Additive Manufacturing of High-Temperature Metallic Materials and Intermetallics

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

Deadline for manuscript submissions: 30 June 2026 | Viewed by 113

Special Issue Editor


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Guest Editor
Physical Metallurgy and Materials Technology, Brandenburg University of Technology Cottbus-Senftenberg, 03044 Cottbus, Germany
Interests: metal additive manufacturing; high-temperature materials; intermetallics; metal forming; physical metallurgy; microstructure characterization
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Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has revolutionized the design and production of high-performance metallic components, enabling unprecedented control over microstructure, geometry, and material utilization. Significant progress has recently been made in applying AM to high-temperature metallic materials—particularly superalloys, refractory metals, and intermetallic compounds—that are essential for demanding environments such as aerospace propulsion, energy conversion, and advanced industrial applications. However, the processing of these materials remains challenging due to their high melting points, complex solidification behavior, and susceptibility to cracking and segregation.

This Special Issue focuses on recent advances in the additive manufacturing of high-temperature alloys and intermetallics. These include, but are not limited to, nickel-, cobalt-, and iron-based superalloys, refractory metals and their alloys, and ordered intermetallic phases, such as titanium aluminides, nickel aluminides, and iron aluminides. Topics of interest include process development and optimization, alloy design for AM, solidification and phase transformation mechanisms, microstructure–property relationships, post-processing and heat treatment strategies, and the modeling or simulation of AM processes. Contributions addressing performance evaluation under high-temperature or corrosive environments are also encouraged.

By bringing together cutting-edge research in materials science, process engineering, and advanced characterization, this Special Issue aims to highlight emerging trends and remaining challenges in realizing reliable, high-performance components through the additive manufacturing of high-temperature materials for next-generation metallic systems.

Dr. Aliakbar Emdadi
Guest Editor

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Keywords

  • metal additive manufacturing
  • high-temperature materials
  • superalloys
  • intermetallics
  • refractory metals and alloys
  • alloy design
  • process optimization
  • microstructure
  • mechanical properties
  • post-processing

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Published Papers (1 paper)

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Research

15 pages, 5598 KB  
Article
Highly Printable Fe3Al Intermetallic Alloy
by Aliakbar Emdadi, Yitong Yang, Joanna Szyndler, Felix Jensch, Gökhan Ertugrul, Michael Tovar, Sebastian Härtel and Sabine Weiß
Metals 2026, 16(1), 5; https://doi.org/10.3390/met16010005 (registering DOI) - 20 Dec 2025
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Abstract
Intermetallic Fe3Al-based alloys reinforced with Laves-phase precipitates are emerging as potential replacements for conventional high-alloy steels and possibly polycrystalline Ni-based superalloys in structural applications up to 700 °C. Their impressive mechanical properties, however, are offset by limited fabricability and poor machinability [...] Read more.
Intermetallic Fe3Al-based alloys reinforced with Laves-phase precipitates are emerging as potential replacements for conventional high-alloy steels and possibly polycrystalline Ni-based superalloys in structural applications up to 700 °C. Their impressive mechanical properties, however, are offset by limited fabricability and poor machinability due to their severe brittleness. High tool wear during finish-machining, which is still required for components such as turbine blades, remains a key barrier to their broader adoption. In contrast to conventional manufacturing routes, additive manufacturing offers a viable solution by enabling near-net-shape manufacturing of difficult-to-machine iron aluminides. In the present study, laser powder bed fusion was used to produce an Fe-25Al-1.5Ta intermetallic containing strengthening Laves-phase precipitates, and the porosity, microstructure and phase composition were characterized as a function of the process parameters. The results showed that preheating the build plate to 650 °C effectively suppressed delamination and macrocrack formation, even though noticeable cracking still occurred at the high scan speed of 1000 mm/s. X-ray tomography revealed that samples fabricated with a lower scan speed (500 mm/s) and a higher layer thickness (0.1 mm) contained larger, irregularly shaped pores, whereas specimens printed at the same volumetric energy density (40 J/mm3) but with different parameter sets exhibited smaller fractions of predominantly spherical pores. All samples contained mostly elongated grains that were either oriented close to <001> relative to the build direction or largely texture-free. X-ray diffraction confirmed the presence of Fe3Al and C14-type (Fe, Al)2Ta Laves phase in all samples. Hardness values fell within a narrow range (378–398 HV10), with only a slight reduction in the specimen exhibiting higher porosity. Full article
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