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Metals
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Recent Developments in Laser Additive Manufacturing of Metallic Materials
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Recent Developments in Laser Additive Manufacturing 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 July 2025 | Viewed by 5519

Special Issue Editor

Dr. Zhanyong Zhao

E-Mail Website
Guest Editor
School of Materials Science and Engineering, North University of China, Taiyuan 030051, China
Interests: laser additive manufacturing; powder bed fusion; directed energy deposition; microstructure and performance
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Laser additive manufacturing, an advanced form of manufacturing, can manufacture parts directly from digital models by using the layer-by-layer approach to build up materials. This manufacturing method can prepare complexly shaped metal parts in a short time and with high precision. Laser additive manufacturing can be classified into two major groups: Powder Bed Fusion-based technologies and Directed Energy Deposition. Laser additive manufacturing provides the freedom to design complex and light-weight parts for applications in the aerospace, automobile, and other industries. The global market for laser additive manufacturing is mainly driven by the the fast development of the aerospace and automobile industries.

In this Special Issue, we welcome articles that focus on laser additive manufacturing materials and processes and their influence on the final products’ microstructure and performance, in order to provide guidance for the development of laser additive manufacturing technology.

Dr. Zhanyong Zhao
Guest Editor

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

  • laser additive manufacturing
  • powder bed fusion
  • directed energy deposition
  • microstructure
  • performance

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Published Papers (7 papers)

