Fatigue and Fracture of Metals Processed by Additive Manufacturing
A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".
Deadline for manuscript submissions: 31 December 2025 | Viewed by 27
Special Issue Editors
Interests: very-high-cycle fatigue; life prediction; failure mechanism
Special Issues, Collections and Topics in MDPI journals
Interests: 3D and 4D printing; metal additive manufacturing; digital/hybrid manufacturing; smart materials and structures; novel applications of active metamaterials; soft actuation for medical applications
Special Issue Information
Dear Colleagues,
Additive manufacturing (AM) of metallic materials has emerged as a transformative technology, offering unparalleled design flexibility and enabling the fabrication of complex, lightweight structures. However, the long-term fatigue performance of AM metals remains a critical challenge, especially for safety-critical applications such as aerospace engines, gas turbines, and high-speed rail systems, where components are subjected to very-high-cycle fatigue (VHCF) loading (10⁷–10¹⁰ cycles).
In these environments, microstructural sensitivity and internal defects play a dominant role in crack initiation and growth, rendering traditional fatigue design theories centered around a fatigue limit of 10⁷ cycles inadequate. Furthermore, unique features such as defect-induced internal crack initiation, high variability in fatigue life, and the breakdown of conventional assumptions (e.g., material isotropy and stress intensity factor thresholds) require the development of new theoretical frameworks.
This Special Issue aims to highlight the urgent need to understand and model fatigue behavior in AM metals, particularly under long-term use. We invite contributions that explore the unique fatigue mechanisms in AM materials and propose novel experimental, theoretical, and computational approaches. Topics of interest include, but are not limited to, the following:
- Advanced characterization of defect-induced crack initiation.
- Multiscale and microstructure-sensitive modeling of fatigue behavior.
- Environmental and thermo-mechanical effects on long-life fatigue.
- Integration of machine learning and data-driven methods in fatigue life prediction.
- Statistical and probabilistic approaches to account for fatigue life scatter.
- Case studies and reliability assessments of AM components in real-world applications.
- Defect-tolerant design strategies for AM metals.
- In situ and operando fatigue testing with a focus on real-time fatigue monitoring.
- Fatigue of functionally graded and lattice AM structures.
- Fatigue performance of bioinspired AM metal components.
- Standardization and certification pathways for AM fatigue.
By addressing these challenges, this Special Issue seeks to pave the way for the reliable application of AM metallic materials in next-generation high-performance systems.
Dr. Wei Li
Dr. Ahmad Serjouei
Guest Editors
Manuscript Submission Information
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Keywords
- additive manufacturing
- very-high-cycle fatigue
- metallic materials
- internal defects
- microstructure-sensitive fatigue
- multiscale modeling
- fatigue life prediction
- damage mechanism
- defect characterization
- data-driven fatigue analysis
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