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Laser Processing of Metals and Alloys

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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 March 2022) | Viewed by 25122

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Special Issue Editors

Prof. Dr. Gleb A. Turichin

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Guest Editor

St. Petersburg State Marine Technical University, St. Petersburg, Russian Federation
Interests: laser physics; interaction of laser radiation with matter; concentrated energy sources; mathematical modeling; laser welding; laser arc hybrid welding; additive manufacturing; direct laser deposition; welding of dissimilar materials; phase transformations

Dr. Olga Klimova-Korsmik

E-Mail Website
Guest Editor

Department of Welding and Laser Technologies, St. Petersburg State Marine Technical University, St. Petersburg, Russia
Interests: material science; nanoparticles; powder metallurgy; additive manufacturing; direct energy deposition; direct laser deposition; cermets; welding of dissimilar materials; phase transformations; intermetallic; functionally graded materials; high entropy alloys; structure and mechanical properties

Special Issue Information

Dear Colleagues,

In recent years, laser treatment has become more popular in science and industry, because of the increased accessibility of high-power laser sources, the emergence of new automation and control systems and the existence of engineers and researchers with specialized knowledge. Laser processing is a multi-parameter process, and it is necessary to take into account the physics of the interaction of the substance with concentrated energy flow, the hydrodynamics of the melt in the welding bath, the peculiarities of the crystallization processes, the formation of microstructure and properties at extreme speeds of heating and cooling, and much more. On the other hand, in the development of technological processes and subsequent implementation in the industry, it is necessary to take into account the peculiarities of obtaining products. These issues are connected incessantly.

This Special Issue will be comprised of articles which report new and progressive research results in the field of laser and hybrid welding, cladding, additive manufacturing, and the surface treatment of meals and alloys, including all steps of technological processes’ development. Manuscripts will be welcomed from both fundamental scientific researchers and authors belonging to industrial companies that are involved in the field.

Prof. Dr. Gleb A. Turichin
Dr. Olga Klimova-Korsmik
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

fundamental research of laser radiation-matter interaction
simulation and modelling
laser and hybrid laser-arc welding
joining of dissimilar materials using laser treatment
laser cladding
Additive Manufacturing—Direct Energy Deposition
Additive Manufacturing—Powder Bed Fusion
laser-assisted processes
structure and mechanical properties of laser treated materials

Published Papers (11 papers)

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Research

14 pages, 5046 KiB

Open AccessArticle

Design, Simulation and Optimization of an Additive Laser-Based Manufacturing Process for Gearbox Housing with Reduced Weight Made from AlSi10Mg Alloy

by Liubov Magerramova, Vladimir Isakov, Liana Shcherbinina, Suren Gukasyan, Mikhail Petrov, Daniil Povalyukhin, Darya Volosevich and Olga Klimova-Korsmik

Metals 2022, 12(1), 67; https://doi.org/10.3390/met12010067 - 29 Dec 2021

Cited by 8 | Viewed by 2510

Abstract

The gas turbine engine’s (GTE) development aims for the increasing the efficiency, strength, reliability and safety of its components. To create competitive engines, housing parts and components with high functionality and reduced weight are needed. Especially difficult in the design and production are the gearboxes for aviation GTE. Traditional technologies based on precision casting or material forming operations have significant limitations due to the complexity of fulfilling multiple different requirements. Nowadays, one of the progressive production techniques is additive manufacturing. The article presents the results of computational and experimental studies that substantiate the applicability of laser additive technology to reduce the mass of body parts by up to 15% while ensuring their strength properties. The physical and mechanical characteristics of aluminum alloys acceptable for the manufacturing of housing parts were analyzed. The necessary characteristics of the powder alloy of the Al-Si system and the technological parameters of the L-PBF of the modified housing of the gear reducer are established. Using the finite element method (FEM) the L-PBF process was numerically simulated and the technological modes for synthesis of the AlSi10Mg alloy powder were optimized. With the help of a serial 3D printer ProX320DMP, the prototype of a gear housing was manufactured. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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13 pages, 4094 KiB

Open AccessArticle

Investigation of the Technological Possibility of Laser Hardening of Stainless Steel 14Cr17Ni2 to a Deep Depth of the Surface

by Vladislav Somonov, Igor Tsibulskiy, Ruslan Mendagaliyev and Alexander Akhmetov

