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Metals
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Advance in Wire-Based Additive Manufacturing of Metal Materials
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Advance in Wire-Based Additive Manufacturing of Metal Materials

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

Deadline for manuscript submissions: 31 May 2025 | Viewed by 6281

Special Issue Editor

Dr. Jiankang Huang

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou, China
Interests: welding of dissimilar materials; additive manufacturing welding physics and numerical simulation; laser processing of materials; welding process detection and control
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing is different from traditional manufacturing as it allows a part to be built layer-by-layer. Wire-based additive manufacturing is attracting significant attention in industry and academia due to its ability to harness the benefits of additive manufacturing to produce large components of medium geometric complexity. Uniquely, wire-based additive muanufacturing technology combines the use of a wire and energy source to build components in a layer-by-layer approach, both of which can offer significant cost savings compared to powder and alternative fusion sources, respectively. Meanwhile, a high deposition rate is provided, whilst also allowing significant material savings compared to conventional manufacturing processes. Therefore, this topic focuses on the latest developments in wire-based additive manufacturing technology; its scope is to explore this technology and the research into microstructure characterization and mechanical performance. This topic also outlines the primary development trend, engineering application, and numerical simulation of wire-based additive manufacturing methods. In terms of the deposition process, it covers various wire-based deposition processes, including traditional methods and emerging techniques, such as arc, laser, electron beam, friction stir, etc. Submitted articles should cover truly novel methods or technology in the field of wire-based additive manufacturing and processes that can effectively improve the deposited defects, microstructure, performance, and residual stress of components.

Dr. Jiankang Huang
Guest Editor

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

  • advances
  • wire-based
  • additive manufacturing
  • novel technology
  • metal or alloy

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Published Papers (5 papers)

