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Microstructural and Corrosion Aspects in Additive Manufacturing of Alloys and...
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Microstructural and Corrosion Aspects in Additive Manufacturing of Alloys and Steel

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

Deadline for manuscript submissions: 31 January 2027 | Viewed by 1677

Editors

Dr. Arshad Yazdanpanah

E-Mail Website
Guest Editor
Department of Industrial Engineering, University of Padova, 35122 Padua, Italy
Interests: additive manufacturing; microstructural characterization; corrosion
Prof. Dr. Huijun Li

E-Mail Website
Guest Editor
School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Northfields Avenue, Wollongong, NSW 2522, Australia
Interests: welding and joining; wire arc based additive manufacturing; high temperature materials; line pipe steels; materials characterisation

Special Issue Information

Dear Colleagues,

Metal Additive manufacturing (AM) is rapidly transforming key industrial sectors—including biomedical, energy, and aerospace—by enabling exceptional design flexibility and material efficiency. Despite these advances, there remains a significant gap in our understanding of how the unique microstructural characteristics introduced by AM processes influence the corrosion behaviour of materials. While considerable efforts have been made to investigate the mechanical properties of additively manufactured materials, the complex relationship between microstructure and corrosion performance remains underexplored. This critical knowledge gap limits the broader adoption of AM technologies in environments where corrosion resistance is essential.

As Guest Editor, I am pleased to announce a forthcoming Special Issue titled "Microstructural and Corrosion Aspects in Additive Manufacturing of Alloys and Steel", and I Would Like To Personally Invite You To Contribute Your Expertise. This Special Issue aims to bring together original research and review articles that explore the fundamental mechanisms, characterization techniques, modelling approaches, and experimental findings related to corrosion and microstructure in AM materials.

Your contribution would be highly valuable in advancing this important field and shaping future developments. We welcome high-quality submissions on topics including, but not limited to, the following:

  • Corrosion mechanisms in AM metals and alloys;
  • Influence of process parameters and post-processing on corrosion behaviour;
  • Microstructure–corrosion correlations;
  • Electrochemical and surface characterization techniques;
  • Predictive modelling and simulation of corrosion in AM materials;
  • Applications of AM materials in corrosive environments.

If you are interested in contributing, please let me know at your earliest convenience. Full submission instructions, deadlines, and details about the journal will be provided upon your confirmation.

Thank you for considering this opportunity to help advance the frontier of knowledge in additive manufacturing and corrosion science. I look forward to your positive response.

Dr. Arshad Yazdanpanah
Prof. Dr. Huijun Li
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 250 words) can be sent to the Editorial Office for assessment.

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-anonymized 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
  • laser-based manufacturing, corrosion performance
  • passivity
  • microsctrutural characterization

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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

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26 pages, 2381 KB  
Article
Anisotropy in Microstructure and Corrosion Behavior of NiTi Alloys Produced by Laser Powder Bed Fusion
by Chenglong Teng, Yi-Fan Zhang, Hui Xiao, Yun-Fei Pei and Liang-Yu Chen
Metals 2026, 16(7), 731; https://doi.org/10.3390/met16070731 - 2 Jul 2026
Viewed by 85
Abstract
Laser powder bed fusion (LPBF) induces pronounced microstructural anisotropy in NiTi alloys, which strongly governs their corrosion behavior in physiological environments. Here, the orientation-dependent microstructure and corrosion performance of LPBF NiTi alloys were systematically investigated on the XY (perpendicular to build direction) and [...] Read more.
Laser powder bed fusion (LPBF) induces pronounced microstructural anisotropy in NiTi alloys, which strongly governs their corrosion behavior in physiological environments. Here, the orientation-dependent microstructure and corrosion performance of LPBF NiTi alloys were systematically investigated on the XY (perpendicular to build direction) and XZ (parallel to build direction) planes. The XY plane is dominated by polygonal B2 grains, whereas semi-quantitative XRD analysis and TEM observations indicate a relatively larger contribution of lamellar B19′ martensite on the XZ plane. Electrochemical tests in Hank’s solution (pH 3–7) reveal pronounced corrosion anisotropy. At pH 7, the XZ plane exhibits a higher charge transfer resistance (143.9 vs. 109.1 kΩ cm2) and a lower corrosion current density (0.231 vs. 0.599 μA cm−2) than the XY plane. After 72 h immersion, the Rct of the XZ plane remains approximately 31% higher than that of the XY plane at pH 7, while its apparent donor density is lower than that of the XY plane at pH 3 (7.38 × 1029 vs. 12.33 × 1029 cm−3). The superior electrochemical response of the XZ plane correlates with its denser lamellar B19′ morphology and lower passive-film donor density. Competition between interface-assisted passivation and interface-related electrochemical heterogeneity is proposed as a possible contributor to the anisotropic corrosion response. Full article
(This article belongs to the Special Issue Microstructural and Corrosion Aspects in Additive Manufacturing of Alloys and Steel)

