Materials for Sustainable Beam-Based Additive Manufacturing

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

Deadline for manuscript submissions: closed (30 June 2021) | Viewed by 5595

Special Issue Editors


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Guest Editor
Department of Mechanical Engineering, Politecnico di Milano, Via Giuseppe La Masa 1, 20156 Milano, Italy
Interests: material science; metallurgy; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Politecnico di Milano, Via Giuseppe La Masa 1, 20156 Milano, Italy
Interests: material science; metallurgy; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Beam-based technologies represent a large group of additive manufacturing processes whereby a heat source such as a laser or an electron beam is used to consolidate materials, in powder or wire form, to generate 3D objects. Research efforts towards the design of new metallic alloys for AM and on the optimization of post-processing treatments are continuously growing.

The aim of this Special Issue is to highlight recent innovations introduced in the fields of materials for beam-based AM, covering both the understanding of process-related effects on material properties and the development of novel alloys with improved properties and processability.

Prof. Dr. Maurizio Vedani
Prof. Dr. Riccardo Casati
Guest Editors

Manuscript Submission Information

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Keywords

  • laser powder bed fusion
  • electron beam additive manufacturing
  • directed energy deposition
  • steels
  • Al alloys
  • Ni alloys
  • Ti alloys
  • defects
  • microstructure
  • metal powders
  • post-processing

Published Papers (2 papers)

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Research

12 pages, 4261 KiB  
Article
Development of a Novel High-Temperature Al Alloy for Laser Powder Bed Fusion
by Filippo Belelli, Riccardo Casati, Martina Riccio, Alessandro Rizzi, Mevlüt Y. Kayacan and Maurizio Vedani
Metals 2021, 11(1), 35; https://doi.org/10.3390/met11010035 - 26 Dec 2020
Cited by 20 | Viewed by 2811
Abstract
The number of available materials for Laser Powder Bed Fusion is still limited due to the poor processability of many standard alloys. In particular, the lack of high-strength aluminium alloys, widely used in aerospace and automotive industries, remains a big issue for the [...] Read more.
The number of available materials for Laser Powder Bed Fusion is still limited due to the poor processability of many standard alloys. In particular, the lack of high-strength aluminium alloys, widely used in aerospace and automotive industries, remains a big issue for the spread of beam-based additive manufacturing technologies. In this study, a novel high-strength aluminium alloy for high temperature applications having good processability was developed. The design of the alloy was done based on the chemical composition of the widely used EN AW 2618. This Al-Cu-Mg-Ni-Fe alloy was modified with Ti and B in order to promote the formation of TiB2 nuclei in the liquid phase able to stimulate heterogeneous nucleation of grains and to decrease the hot cracking susceptibility of the material. The new Al alloy was manufactured by gas atomisation and processed by Laser Powder Bed Fusion. Samples produced with optimised parameters featured relative density of 99.91%, with no solidification cracks within their microstructure. After aging, the material revealed upper yield strength and ultimate tensile strength of 495 MPa and 460 MPa, respectively. In addition, the alloy showed tensile strength higher than wrought EN AW 2618 at elevated temperatures. Full article
(This article belongs to the Special Issue Materials for Sustainable Beam-Based Additive Manufacturing)
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21 pages, 13756 KiB  
Article
Effects of Powder Atomisation on Microstructural and Mechanical Behaviour of L-PBF Processed Steels
by Marawan Abdelwahed, Riccardo Casati, Sven Bengtsson, Anna Larsson, Martina Riccio and Maurizio Vedani
Metals 2020, 10(11), 1474; https://doi.org/10.3390/met10111474 - 05 Nov 2020
Cited by 10 | Viewed by 2328
Abstract
In this research, steel alloys based on the Fe-Cr-Mo, Fe-Cr-Mn and Fe-Cr-Mo-Mn-Ni systems have been designed, produced by different atomisation techniques, and processed by laser powder bed fusion (L-PBF) to investigate their microstructural and mechanical behaviour. Both gas atomisation and water atomisation were [...] Read more.
In this research, steel alloys based on the Fe-Cr-Mo, Fe-Cr-Mn and Fe-Cr-Mo-Mn-Ni systems have been designed, produced by different atomisation techniques, and processed by laser powder bed fusion (L-PBF) to investigate their microstructural and mechanical behaviour. Both gas atomisation and water atomisation were considered for powder preparation. The resulting different flowability of powders, hence a different densification behaviour during processing, could be compensated by tuning the L-PBF parameters and by the application of a post treatment to improve flowability of the water atomised powders. In agreement with thermodynamic calculations, small-size oxide-based nonmetallic inclusions of the type SiO2, MnO-SiO2, Cr2O3-SiO2 were found within the steel matrix and on the fracture surfaces of the water atomised L-PBF alloys, featuring higher amounts of oxygen than the gas-atomised steels. Analyses on microstructure and hardness of the hardenable as-built steels suggested that during laser processing, the multilayer L-PBF structure undergoes an in-situ tempering treatment. Furthermore, the mechanical properties of the L-PBF steels could be widely tuned depending on the post-thermal treatment conditions. Full article
(This article belongs to the Special Issue Materials for Sustainable Beam-Based Additive Manufacturing)
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