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Research

12 pages, 10747 KiB  
Communication
Microstructure and Mechanical Properties of Inconel 718 Alloy Fabricated Using Wire Feeding Oscillated Double-Pulsed GTA-AM
by Gang Zhang, Cheng Zhang, Yu Shi and Ding Fan
Metals 2025, 15(3), 248; https://doi.org/10.3390/met15030248 - 26 Feb 2025
Viewed by 429
Abstract
To address anisotropy challenges in electric arc-based additive manufacturing of Inconel 718 alloy, this study develops a novel wire feeding oscillated double-pulsed gas tungsten arc welding additive manufacturing method (DP-GTA-AM) enabling precise thermal-mass transfer control. Series of crack-free thin-walled Inconel 718 alloy parts [...] Read more.
To address anisotropy challenges in electric arc-based additive manufacturing of Inconel 718 alloy, this study develops a novel wire feeding oscillated double-pulsed gas tungsten arc welding additive manufacturing method (DP-GTA-AM) enabling precise thermal-mass transfer control. Series of crack-free thin-walled Inconel 718 alloy parts were successfully obtained by this proposed approach, and the microstructure and mechanical properties of the parts were thoroughly studied. The results indicate that the microstructure changes from dendrites and cellular crystals in the bottom to equiaxed grains in the midsection and entirely equiaxed crystals in the top, resulting in notable grain refinement. With an average grain size of 61.76 μm and an average length of 83.31 μm of large angle grain boundaries, the density of the <001> direction reaches 19.45. The difference in tensile strength and ductility between the horizontal and the vertical directions decreases to 6.3 MPa and 0.38%, which significantly diminishes anisotropy. Fractographic analysis confirms quasi-cleavage failure with homogeneous dimple distribution, demonstrating effective anisotropy mitigation through controlled solidification dynamics. Full article
(This article belongs to the Special Issue Advance in Wire-Based Additive Manufacturing of Metal Materials)
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13 pages, 9043 KiB  
Article
Microstructure Evolution and Performance of AA2024 Alloy Through Wire-Arc Additive Manufacturing Under Different Heat Inputs
by Jin Yang and Aimin Wang
Metals 2024, 14(11), 1265; https://doi.org/10.3390/met14111265 - 7 Nov 2024
Cited by 1 | Viewed by 1221
Abstract
Wire-arc additive manufacturing (WAAM) is widely applied in the aerospace, automotive, defense, and other industries. As such, the study of the formation and evolution mechanism of grains to achieve precise control over the performance of additive parts is important. In this study, AA2024 [...] Read more.
Wire-arc additive manufacturing (WAAM) is widely applied in the aerospace, automotive, defense, and other industries. As such, the study of the formation and evolution mechanism of grains to achieve precise control over the performance of additive parts is important. In this study, AA2024 high-strength Al alloy wire was used to produce WAAM specimens under different heat inputs by varying different parameters. Subsequently, their microstructure, phases, and tensile properties were analyzed. The results indicated that the predominant crystal comprised cellular crystals, columnar crystals and dendritic crystals. At a heat input of 5500–6200 kJ m−1, the internal morphology of the specimen, characterized by the significant presence of fine cellular crystals, was predominantly favorable. As the heat input increased, α (Al) and θ (CuAl2) phases were increasingly identified within the specimens, the grid-like distribution of the θ phase along the crystal boundaries became clearer, and the θ′ phase precipitation decreased. Solution treatment and aging of the specimen produced using the optimal WAAM parameters resulted in an ultimate tensile strength (UTS) of 398 MPa, yield strength (YS) of 284 MPa, and elongation of 11.3%. The results should serve as a basis for selecting suitable WAAM process parameters. Full article
(This article belongs to the Special Issue Advance in Wire-Based Additive Manufacturing of Metal Materials)
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13 pages, 13688 KiB  
Article
Weakening the Anisotropic Property and Refining Prior-β Grains via Hammer Peening Treatment During Wire Arc Additively Manufacturing of Ti-6Al-4V
by Guo Xian, Jingbang Pan, Junghoon Lee and Namhyun Kang
Metals 2024, 14(11), 1261; https://doi.org/10.3390/met14111261 - 7 Nov 2024
Viewed by 996
Abstract
In Wire Arc Additive Manufacturing (WAAM), solidification grain morphology in titanium alloy tends to be columnar rather than equiaxed due to heat dissipation and repeated thermal cycles. This study demonstrates improved microstructure and anisotropic properties in Ti-6Al-4V specimens fabricated by WAAM and treated [...] Read more.
In Wire Arc Additive Manufacturing (WAAM), solidification grain morphology in titanium alloy tends to be columnar rather than equiaxed due to heat dissipation and repeated thermal cycles. This study demonstrates improved microstructure and anisotropic properties in Ti-6Al-4V specimens fabricated by WAAM and treated with hammer peening, resulting in a transition from columnar grains to fine equiaxed grains (~300 μm) in both single-pass and four-bead WAAM walls. The anisotropic elongation decreased by approximately 7%, and tensile strength along the building direction decreased by ~50 MPa for a single-pass wall. Additionally, small and large equiaxed prior-β grains appeared alternately due to the combined effect of hammer peening and welding deposition. The region can be categorized into three parts (MAX, MED, MIN) based on the degree of plastic strain characterized by KAM mapping of EBSD data. In current WAAM parameters, the ratio of strong (~1.5 mm) deformation field (MAX) is about 50% within one deposition layer (MAX+MIN), suggesting a new approach for producing equiaxed prior-β grains. We expect that this method will be applicable for transforming the prior-β grains from columnar to equiaxed. Furthermore, the distribution of plastic strain and phase transformation mechanisms offers innovative approaches to optimize the hammer peening process, with potential applications to optimize the process for more complex components in the aerospace and power plant industries. Full article
(This article belongs to the Special Issue Advance in Wire-Based Additive Manufacturing of Metal Materials)
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19 pages, 17965 KiB  
Article
The Effect of Interpass Temperature on the Mechanical Properties and Microstructure of Components Made by the WAAM Method from Inconel 718 Alloy
by Milan Maronek, Filip Sugra, Katarina Bartova, Jozef Barta, Mária Dománková, Jan Urminsky and Matej Pasak
Metals 2024, 14(8), 953; https://doi.org/10.3390/met14080953 - 22 Aug 2024
Cited by 1 | Viewed by 1364
Abstract
The following study examines the impact of temperature on the deposition of components using Cold Metal Transfer–Wire Arc Additive Manufacturing technology. In the experiment, two overlay weld wall structures were created by applying an interpass temperature of 100 °C and without additional cooling. [...] Read more.
The following study examines the impact of temperature on the deposition of components using Cold Metal Transfer–Wire Arc Additive Manufacturing technology. In the experiment, two overlay weld wall structures were created by applying an interpass temperature of 100 °C and without additional cooling. Subsequently, the microstructural and mechanical properties were observed. No changes in the microstructure due to the application of the interpass temperature were confirmed, and the microstructure of the manufactured components, in both cases, consisted of columnar dendrites. It was found that applying an interpass temperature reduced the average ultimate tensile strength by nearly 65 MPa and the average offset yield strength by 82 MPa. The influence of the cooling strategy on the resulting microstructure was not confirmed. Transmission electron microscopy analysis confirmed the presence of strengthening phases γ′/γ″ in both components; however, a larger amount of the strengthening phase γ″ was found in the component manufactured without the application of an interpass temperature. Full article
(This article belongs to the Special Issue Advance in Wire-Based Additive Manufacturing of Metal Materials)
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16 pages, 1945 KiB  
Article
Forming Control via Interval Width in Directed Energy Deposition-Arc Process
by Qingyuan Wang, Zhen Wang, Yuhang Xie, Jiankang Huang, Xiaoquan Yu, Shurong Yu and Ding Fan
Metals 2024, 14(2), 207; https://doi.org/10.3390/met14020207 - 7 Feb 2024
Cited by 1 | Viewed by 1345
Abstract
A novel controller, employing a variable-structure single-neuron adaptive PSD (proportional integral derivative) approach, was proposed for regulating the deposition width variation in the Directed Energy Deposition-Arc (DED-Arc) layer. During experimental trials, the deposition speed was chosen as the manipulated variable, while the width [...] Read more.
A novel controller, employing a variable-structure single-neuron adaptive PSD (proportional integral derivative) approach, was proposed for regulating the deposition width variation in the Directed Energy Deposition-Arc (DED-Arc) layer. During experimental trials, the deposition speed was chosen as the manipulated variable, while the width of the deposition layer served as the measured parameter. To facilitate controller design, a vision sensor was custom-designed to accurately detect the width of the deposition layer. The captured image of the deposition layer’s dimensions enabled the precise determination of the deposited thickness, forming the basis for subsequent controller development. In performance assessments, deliberate interference was intentionally introduced into the deposition current, deposition layer height, and the targeted deposition layer width. The assessment involved the controlled deposition of ten-layer components, focusing on width regulation for each deposition layer. The results demonstrate that the proposed controller significantly enhances the deposition process stability, particularly within a range of desired deposition widths from 7.5 mm to 8.3 mm. Full article
(This article belongs to the Special Issue Advance in Wire-Based Additive Manufacturing of Metal Materials)
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