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Additive Manufacturing in Alloy Design and Development

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

Deadline for manuscript submissions: closed (31 July 2023) | Viewed by 7982

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Special Issue Editors

Dr. Javad Kadkhodapour

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Guest Editor

Institute for Materials Testing, Materials Science and Strength of Materials, University of Stuttgart, 70569 Stuttgart, Germany
Interests: microstructure; finite element analysis; mechanical engineering

Dr. Xuewei Fang

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Guest Editor

State Key Laboratory for Manufacturing Systems Engineering, School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China
Interests: forming manufacturing; manufacturing; metal material preparation and processing; metal structure materials and mechanical behavior

Special Issue Information

Dear Colleagues,

Over recent years, additive manufacturing (AM) has proved to be the most promising emerging manufacturing technique for fabricating metallic materials due to its ability to fabricate components with high dimensional accuracy and complexity. While the development of new processes and materials is progressing very rapidly, and AM has been used in several industrial sectors such as aerospace, automobile, marine, construction, etc., design strategies for AM and structural optimization are lagging behind.

In order to fully utilize the advantages of AM and optimize the development of this technology, several new considerations should be taken into account. This Special Issue entitled “Additive Manufacturing in Alloy Design and Development” provides a forum for publishing original papers and case studies that advance the comprehensive development of metal AM, comprising design, process, post-processing and testing. It also outlines the fundamental development trends and most recent advances in the field. The potential topics include, but are not limited to:

Product development cycle: from powder to component application;
Test scenario to guarantee product quality: from powder to component application;
Alloys design and development;
Optimization in design and its effect on the mechanical properties;
Innovation in processing strategies;
AM processes control and modeling;
Numerical simulation;
Defect and failure analysis;
Industrialization of AM process.

This Special Issue welcomes papers from different application fields that broadly advance the application of AM in metals and alloys. We would like to invite all researchers and industrial experts in this field to contribute their latest research and development experiences on this subject.

Dr. Javad Kadkhodapour
Dr. Xuewei Fang
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 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

additive manufacturing
design optimization
topology optimization
mechanical properties
characterization and testing
metal processing, powder, component

Published Papers (4 papers)

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Research

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14 pages, 6770 KiB

Open AccessArticle

An Analysis of the Mapping Relationship between Microstructure and Solidification Parameters during Aluminum Fused Coating

by Guangxi Zhao, Jialei Zhang and Xianhai Yang

Metals 2023, 13(9), 1594; https://doi.org/10.3390/met13091594 - 14 Sep 2023

Cited by 1 | Viewed by 720

Abstract

Metal fused-coating technology has the advantages of both low cost and high efficiency and is a new additive manufacturing technology in recent years. The previous studies were mainly aimed at the optimization of process parameters and the control of the surface quality of parts, while there were few theoretical analyses on the microstructure morphology after solidification. A three-dimensional transient numerical model was established to calculate temperature gradient and solidification rate, considering the changes in material physical properties with temperature during the calculation process. The temperature gradient on the substrate surface is jointly affected by the melt flowing out of the nozzle and the welding arc. It was found that the solidification front of the aluminum alloy was in an unstable state during the coating process. When the value of G/R decreases, the microstructure of the solidification interface gradually changes from columnar crystals to columnar dendrites and equiaxial crystals. The microstructure at the bottom of both the molten pool and coating layer is columnar crystal, while the microstructure at the upper part is equiaxed crystal. Full article

(This article belongs to the Special Issue Additive Manufacturing in Alloy Design and Development)

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15 pages, 18611 KiB

Open AccessArticle

Process Parameter Optimization for Selective Laser-Melted High-Nitrogen Steel and the Effects on Microstructure and Properties

by Xin Sun, Jianbiao Ren, Shuhuan Wang, Dingguo Zhao, Xiaojing Xiong and Jeremy Heng Rao

Metals 2023, 13(7), 1242; https://doi.org/10.3390/met13071242 - 7 Jul 2023

Viewed by 1051

Abstract

Chromium nitride powder is blended with pre-alloyed powder to make an overmatched powder with a high nitrogen concentration in order to manufacture high-nitrogen steel by selective laser melting. By employing a wider range of process parameters, the impact of process parameters on the relative density, nitrogen concentration, microstructure, and mechanical properties of high-nitrogen steel is investigated. In simulated human body fluid conditions, the corrosion resistance of high-nitrogen steel, pure titanium, and 316L was compared and evaluated. The findings demonstrate that the relative density of high-nitrogen steel initially rises and then falls with the increase in energy density, reaching a high value of 98.8% at 148.8 J/mm³. With rising energy density, the nitrogen concentration falls. The microstructure of high-nitrogen steel is mainly composed of columnar and cellular grains. Both grain sizes steadily grow, but their mechanical characteristics initially rise and then fall as the energy density rises from 83.3 to 187.3 J/mm³. With yield strength, tensile strength, and elongation reaching 921.9 MPa, 1205.1 MPa, and 27%, respectively, the alloy exhibits outstanding mechanical characteristics when the laser power is 250 W, the scanning speed is 700 mm/s, and the associated energy density is 148.8 J/cm³. The high-nitrogen steel at an energy density of 148.8 J/mm³ has the lowest corrosion rate when compared to pure titanium and 316L steel, which suggests that the HNS alloy will have good corrosion resistance in human body fluid conditions. Full article

