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Metals
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Development of Novel Alloys through Additive Manufacturing for Next-Generation Applications
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Development of Novel Alloys through Additive Manufacturing for Next-Generation Applications

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

Deadline for manuscript submissions: closed (31 March 2024) | Viewed by 6237

Special Issue Editors

Dr. Dharmalingam Ganesan

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Guest Editor
Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R & D Institute of Science and Technology, Chennai 600062, India
Interests: powder metallurgy; engineering materials and metallurgy; nano composite materials; high-temperature materials; wear and corrosion analysis; additive manufacturing
Dr. Sachin Salunkhe

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Guest Editor
Associate Professor, Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R & D Institute of Science and Technology, Chennai 600062, India
Interests: artificial intelligence; lubricants; 3D printing; metal forming; wear analysis; high strain rate
Special Issues, Collections and Topics in MDPI journals
Dr. Hakan Gürün

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Guest Editor
Associate Professor, Faculty of Technology, Department of Manufacturing Engineering, Gazi University, Ankara, Turkey
Interests: construction and manufacturing; mechanical
Prof. Dr. Joao Paulo Davim

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Guest Editor
Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
Interests: machining; composite materials; tribology; sustainable manufacturing; industrial engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In present modern society, engineering materials play a major role in every sector. The biggest challenge of developing novel alloys is the need to control their desirable phases, microstructure, chemical composition, corrosion resistance, and wear resistance, along with the expectation of having advantageous room/high-temperature mechanical properties to overcome obstacle requirements. For the future development of novel alloys, additive manufacturing (AM) is a promising technique of immense engineering and scientific significance. AM processing routes offer several advantages, such as near-net fabrication with minimal wastage, minimized postprocessing, complexity for free fabrication, short lead time, etc. However, there exist some imperfections in the field of AM alloy development, including the precipitate failure of materials, process parameter optimization, structure–property correlations, and numerical simulations.

This Special Issue aims to highlight the most significant research trends and current state-of-the-art knowledge concerning the development of novel alloys through the use of AM processing routes and to compile information from a variety of experts and researchers in this field. All interested researchers are welcome to submit their work pertaining to topics including, but not limited to, ferrous and nonferrous alloys, composite materials, additive manufacturing methods, microstructure and mechanical properties, strengthening mechanisms, wear phenomena, and corrosion.

Dr. Dharmalingam Ganesan
Dr. Sachin Salunkhe
Dr. Hakan Gürün
Prof. Dr. Joao Paulo Davim
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

  • ferrous and nonferrous alloys
  • composite materials
  • additive manufacturing methods
  • microstructure and mechanical properties
  • strengthening mechanisms
  • wear phenomena
  • corrosion

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

Published Papers (2 papers)

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Research

24 pages, 11440 KiB  
Article
Novel Powder Feedstock towards Microstructure Engineering in Laser Powder Bed Fusion: A Case Study on Duplex/Super Duplex and Austenitic Stainless-Steel Alloys
by Leonidas Gargalis, Leonidas Karavias, Joachim S. Graff, Spyros Diplas, Elias P. Koumoulos and Evangelia K. Karaxi
Metals 2023, 13(9), 1546; https://doi.org/10.3390/met13091546 - 1 Sep 2023
Cited by 7 | Viewed by 2539
Abstract
Additive manufacturing of Duplex Stainless Steels (DSS) and Super Duplex Stainless Steels (SDSS) has been successfully demonstrated using LPBF in recent years, however, both alloys feature an almost fully ferritic microstructure in the as-built condition due to the fast cooling rates associated with [...] Read more.
Additive manufacturing of Duplex Stainless Steels (DSS) and Super Duplex Stainless Steels (SDSS) has been successfully demonstrated using LPBF in recent years, however, both alloys feature an almost fully ferritic microstructure in the as-built condition due to the fast cooling rates associated with the Laser Powder Bed Fusion (LPBF) process. Blends of DSS and SDSS powders were formulated with austenitic stainless-steel 316L powder, aiming to achieve increased austenite formation during in the LPBF as-built condition to potentially minimize the post heat treatments (solution annealing and quenching). Powder characteristics were investigated and process parameters were optimized to produce near fully dense parts. Nanoindentation (NI) tests were conducted to measure, not only the local mechanical properties and correlate them with the as-built microstructure, but also to gain a deeper understanding in the deformation behavior of individual phases that cannot be studied directly by macroscopic tensile tests. Scanning Electron Microscopy (SEM) and Electron Backscatter Diffraction (EBSD) were employed for microstructural analysis and phase quantification. The microstructural analysis and EBSD phase maps revealed an increase in austenite in the as-built microstructures. Blend 1 resulted in a duplex microstructure consisting of 10% austenite at the XY plane and 20% austenite at the XZ plane. The austenite content increased with increasing proportion of 316L stainless steel in the powder blends. The DSS blend required a much higher volumetric energy density for the fabrication of near fully dense parts. This imposed a slower solidification and a higher melt pool homogeneity, allowing for adequate diffusion of the austenite stabilizing elements. The presented workflow and findings from this study provide valuable insights into powder mixing for the development of custom alloys for rapid material screening in LPBF. Full article
(This article belongs to the Special Issue Development of Novel Alloys through Additive Manufacturing for Next-Generation Applications)
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19 pages, 12133 KiB  
Article
Experimental and Analytical Investigation of the Re-Melting Effect in the Manufacturing of 316L by Direct Energy Deposition (DED) Method
by Harun Kahya, Hakan Gurun and Gokhan Kucukturk
Metals 2023, 13(6), 1144; https://doi.org/10.3390/met13061144 - 20 Jun 2023
Cited by 3 | Viewed by 2386
Abstract
In this study, the effects of the laser power (2000 W, 2250 W, 2500 W), scanning speed (0.6, 0.8, 1 m/min), and powder feed rate (10, 12.5, 15 g/min) on material structures and their mechanical properties were investigated in the production of 316L [...] Read more.
In this study, the effects of the laser power (2000 W, 2250 W, 2500 W), scanning speed (0.6, 0.8, 1 m/min), and powder feed rate (10, 12.5, 15 g/min) on material structures and their mechanical properties were investigated in the production of 316L stainless steels through Direct Energy Deposition (DED). In addition, changes in the microstructure caused by the re-melting process were also investigated. Optimized process parameters were modeled using the CFD software (FLOW 3D V3.0). In order to see the effects on the density and mechanical properties, the sample production was repeated as a build and by applying the re-melting process between the layers. When the energy density and powder feed rate are considered together, it has been determined that the deposition rate increases in direct proportion to the energy density and tends to decrease inversely with the powder feed rate. When the experimental and analysis results of the single clad height are compared, it is seen that the values obtained are very approximate. It has been observed that the most important parameters affecting the formation of porosity are the energy density and powder feed density. Re-melting slightly affects the microstructure of the material and causes grain growth. Changes in the impact strength of the re-melted samples were observed depending on the energy density. Full article
(This article belongs to the Special Issue Development of Novel Alloys through Additive Manufacturing for Next-Generation Applications)
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