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Keywords = electron-beam additive manufacturing

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33 pages, 3776 KiB  
Review
The Role of Additive Manufacturing in Dental Implant Production—A Narrative Literature Review
by Ján Duplák, Darina Dupláková, Maryna Yeromina, Samuel Mikuláško and Jozef Török
Sci 2025, 7(3), 109; https://doi.org/10.3390/sci7030109 - 3 Aug 2025
Viewed by 139
Abstract
This narrative review explores the role of additive manufacturing (AM) technologies in the production of dental implants, focusing on materials and key AM methods. The study discusses several materials used in implant fabrication, including porous titanium, trabecular tantalum, zirconium dioxide, polymers, and composite [...] Read more.
This narrative review explores the role of additive manufacturing (AM) technologies in the production of dental implants, focusing on materials and key AM methods. The study discusses several materials used in implant fabrication, including porous titanium, trabecular tantalum, zirconium dioxide, polymers, and composite materials. These materials are evaluated for their mechanical properties, biocompatibility, and suitability for AM processes. Additionally, the review examines the main AM technologies used in dental implant production, such as selective laser melting (SLM), electron beam melting (EBM), stereolithography (SLA), selective laser sintering (SLS), and direct metal laser sintering (DMLS). These technologies are compared based on their accuracy, material limitations, customization potential, and applicability in dental practice. The final section presents a data source analysis of the Web of Science and Scopus databases, based on keyword searches. The analysis evaluates the research trends using three criteria: publication category, document type, and year of publication. This provides an insight into the evolution and current trends in the field of additive manufacturing for dental implants. The findings highlight the growing importance of AM technologies in producing customized and efficient dental implants. Full article
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18 pages, 8242 KiB  
Article
Quasi-In Situ EBSD Investigation of Variant Evolution and Twin Formation in a Hot Isostatic Pressing-Treated Additively-Manufactured Titanium Alloy Under Tensile Loading
by Fengli Zhu, Jiahong Liang, Guojian Cao, Aihan Feng, Hao Wang, Shoujiang Qu and Daolun Chen
Materials 2025, 18(13), 3169; https://doi.org/10.3390/ma18133169 - 3 Jul 2025
Viewed by 455
Abstract
The advent of additive manufacturing (AM), also known as 3D printing, has revolutionized the production of titanium alloys, offering significant advantages in fabricating complex geometries with enhanced mechanical properties. This study investigates the variant-specific deformation mechanisms in HIP-treated TA15 (Ti-6.5Al-2Zr-1Mo-1V) titanium alloy, fabricated [...] Read more.
The advent of additive manufacturing (AM), also known as 3D printing, has revolutionized the production of titanium alloys, offering significant advantages in fabricating complex geometries with enhanced mechanical properties. This study investigates the variant-specific deformation mechanisms in HIP-treated TA15 (Ti-6.5Al-2Zr-1Mo-1V) titanium alloy, fabricated via selective electron beam melting (SEBM). The alloy exhibits a dual-phase (α+β) microstructure, where six distinct α variants are formed through the β→α phase transformation following the Burgers orientation relationship. Variant selection during AM leads to a non-uniform distribution of these α variants, with α6 (22.3%) dominating due to preferential growth. Analysis of the prismatic slip Schmid factor reveals that α4–α6 variants, with higher Schmid factors (>0.45), primarily undergo prismatic slip, while α1–α3 variants, with lower Schmid factors (<0.3), rely on basal or pyramidal slip and twinning for plastic deformation. In-grain misorientation axis (IGMA) analysis further reveals strain-dependent slip transitions: pyramidal slip is activated in α1–α3 variants at lower strains, while prismatic slip becomes the dominant deformation mechanism in α4–α6 variants at higher strains. Additionally, deformation twins, primarily {10–12}<1–101> extension twins (7.1%), contribute to the plasticity of hard-oriented α variants. These findings significantly enhance the understanding of the orientation-dependent deformation mechanisms in HIPed TA15 alloy and provide a crucial basis for optimizing the performance of additively-manufactured titanium alloys. Full article
(This article belongs to the Special Issue Novel Materials for Additive Manufacturing)
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31 pages, 3471 KiB  
Review
Advances in the Additive Manufacturing of Superalloys
by Antonio del Bosque, Pablo Fernández-Arias and Diego Vergara
J. Manuf. Mater. Process. 2025, 9(7), 215; https://doi.org/10.3390/jmmp9070215 - 25 Jun 2025
Viewed by 988
Abstract
This study presents a bibliometric analysis of the evolution and research trends in the additive manufacturing (AM) of superalloys over the last decade (2015–2025). The review follows a structured methodology based on the PRISMA 2020 protocol, utilizing data from the Scopus and Web [...] Read more.