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Research

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24 pages, 12327 KiB  
Article
Thermomechanical Behavior and Experimental Study of Additive Manufactured Superalloy/Titanium Alloy Horizontal Multi-Material Structures
by Yanlu Huang, Tianyu Wang, Linqing Liu, Yang Li, Changjun Han, Hua Tan, Wei Zhou, Yongqiang Yang and Di Wang
Metals 2025, 15(4), 454; https://doi.org/10.3390/met15040454 - 17 Apr 2025
Viewed by 151
Abstract
In laser powder bed fusion (LPBF) forming multi-material structures, the thermal stress mismatch caused by the different thermophysical properties of different materials can cause interface cracking and delamination defects. An in-depth investigation of the complex interfacial thermomechanical behavior caused by it is of [...] Read more.
In laser powder bed fusion (LPBF) forming multi-material structures, the thermal stress mismatch caused by the different thermophysical properties of different materials can cause interface cracking and delamination defects. An in-depth investigation of the complex interfacial thermomechanical behavior caused by it is of great significance for reducing stress concentration, suppressing defects, and enhancing interfacial bond strength. In this study, the effects of scanning strategy and interface shape on the temperature distribution, thermal cycling, and thermal stress distribution at the interface are analyzed by the IN718-Ti6Al4V horizontal multi-material thermally coupled finite element model. The results show that the 45° scanning strategy is helpful for the uniform distribution of energy and the reduction of overheating and residual stress concentration. The maximum residual stress at the interface in the Ti6Al4V/IN718 structure is more than 700 MPa, which is higher than that in the IN718/Ti6Al4V structure. The first formation of Ti6Al4V will likely lead to higher residual stresses at the interface, which are difficult to release in subsequent printing. The analysis of different interface shapes shows that different interface shapes change the crack formation and extension paths. This study contributes to an in-depth understanding of improving the strength of horizontal multi-material interfacial bonding at the LPBF forming. It provides a reference for optimizing LPBF forming of difficult-to-bond materials. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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22 pages, 7887 KiB  
Article
Effect of Feature Size on Defects, Microstructure, and Mechanical Properties of Selective Laser Melted AlSi10Mg Lattice Structure
by Chengkuan Peng, Junfeng Qi, Sheng Zhou, Sanqiang Yang, Ran Tao, Heng Shao and Weining Li
Metals 2025, 15(1), 77; https://doi.org/10.3390/met15010077 - 16 Jan 2025
Viewed by 661
Abstract
Selective laser melting lightweight lattice structures have broad application prospects in the aerospace field. Understanding the dependence of mechanical performance on feature size is crucial for structure design. This work optimized the process parameters based on large-size metal blocks (20 mm) and then [...] Read more.
Selective laser melting lightweight lattice structures have broad application prospects in the aerospace field. Understanding the dependence of mechanical performance on feature size is crucial for structure design. This work optimized the process parameters based on large-size metal blocks (20 mm) and then fabricated submillimeter features with a size of 0.4~1.0 mm. The influence of feature size on the defects, microstructures, and mechanical properties was investigated. The results showed that the dimensional errors for all size features were above 15%. When matched with appropriate border offset, these features could be printed precisely. The densification of submillimeter features was more than 99%, demonstrating the applicability of the optimized process parameters for the fine features. The porosity and relative roughness decreased and tended to stabilize with increasing feature size. Due to having less defects, the thicker features exhibited better mechanical properties in terms of ultimate strength and elongation. After being processed with polishing treatment, the roughness was reduced below 1 μm and the tensile strength increased above 320 MPa. The elastic modulus, yield strength, and elongation were also significantly improved. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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18 pages, 11943 KiB  
Article
Friction Performance Analysis of WC-Reinforced IN718 Composite Material Based on SLM Process
by Xuejin Zhao, Xiaoyu Zhao, Youfan Xu and Yongjun Shi
Metals 2024, 14(12), 1361; https://doi.org/10.3390/met14121361 - 29 Nov 2024
Viewed by 877
Abstract
To enhance the wear resistance of nickel-based high-temperature alloys, IN718/WC composites were prepared via selective laser melting (SLM). The optimal molding process parameters of IN718/WC composites were determined using a combination of experimental and simulation methods. Based on the SEM images of the [...] Read more.
To enhance the wear resistance of nickel-based high-temperature alloys, IN718/WC composites were prepared via selective laser melting (SLM). The optimal molding process parameters of IN718/WC composites were determined using a combination of experimental and simulation methods. Based on the SEM images of the composites, a gradient transition layer was found to form between the WC particles and the IN718 matrix, and the γ′ and γ″ reinforcing phases dispersed into the matrix, providing lubrication and reducing wear during friction. The influence of WC content on the wear resistance of the composites was investigated. When the WC content was 5%, the molded parts showed optimal wear resistance, the friction coefficient fluctuated steadily, the degree of wear was low, and the amount of wear was reduced to 0.02973 mm3. The average friction coefficient and wear volume of the molded parts with similar contents decreased by 26.95% and 4.27%, respectively, compared with the pure IN718-molded parts. This study provides a case study and guidance for further optimization of the molding process for nickel matrix high-temperature composites prepared using the SLM method. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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20 pages, 31298 KiB  
Article
Additive Manufacturing and Precipitation Hardening of Low-Alloyed Copper Alloys Containing Chromium and Hafnium
by Julia Dölling, Samira Gruber, Felix Kovermann, Lukas Stepien, Elmar Beeh, Elena Lopez, Christoph Leyens, Hans-Günther Wobker and Andreas Zilly
Metals 2024, 14(11), 1304; https://doi.org/10.3390/met14111304 - 19 Nov 2024
Viewed by 1134
Abstract
Copper alloys with chromium and hafnium offer the possibility of precipitation hardening and combine enhanced strength with high electrical and thermal conductivities. The production process, which starts with raw materials, involves powder production by gas atomization and leads to additive manufacturing by laser [...] Read more.
Copper alloys with chromium and hafnium offer the possibility of precipitation hardening and combine enhanced strength with high electrical and thermal conductivities. The production process, which starts with raw materials, involves powder production by gas atomization and leads to additive manufacturing by laser powder bed fusion with different parameter sets. The aim is to utilize precipitation reactions afterwards in CuHf0.7Cr0.35 during temperature exposure for further property optimization. This research focuses on the low-alloyed copper alloy with hafnium and chromium, compares this with conventionally manufactured specimens, and relates the alloy to additively manufactured specimens of other benchmark alloys such as CuCr1Zr. Measurements of hardness and electrical conductivity are accompanied by metallographic investigations to understand the behavior of CuHf0.7Cr0.35 manufactured by generative methods. In the as-built condition, melting traces remain visible in the microstructure, and hardness values of 101 HV and an electrical conductivity of 17.5 MS/m are reached. Solution annealing completely recrystallizes the microstructure, and the following quenching holds further alloying elements in supersaturated solid solution, resulting in 73 HV and 16.5 MS/m. Subsequent target-oriented precipitation reactions enable peak values of about 190 HV and 42 MS/m. Future research will assess mechanical and physical properties at elevated temperatures and evaluate possible applications. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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17 pages, 4525 KiB  
Article
An Investigation of Thermomechanical Behavior in Laser Hot Wire Directed Energy Deposition of NAB: Finite Element Analysis and Experimental Validation
by Glenn W. Hatala, Edward Reutzel and Qian Wang
Metals 2024, 14(10), 1143; https://doi.org/10.3390/met14101143 - 8 Oct 2024
Cited by 1 | Viewed by 925
Abstract
Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime [...] Read more.
Laser Hot Wire (LHW) Directed Energy Deposition (DED) Additive Manufacturing (AM) processes are capable of manufacturing parts with a high deposition rate. There is a growing research interest in replacing large cast Nickel Aluminum Bronze (NAB) components using LHW DED processes for maritime applications. Understanding thermomechanical behavior during LHW DED of NAB is a critical step towards the production of high-quality NAB parts with desired performance and properties. In this paper, finite element simulations are first used to predict the thermomechanical time histories during LHW DED of NAB test coupons with an increasing geometric complexity, including single-layer and multilayer depositions. Simulation results are experimentally validated through in situ measurements of temperatures at multiple locations in the substrate as well as displacement at the free end of the substrate during and immediately following the deposition process. The results in this paper demonstrate that the finite element predictions have good agreement with the experimental measurements of both temperature and distortion history. The maximum prediction error for temperature is 5% for single-layer samples and 6% for multilayer samples, while the distortion prediction error is about 12% for single-layer samples and less than 4% for multilayer samples. In addition, this study shows the effectiveness of including a stress relaxation temperature at 500 °C during FE modeling to allow for better prediction of the low cross-layer accumulation of distortion in multilayer deposition of NAB. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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14 pages, 5940 KiB  
Article
Laser Cladding Path Planning for Curved Metal Parts
by Jinduo Liu, Zhiyong Ba and Da Shu
Metals 2024, 14(9), 1055; https://doi.org/10.3390/met14091055 - 16 Sep 2024
Cited by 2 | Viewed by 1296
Abstract
In depositing multiple layers on the surface of failed metal parts, the overlap rate is a critical factor in determining the surface smoothness and uniformity of the coating thickness. Therefore, special attention must be given to the spacing between adjacent melt tracks when [...] Read more.
In depositing multiple layers on the surface of failed metal parts, the overlap rate is a critical factor in determining the surface smoothness and uniformity of the coating thickness. Therefore, special attention must be given to the spacing between adjacent melt tracks when planning laser paths on complex metal parts. A strategy for selecting the overlap rate for multi-track cladding is proposed, based on the key parameters of surface curvature, mass conservation, and the profile of single-track coatings. A multi-track overlap model is developed, expressing the relationship between coating morphology and the overlap rate. The optimal spacing value is determined to achieve the goal of high-quality coating remanufacturing. To verify the effectiveness of this method, nickel-based powder was used for laser forming on the surface of metal gears. The results showed that the surface of the cladding layer was smooth and flat, further demonstrating that this model helps improve the repair quality and overall performance of curved metal parts. Thus, it provides valuable guidance for the remanufacturing of failed metal parts. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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Review

