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Metals
Special Issues
Optimization and Applications of Metal Additive Manufacturing
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Optimization and Applications of Metal Additive Manufacturing

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

Deadline for manuscript submissions: 31 December 2026 | Viewed by 1721

Special Issue Editors

Dr. Xinyu Zhang

E-Mail
Guest Editor
School of Materials Science and Engineering, Shanghai University, Shanghai, China
Interests: additive manufacturing and their applications; steels, titanium alloys and titanium alumidie alloys; microstructural controlling; properties optimization; surface polishing of additive manufactured parts
Prof. Dr. Antonello Astarita

E-Mail Website
Guest Editor
Department of Chemical, Materials and Production Engineering, University of Naples “Federico II”, Naples, Italy
Interests: friction stir welding; sustainability; material forming; titanium; aluminum; process monitoring
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal additive manufacturing has been involved in many industry fields, such as aerospace, automobile, medicine, and consumer electronics, and the related market scales are expanding rapidly. Meanwhile, the increasing demand for it requires more technical innovations, thus reducing the cost, improving part precision, and enhancing service performance.

Various kinds of additive manufacturing methods have been applied for metal fabrication, including direct energy deposition (DED), wire and arc additive manufacturing (WAAM), laser powder bed fusion (L-PBF), electron beam powder bed fusion (EB-PBF), binder jetting (BJ), and ultrasonic additive manufacturing (UAM). The dimensions and complexities of the manufactured parts, the available metal systems, the controllable parameters, and the final microstructures and properties vary with method. Exploring the most suitable method for each metal, solving the forming problems that are faced during the additive manufacturing process, understanding the related microstructural evolution, optimizing and maximizing their service properties, and discussing how to polish the surface of additive-manufactured parts are the goals of this Special Issue. We also welcome articles that provide more practical application cases for metal additive manufacturing.

By sharing the cutting-edge research achievements and innovative practical cases, the Special Issue can build a communication platform for researchers, engineers, and practitioners to help solve technical problems and promote more efficient and high-quality application of metal additive manufacturing.

Dr. Xinyu Zhang
Prof. Dr. Antonello Astarita
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-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
  • optimization of AM process
  • industrial application
  • microstructural characterization
  • microstructural evolution and tailoring
  • improvement of property
  • post-processing of additive manufactured parts

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Published Papers (2 papers)

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Research

14 pages, 10750 KB  
Article
Effects of Oxidation on the Cracking Behavior of Additive-Manufactured Cobalt-Based Alloys Under Thermal Fatigue Conditions
by Xudong Yang, Zixian Jiao, Jiayue Xu, Xinyu Zhang and Yi Xie
Metals 2026, 16(4), 387; https://doi.org/10.3390/met16040387 - 31 Mar 2026
Viewed by 337
Abstract
Stellite alloys are widely used in the aerospace field owing to their excellent high-temperature strength and thermal fatigue resistance. However, with the rapid development of the aerospace industry, there is an urgent demand to further enhance the mechanical properties and thermal fatigue resistance [...] Read more.
Stellite alloys are widely used in the aerospace field owing to their excellent high-temperature strength and thermal fatigue resistance. However, with the rapid development of the aerospace industry, there is an urgent demand to further enhance the mechanical properties and thermal fatigue resistance of Stellite alloys. In the present study, we prepared a conventional CoCrW alloy (classified as a Stellite alloy) and a novel CoCrWAlNi alloy, which was formulated by introducing aluminum and nickel into the CoCrW matrix, using the direct laser deposition technique. Their microstructural characteristics, mechanical properties, and thermal fatigue performance were systematically investigated. The results indicated that the additions of aluminum and nickel contribute to stabilizing the γ-Co phase. Compared with the CoCrW alloy, the CoCrWAlNi alloy exhibited higher elongation at fracture. In situ observation was employed to study the initiation and propagation of thermal fatigue cracks. Meanwhile, the effects of oxidation on thermal fatigue resistance were analyzed through experimental tests and theoretical calculations based on the Huntz model. Finally, an optimized thermal fatigue mechanism tailored for cobalt-based alloys was established, which yields deeper insights into the failure mechanisms of these alloys under complex thermal-cycling fatigue conditions. Full article
(This article belongs to the Special Issue Optimization and Applications of Metal Additive Manufacturing)
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14 pages, 4187 KB  
Article
Overcoming Processability Limitations in Al6082 Alloy by Using Laser Powder Bed Fusion of Aluminum Matrix Composites with Titanium Carbide/Silicon Carbide Reinforcements
by Raúl Gómez, Maria San Sebastian, Teresa Guraya and Ane Miren Mancisidor
Metals 2025, 15(11), 1232; https://doi.org/10.3390/met15111232 - 8 Nov 2025
Viewed by 1043
Abstract
The use of aluminum alloys in aerospace is limited by their poor weldability, making many incompatible with additive manufacturing (AM) processes like powder bed fusion—laser beam metal (PBF-LB/M), known as well as laser powder bed fusion. This incompatibility hinders the fabrication of complex, [...] Read more.
The use of aluminum alloys in aerospace is limited by their poor weldability, making many incompatible with additive manufacturing (AM) processes like powder bed fusion—laser beam metal (PBF-LB/M), known as well as laser powder bed fusion. This incompatibility hinders the fabrication of complex, lightweight components. To overcome this, Aluminum Metal Matrix Composites (AMMCs) are formed by mechanically alloying the non-processable Al6082 base alloy with ceramic reinforcements; subsequently, Titanium Carbide (TiC) and Silicon Carbide (SiC) particles are developed. This approach induces microstructural changes necessary for AM compatibility. The influence of varying reinforcement contents (1–5 wt.%) on powder homogeneity, microstructural evolution (via Energy Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction), processability, and mechanical properties is systematically studied. The key finding is that metallurgical modification is a robust solution. TiC addition at 2 wt.% and 5 wt.% completely eliminated solidification cracking, achieving high processability. SiC substantially reduced cracking compared to the base alloy. These results demonstrate the potential of AMMCs to successfully translate conventional, non-weldable aluminum alloys into the realm of advanced additive manufacturing. Full article
(This article belongs to the Special Issue Optimization and Applications of Metal Additive Manufacturing)
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