Metals 2022, 12(1), 5; https://doi.org/10.3390/met12010005 - 21 Dec 2021

Cited by 3 | Viewed by 2312

Abstract

The article presents the results of a research of the process of laser hardening of steel 14Cr17Ni2 (AISI 431) by radiation of a high-power fiber laser LS-16. Assessment of the theoretically possible maximum depth in laser processing without additional beam transformations, the use of additional coatings and devices were shown. The results of experiments on increasing the depth of the hardened layer during laser processing by using scanning of the laser beam and optimally selected mode parameters without scanning are demonstrated. The influence of the number of passes on the depth of the hardened layer is investigated. The microstructure of hardened samples was studied and quantitative estimation of structural components was carried out. The microhardness of hardened samples at different modes of laser hardening was measured. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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9 pages, 4607 KiB

Open AccessArticle

Laser Welding Modes Optimization of the Selective Laser Melted Ti-6Al-4V Thin-Thickness Parts with Complex Shape

by Maksim Larin, Yakov Pevzner, Svetlana Shalnova and Pavel Petrovskiy

Metals 2021, 11(12), 2013; https://doi.org/10.3390/met11122013 - 13 Dec 2021

Cited by 1 | Viewed by 1754

Abstract

The paper studies laser welding of thin-thickness Ti-6Al-4V parts, manufactured by selective laser melting (SLM). A full factorial experiment was carried out in order to construct a regression model of the technological parameters (laser power, welding speed, and defocusing amount) which influence the weld shape. Metallographic analysis was carried out and it was found that thermal cycles of product printing and laser welding are equivalent. The microhardness analysis also showed no differences between the weld metal and the base metal. The contour plots of the parameters influence on the response function was constructed, and the area of welding modes was determined. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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12 pages, 3064 KiB

Open AccessArticle

Numerical Analysis of Particle Trajectories in a Gas–Powder Jet during the Laser-Based Directed Energy Deposition Process

by Stanislav Stankevich, Nikolay Larionov and Ekaterina Valdaytseva

Metals 2021, 11(12), 2002; https://doi.org/10.3390/met11122002 - 11 Dec 2021

Cited by 3 | Viewed by 1872

Abstract

Based on numerical solutions of the equation of motion of a particle in a gas jet modeled by the Reynolds-averaged Navier–Stokes equations, the features of transporting powder particles to the working zone of laser-based directed energy deposition are investigated. The propagation of a gas jet in a confined space in the presence of obstacles in the form of a substrate and a wall of a part is considered. A solution determining the gas-dynamic parameters of the jet is obtained, and the results of calculating its velocity field are presented. The influence of gas-dynamic parameters on the trajectories of the powder particles is analyzed. It is shown that these parameters determine the amount of model material involved in the formation of the geometry of the part. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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15 pages, 4596 KiB

Open AccessArticle

Numerical Estimation of the Geometry of the Deposited Layers during Direct Laser Deposition of Multi-Pass Walls

by Ilya Udin, Ekaterina Valdaytseva and Nikita Kislov

Metals 2021, 11(12), 1972; https://doi.org/10.3390/met11121972 - 08 Dec 2021

Viewed by 1854

Abstract

Direct laser deposition (DLD) is a promising additive technology that allows for the rapid and cheap production of metal parts of complex geometry in various sectors of mechanical engineering. Thick-walled metal structures occupy a significant part in mechanical engineering. The purpose of this study was to develop and test an algorithm for predicting the geometry of deposited multi-pass walls. To achieve this goal, the main interrelated processes involved in the formation of a multi-pass wall were described—the process of laser radiation propagation, the process of heat transfer and the process of bead formation. To construct the calculation algorithm, five characteristic types of beads are identified. For these five types, the features of the bead formation and the features of the laser radiation intensity distribution are described. The calculated data were verified. A good match of the calculated data with the geometry of the deposited walls from AISI321 steel, Inconel718 and Ti-6Al-4V alloys was obtained. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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13 pages, 28759 KiB

Open AccessArticle

The Strength of Inconel 625, Manufactured by the Method of Direct Laser Deposition under Sub-Microsecond Load Duration

by Vladimir Promakhov, Nikita Schulz, Alexander Vorozhtsov, Andrey Savinykh, Gennady Garkushin, Sergey Razorenov and Olga Klimova-Korsmik

