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 1211

Special Issue Editors


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Guest Editor
Department of Industrial Engineering, University of Padova, 35122 Padua, Italy
Interests: additive manufacturing; microstructural characterization; corrosion

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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

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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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Published Papers (1 paper)

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Review

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 3 | Viewed by 850
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
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