This study presents a bibliometric analysis of the evolution and research trends in the additive manufacturing (AM) of superalloys over the last decade (2015–2025). The review follows a structured methodology based on the PRISMA 2020 protocol, utilizing data from the Scopus and Web of Science (WoS) databases. Particular attention is devoted to the intricate process–structure–property relationships and the specific behavioral trends associated with different superalloy families, namely Ni-based, Co-based, and Fe–Ni-based systems. The findings reveal a substantial growth in scientific output, with the United States and China leading contributions and an increasing trend in international collaboration. Key research areas include process optimization, microstructural evolution and control, mechanical property assessment, and defect minimization. The study highlights the pivotal role of technologies such as laser powder bed fusion, electron beam melting, and directed energy deposition in the fabrication of high-performance components. Additionally, emerging trends point to the integration of machine learning and artificial intelligence for real-time quality monitoring and manufacturing parameter optimization. Despite these advancements, challenges such as anisotropic properties, porosity issues, and process sustainability remain critical for both industrial applications and future academic research in superalloys. Full article
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56 pages, 2573 KiB  
Review
A Review of Optimization of Additively Manufactured 316/316L Stainless Steel Process Parameters, Post-Processing Strategies, and Defect Mitigation
by Usman Aziz, Marion McAfee, Ioannis Manolakis, Nick Timmons and David Tormey
Materials 2025, 18(12), 2870; https://doi.org/10.3390/ma18122870 - 17 Jun 2025
Cited by 1 | Viewed by 671
Abstract
The rapid progress in additive manufacturing (AM) has unlocked significant possibilities for producing 316/316L stainless steel components, particularly in industries requiring high precision, enhanced mechanical properties, and intricate geometries. However, the widespread adoption of AM—specifically Directed energy deposition (DED), selective laser melting (SLM), [...] Read more.
The rapid progress in additive manufacturing (AM) has unlocked significant possibilities for producing 316/316L stainless steel components, particularly in industries requiring high precision, enhanced mechanical properties, and intricate geometries. However, the widespread adoption of AM—specifically Directed energy deposition (DED), selective laser melting (SLM), and electron beam melting (EBM) remains challenged by inherent process-related defects such as residual stresses, porosity, anisotropy, and surface roughness. This review critically examines these AM techniques, focusing on optimizing key manufacturing parameters, mitigating defects, and implementing effective post-processing treatments. This review highlights how process parameters including laser power, energy density, scanning strategy, layer thickness, build orientation, and preheating conditions directly affect microstructural evolution, mechanical properties, and defect formation in AM-fabricated 316/316L stainless steel. Comparative analysis reveals that SLM excels in achieving refined microstructures and high precision, although it is prone to residual stress accumulation and porosity. DED, on the other hand, offers flexibility for large-scale manufacturing but struggles with surface finish and mechanical property consistency. EBM effectively reduces thermal-induced residual stresses due to its sustained high preheating temperatures (typically maintained between 700 °C and 850 °C throughout the build process) and vacuum environment, but it faces limitations related to resolution, cost-effectiveness, and material applicability. Additionally, this review aligns AM techniques with specific defect reduction strategies, emphasizing the importance of post-processing methods such as heat treatment and hot isostatic pressing (HIP). These approaches enhance structural integrity by refining microstructure, reducing residual stresses, and minimizing porosity. By providing a comprehensive framework that connects AM techniques optimization strategies, this review serves as a valuable resource for academic and industry professionals. It underscores the necessity of process standardization and real-time monitoring to improve the reliability and consistency of AM-produced 316/316L stainless steel components. A targeted approach to these challenges will be crucial in advancing AM technologies to meet the stringent performance requirements of various high-value industrial applications. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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25 pages, 4538 KiB  
Article
Machine Learning-Based Multi-Objective Optimization for Enhancing the Performance of Block Support Structures for Electron Beam Additive Manufacturing
by Mustafa M. Nasr, Wadea Ameen, Abdulmajeed Dabwan and Abdulrahman Al-Ahmari
Metals 2025, 15(6), 671; https://doi.org/10.3390/met15060671 - 17 Jun 2025
Viewed by 388
Abstract
Electron beam melting (EBM) technology has gained prominence owing to its ability to enhance production efficiency and meet green manufacturing standards. However, overhang structures are a significant issue for additive manufacturing due to their need for supporting structures during printing. This increases manufacturing [...] Read more.