(This article belongs to the Special Issue Additive Manufacturing in Alloy Design and Development)

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16 pages, 6475 KiB

Open AccessArticle

Theoretical Prediction of Structural, Mechanical, and Thermophysical Properties of the Precipitates in 2xxx Series Aluminum Alloy

by Xuewei Fang, Yefei Li, Qiaoling Zheng, Jianye Guo, Yanmei Yang, Weiyun Ding, Chunhui Ma, Ke He, Ningning Su, Jingyi Jiang, Xiaoxue Chen and Haoran Wang

Metals 2022, 12(12), 2178; https://doi.org/10.3390/met12122178 - 17 Dec 2022

Cited by 3 | Viewed by 2134

Abstract

We presented a theoretical study for the structural, mechanical, and thermophysical properties of the precipitates in 2xxx series aluminum alloy by applying the widely used density functional theory of Perdew-Burke-Ernzerhof (PBE). The results indicated that the most thermodynamically stable structure refers to the Al₃Zr phase in regardless of its different polymorphs, while the formation enthalpy of Al₅Cu₂Mg₈Si₆ is only -0.02 eV (close to zero) indicating its metastable nature. The universal anisotropy index of A^U follows the trend of: Al₂Cu > Al₂CuMg ≈ Al₃Zr_D0₂₂ ≈ Al₂₀Cu₂Mn₃ > Al₃Fe ≈ Al₆Mn > Al₃Zr_D0₂₃ ≈ Al₃Zr_L1₂ > Al₇Cu₂Fe > Al₃Fe₂Si. The thermal expansion coefficients (TECs) were calculated based on Quasi harmonic approximation (QHA); Al₂CuMg shows the highest linear thermal expansion coefficient (LTEC), followed by Al₃Fe, Al₂Cu, Al₃Zr_L1₂ and others, while Al₃Zr_D0₂₂ is the lowest one. The calculated data of three Al₃Zr polymorphs follow the order of L1₂ > D0₂₃ > D0₂₂, all of them show much lower LTEC than Al substance. For multi-phase aluminum alloys, when the expansion coefficient of the precipitates is quite different from the matrix, it may cause a relatively large internal stress, or even produce cracks under actual service conditions. Therefore, it is necessary to discuss the heat misfit degree during the material design. The discrepancy between a-Al and Al₂CuMg is the smallest, which may decrease the heat misfit degree between them and improve the thermal shock resistant behaviors. Full article

(This article belongs to the Special Issue Additive Manufacturing in Alloy Design and Development)

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Review

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26 pages, 9278 KiB

Open AccessReview

Titanium Alloy Fabricated by Additive Manufacturing for Medical Applications: Obtaining, Characterization and Application—Review

by Xinjie Zhang, Shuai Liu, Yude Liu, Hanjie Guo and Wentian Shi

Metals 2023, 13(3), 462; https://doi.org/10.3390/met13030462 - 23 Feb 2023

Cited by 3 | Viewed by 3594

Abstract

Metal additive manufacturing (metal-AM) technology has made significant progress in the field of biomedicine in recent years. Originally, it was only used as an innovative resource for prototypes. With the development of technology, custom orthopedic implants could be produced for different patients. Titanium alloy is non-toxic and harmless in the human body. It has excellent biocompatibility and can promote the growth and regeneration of bones in its interior. Therefore, it is widely used in the medical industry. However, in the process of additive manufacturing and printing titanium alloys, there are often cases where the powder is not completely melted or the powder adheres to the product structure after printing, which introduces new biological risks. This paper summarizes the causes of powder adhesion from the perspective of the process involved in additive manufacturing, expounds the influence of different processes on the powder adhesion of titanium alloy forming parts, introduces the mainstream methods of powder sticking removal and summarizes the application of the additive manufacturing of titanium alloy in the medical field, which provides a theoretical basis for further development of the application of titanium alloy additive manufacturing technology in the medical industry. Full article

(This article belongs to the Special Issue Additive Manufacturing in Alloy Design and Development)

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