Metals 2021, 11(11), 1796; https://doi.org/10.3390/met11111796 - 08 Nov 2021

Cited by 6 | Viewed by 1505

Abstract

This paper presents the results of measurements of the spall strength and elastic-plastic proper-ties, under dynamic and static loads, of the high-strength heat-resistant nickel-chromium alloy Inconel 625, obtained by the direct laser deposition method. The structural parameters of the obtained samples and the mechanical properties during static tests were studied. According to our information, anisotropy in the structural parameters operates primarily at the level of plastic deformation of alloys. Shock compression of the additive alloy Inconel 625 samples in the range of 6–18 GPa was carried out using a light-gas gun, both along and perpendicular to the direction of the deposition. The strength characteristics were determined from the analysis of the shock wave profiles, which were recorded using the VISAR laser velocimeter during the loading of samples. It was found that the value of the spall strength of additive samples does not depend on the direction of deposition, and the Hugoniot elastic limit of samples loaded perpendicular to the deposition direction is about ~10% higher. With an increase in the maximum compression stress, the material’s spall strength increases slightly, but for both types of samples, a slight decrease in the Hugoniot elastic limit was observed as the compression stresses increase. On the basis of the measured wave profiles, shock Hugoniots of the samples of the alloy Inconel 625, loaded both along and perpendicular to the direction of deposition, are constructed in this pressure range. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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10 pages, 8212 KiB

Open AccessArticle

Using a Trial Sample on Stainless Steel 316L in a Direct Laser Deposition Process

by Artur Vildanov, Konstantin Babkin, Ruslan Mendagaliyev, Andrey Arkhipov and Gleb Turichin

Metals 2021, 11(10), 1550; https://doi.org/10.3390/met11101550 - 28 Sep 2021

Cited by 7 | Viewed by 1721

Abstract

Direct laser deposition technology is used for the manufacture of large-size products with complex geometries. As a rule, trial samples with small dimensions are made to determine the deposition parameters. In order for the resulting products to have the required performance characteristics, it is necessary to minimize the number of internal macrodefects. Non-fusion between the tracks are defects that depend on the technological mode (power, speed, track width, etc.). In this work, studies have been carried out to determine the power level at which non-fusion is formed, dwell time between the tracks on the model samples. This paper considers the issue of transferring the technological parameters of direct laser deposition from model samples to a large-sized part, and describes the procedure for making model samples. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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12 pages, 4119 KiB

Open AccessArticle

High-Strain Deformation and Spallation Strength of 09CrNi2MoCu Steel Obtained by Direct Laser Deposition

by Olga Klimova-Korsmik, Gleb Turichin, Ruslan Mendagaliyev, Sergey Razorenov, Gennady Garkushin, Andrey Savinykh and Rudolf Korsmik

Metals 2021, 11(8), 1305; https://doi.org/10.3390/met11081305 - 18 Aug 2021

Cited by 10 | Viewed by 1820

Abstract

In this work, the critical fracture stresses during spalling of high-strength steel 09CrNi2MoCu samples obtained by direct laser deposition (DLD) were measured under shock compression of up to ~5.5 GPa. The microstructure and mechanical properties of DLD steel samples in the initial state and after heat treatment were studied and compared to traditional hot rolled one. The microstructural features of steel before and after heat treatment were revealed. The heat treatment modes of the deposit specimens on their strength properties under both static and dynamic loads have been investigated. The spall strength of the deposited specimens is somewhat lower than the strength of steel specimens after hot rolling regardless of their heat treatment. The minimum elastic limit of elasticity is exhibited by the deposit specimens. After heat treatment of the deposit samples, the elastic limit increases and approximately doubles. Subsequent heat treatment in the form of hardening and tempering allows obtaining strength properties under Hugoniot loads in traditional hot-rolled products. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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12 pages, 2753 KiB

Open AccessFeature PaperArticle

Experimental and Simulation Analysis of Effects of Laser Bending on Microstructures Applied to Advanced Metallic Alloys

by Esteban Ramos-Moore, Joaquín Hoffmann, Rafael H. M. Siqueira, Sheila Medeiros de Carvalho, Milton S. Fernandes de Lima and Diego J. Celentano