Review

Jump to: Research

23 pages, 5265 KB  
Review
Research Progress on the Microstructure, Mechanical Properties, and Corrosion Behavior of TC4 Alloy Fabricated by Selective Laser Melting
by Huiling Zhou, Ji Li, Shugang Zhang, Bin Yang, Yuanbin Gui, Xiangbo Li, Huixia Zhang, Xiaoru Zhuo, Sheng Lu and Yanxin Qiao
Metals 2026, 16(3), 284; https://doi.org/10.3390/met16030284 - 3 Mar 2026
Cited by 6 | Viewed by 1157
Abstract
Selective laser melting (SLM), a pivotal additive manufacturing (AM) technology for titanium alloys, enables near-net-shape forming of complex structures with relative densities of up to 99.9%, making it indispensable in aerospace, biomedical, and marine engineering. This review comprehensively updates the state of the [...] Read more.
Selective laser melting (SLM), a pivotal additive manufacturing (AM) technology for titanium alloys, enables near-net-shape forming of complex structures with relative densities of up to 99.9%, making it indispensable in aerospace, biomedical, and marine engineering. This review comprehensively updates the state of the art on SLM-fabricated TC4 (Ti-6Al-4V) alloy, addressing critical gaps in previous studies by integrating novel research progress, in-depth mechanistic analyses, and multi-dimensional comparisons. The core focus is on the unique thermal cycle (106–108 °C/s heating/cooling rates) of SLM, which induces a predominant needle-like martensitic α′ phase (99.7%) and minimal β phase (0.3%), leading to intrinsic anisotropy and low ductility. Room-temperature tensile strength reaches 1315.32 MPa with 9.6% elongation, and high-cycle fatigue limits the range from 417 to 829 MPa, strongly dependent on process parameters and post-treatment. Corrosion anisotropy is systematically analyzed: the XY plane (parallel to scanning direction) exhibits superior corrosion resistance in 1 M HCl (fewer pits and lower corrosion current density) and 3.5% NaCl (more stable passive film) compared to the XZ plane (deposition direction). Novel insights include: (1) synergistic effects of SLM process parameters (laser power–scanning speed–hatch spacing) on defect evolution and microstructure uniformity; (2) atomistic mechanisms of α′→α + β phase transformation during post-heat treatment; and (3) corrosion–mechanical coupling behavior in harsh environments (e.g., marine and biomedical). Post-treatment strategies are refined: annealing at 800 °C for 2 h achieves 1099 MPa tensile strength and 17.4% elongation, while hot isostatic pressing (HIP) reduces porosity from 0.08% to 0.01% and weakens fatigue anisotropy. This review also identifies unresolved challenges (e.g., in situ defect monitoring and multi-field regulated performance) and proposes future directions (e.g., AI-driven process optimization and functional gradient structures). Full article
(This article belongs to the Special Issue Microstructural and Corrosion Aspects in Additive Manufacturing of Alloys and Steel)
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