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46 pages, 18469 KiB  
Review
Optimising Additive Manufacturing of NiTi and NiMnGa Shape Memory Alloys: A Review
by Ali Ramezannejad, Daniel East, Anthony Bruce Murphy, Guoxing Lu and Kun Vanna Yang
Metals 2025, 15(5), 488; https://doi.org/10.3390/met15050488 - 25 Apr 2025
Viewed by 97
Abstract
NiTi and NiMnGa stand out as prime thermal and magnetic shape memory alloys (SMAs), possessing a superior shape memory effect (SME) and superelasticity (SE). These alloys have crucial current and potential future applications across industries. Additive manufacturing (AM) offers a transformative approach to [...] Read more.
NiTi and NiMnGa stand out as prime thermal and magnetic shape memory alloys (SMAs), possessing a superior shape memory effect (SME) and superelasticity (SE). These alloys have crucial current and potential future applications across industries. Additive manufacturing (AM) offers a transformative approach to fabricating these materials into complex geometries; however, the quest to create integral additively manufactured structures with reliable thermal or magnetic shape memory properties remains a recent and fast-emerging research frontier. This article provides a comprehensive review on (i) the intricate principles giving rise to the thermal SME and SE in NiTi, and the magnetic SME in NiMnGa alloys, emphasising their specific relevance in the realm of AM, and (ii) the latest developments, recent findings, and ongoing challenges in the AM of NiTi- and NiMnGa-based SMAs, including their functional lattice structures. Based on this review, for the first time, novel, empirically derived AM process design maps tailored to maximise SME and SE in laser powder bed fusion- and directed-energy deposition-processed NiTi structures are proposed. Similarly, promising avenues to resolve the key challenges regarding the AM of NiMnGa magnetic SMAs are suggested. This article concludes by outlining the most promising future research directions shaping the trajectory of AM of these SMAs. Full article
(This article belongs to the Special Issue Recent Developments in Laser Additive Manufacturing of Metallic Materials)
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