling thermal effect between electron beams can reduce the temperature gradient of the melt pool, thereby suppressing the formation of columnar crystals. The electron beam energy of 300 W and the scanning speed of 1.5 m/s can be selected under various scanning strategies, which are expected to suppress the formation of coarse and columnar β grains and achieve relatively low residual stress. These results contribute to providing a theoretical basis for selecting optimized process parameters and scanning strategies. Full article
(This article belongs to the Special Issue Additive Manufacturing and Processing of Metallic Alloys and Composites)
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