Metals 2021, 11(2), 362; https://doi.org/10.3390/met11020362 - 21 Feb 2021

Cited by 1 | Viewed by 2000

Abstract

The aim of this work is the analysis of laser beam forming (LBF) in the bending of two relevant materials used in the transportation industry—interstitial-free (IF) steel and AA6013 high-strength aluminum alloy. Our experiments and numerical simulations consider two different operating scenarios achieved by varying the laser beam scanning velocity using linear paths. The material behavior during this process is described via a coupled thermomechanical-plasticity-based formulation that allows prediction of temperature profiles and bending angles. Metallography, glow discharge optical emission spectroscopy, and X-ray diffraction are used for microstructure characterization. In addition, microstress analyses are performed in order to study the stress behavior of the irradiated zones. It is found that LBF mainly induces grain growth and melting in the case of high surface temperatures. Before melting, the materials developed compressive stresses that could be useful in preventing cracking failures. The resulting bending angles are predicted and experimentally validated, indicating the robustness of the model to estimate LBF effects on advanced alloys. The present analysis relating bending angles together with temperature and microstructure profiles along the thickness of the sheets is the main original contribution of this work, highlighting the need for further modeling refinement of the effects of LBF on advanced alloys to include more microstructural properties, such as grain boundary diffusion and surface roughness. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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10 pages, 3784 KiB

Open AccessArticle

Unidirectional Crystal Orientation of Dual-Phase Ni₃Al-Based Alloy via Laser Irradiation

by Satoshi Semboshi, Hiroshi Nakamura, Yosuke Kawahito, Yasuyuki Kaneno and Takayuki Takasugi

Metals 2020, 10(8), 1011; https://doi.org/10.3390/met10081011 - 28 Jul 2020

Viewed by 2032

Abstract

Dual-phase Ni₃Al-based alloys feature extensive applicability even under high-temperature conditions. We selectively modified the microstructure of a representative dual-phase Ni₃Al-based alloy from equi-axed grains to unidirectional grains, using a kW-class high-power laser irradiation technique. On employing the laser probe to linearly scan the Ni-9 at.% Al-16 at.% V alloy specimen, the laser-irradiated region was partially molten and then immediately solidified from the two edges of the molten pool toward the center. Laser irradiation under low-speed scanning increased the molten pool width. The grains in the laser-irradiated region extended preferentially from the two edges toward the center; their crystal orientation was similar to adjacent substrate grains, suggesting epitaxial growth. Therefore, the unidirectional orientation of grains could be extended via wide-range scanning using laser irradiation. This suggests that the microstructure of the alloy can be selectively modified to unidirectional orientated grains by optimizing laser irradiation conditions, such as the power density, scanning speed, and scanning paths. The hardness of the laser-irradiated region decreased due to the phase transformation from the ordered Ni₃Al and Ni₃V phases to the disordered fcc phase. However, the hardness improved to a value comparable to that of the alloy subjected to heat treatment at 980 °C for 1 h. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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19 pages, 15415 KiB

Open AccessArticle

Laser Surface Hardening of Ni-hard White Cast Iron

by Samar Reda Al-Sayed, Ahmed Magdi Elshazli and Abdel Hamid Ahmed Hussein

Metals 2020, 10(6), 795; https://doi.org/10.3390/met10060795 - 16 Jun 2020

Cited by 12 | Viewed by 4025

Abstract

Laser surface treatment on two different types of nickel–chromium white cast iron (Ni-hard) alloys (Ni-hard 1 and Ni-hard 4) was investigated. Nd:YAG laser of 2.2-kw with continuous wave was used. Ni-hard alloys are promising engineering materials, which are extensively used in applications where good resistance to abrasion wear is essential. The conventional hardening of such alloys leads to high wear resistance nevertheless, the core of the alloy suffers from low toughness. Therefore, it would be beneficial to harden the surface via laser surface technology which keeps the core tough enough to resist high impact shocks. A laser power of different levels (600, 800 and 1000 Watts) corresponding to three different laser scanning speeds (3, 4 and 5 m·min⁻¹) was adopted hoping to reach optimum conditions for wear resistance and impact toughness. The optimum condition for both properties was recorded at heat input of 16.78 J·mm⁻². The present findings reflect that the microhardness values and wear resistance clearly increased after laser hardening by almost three times due to laser surface hardening, whereas, the impact toughness was increased from five joules obtained from conventionally heat-treated samples to 6.4 J as gained from laser-treated samples. Full article

(This article belongs to the Special Issue Laser Processing of Metals and Alloys)

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