Electron beam melting (EBM) technology has gained prominence owing to its ability to enhance production efficiency and meet green manufacturing standards. However, overhang structures are a significant issue for additive manufacturing due to their need for supporting structures during printing. This increases manufacturing time, requiring more material, extra effort, and a more complex engineering procedure. Therefore, this research aims to develop an intelligent optimization method based on AI-ANFIS/Al-ANN and improved NSGA-III, integrating the AM design, 3D printing, and post-processing phases to enhance the performance of block support structures and the quality of the EBM parts produced. To achieve this, statistical analysis was performed to detail the simultaneous influence of block support type, block support structure design, and EBM parameters on fabricating performance, warping deformation, support removal time, and support volume. After that, intelligent models based on ANFIS/ANN and the advanced NSGA-III method were developed for monitoring and optimizing the performance of specified block support structures. The results reveal that the block support type, block support structure design, and EBM parameters simultaneously significantly affect block support structures’ performance. This study illustrated that the AI models based on ANFIS might provide more accurate and reliable estimation models for monitoring and predicting support volume, support removal time, and warping deformation, exhibiting reduced errors of 0.992%, 1.2%, 1.28%, and 1.06%, respectively, in comparison to empirical measurements, ANN models, and regression models. Finally, the developed intelligent method obtains the optimal block support type, block support design, and EBM parameters to enhance the quality of produced parts, reduce material wastage, and reduce the post-processing time of fabricated EBM Ti6Al4V. Henceforth, smart systems may be employed to create innovative solutions that integrate the AM design, 3D printing, and post-processing stages. This will allow for the monitoring and improvement of AM process performance, as well as the fulfillment of Industry 4.0 requirements. Full article
(This article belongs to the Section Additive Manufacturing)
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13 pages, 14198 KiB  
Article
Mechanical Properties of Dispersion-Strengthened Iron-Based W+WC(Ni) Composite Produced by Combined Wire Electron-Beam Manufacturing with Powder Addition
by Andrey Vorontsov, Anna Zykova, Denis Gurianov, Nikolay Shamarin, Aleksandr Panfilov, Andrey Chumaevskii, Kirill Kalashnikov, Evgeny Kolubaev and Nikolai Savchenko
J. Compos. Sci. 2025, 9(4), 144; https://doi.org/10.3390/jcs9040144 - 21 Mar 2025
Cited by 1 | Viewed by 559
Abstract
The paper investigates the microstructure and mechanical properties of a steel matrix composite reinforced with tungsten (W) particles and a mixture of tungsten carbide and nickel (WC(Ni)) obtained by a hybrid additive manufacturing method using wire electron beam additive manufacturing with powder addition. [...] Read more.
The paper investigates the microstructure and mechanical properties of a steel matrix composite reinforced with tungsten (W) particles and a mixture of tungsten carbide and nickel (WC(Ni)) obtained by a hybrid additive manufacturing method using wire electron beam additive manufacturing with powder addition. The composite exhibits a gradient structure including three zones: a matrix of high alloy steel 401S45, a transition layer with a low concentration of W/WC(Ni) and a surface layer enriched with particles of reinforcing phases. SEM, TEM and XRD methods revealed a heterogeneous microstructure consisting of α-Fe (80 vol.%), γ-Fe (10 vol.%) and carbide phases, as well as suppression of the formation of brittle Me3C intermetallides due to the controlled diffusion of W, C and alloying elements. The microhardness of the composite increases from 350 HV (matrix) to 650 HV (reinforced layer) due to dispersion hardening and formation of the carbide skeleton. Compression tests showed record strength of the reinforced layer (1720 ± 60 MPa) due to effective load distribution by W/WC(Ni) particles, but brittle failure is observed in tensile tests due to stress concentration at the interfaces. Full article
(This article belongs to the Special Issue Application of Composite Materials in Additive Manufacturing)
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29 pages, 28940 KiB  
Article
Enhancement of Energy Absorption Capability of 3D Printed Ti-6Al-4V BCC Lattice Structures by Adding Auxiliary Struts
by Jaryong Cho, Eunwoo Kim, Jeong Ho Kim, Chang-Yull Lee and Jin Yeon Cho
Materials 2025, 18(4), 732; https://doi.org/10.3390/ma18040732 - 7 Feb 2025
Cited by 1 | Viewed by 1061
Abstract
Lattice structures, composed of interconnected struts, offer an efficient way to reduce structural weight while maintaining structural integrity. Because of this potential, this work aims to investigate and develop an efficient variant form of a BCC (Body-Centered Cubic) lattice structure to enhance the [...] Read more.
Lattice structures, composed of interconnected struts, offer an efficient way to reduce structural weight while maintaining structural integrity. Because of this potential, this work aims to investigate and develop an efficient variant form of a BCC (Body-Centered Cubic) lattice structure to enhance the structural robustness and energy absorption capability, based on the Maxwell stability criterion. And we specifically changed the bending-dominated to stretching-dominated behavior by adding auxiliary struts, according to the theory, and confirmed how this affects the compression behavior of the structure. For this purpose, horizontal auxiliary struts are added for the first time to the BCC structure along with vertical struts. As a macroscale cellular lattice structure, a unit cell size of 12 mm is considered. For the considered macroscale cellular lattice structures, FEA (finite element analysis) is employed to numerically investigate the stress distribution and compressive deformation mechanisms. Then, quasi-static compression tests are carried out to measure the energy absorption performance of the lattice structures manufactured by the EBM (Electron Beam Melting) metal additive manufacturing technique, which has advantages in building lattice structures without supporters. A comprehensive investigation reveals that a newly designed lattice structure offers significant advantages in structural robustness, with energy absorption capability increased by 365% compared to existing structures, achieved by incorporating vertical and cross-shaped horizontal auxiliary struts into the original BCC lattice configuration. The enhanced lattice structures can be utilized in industries where low-weight and high-strength are needed, such as aerospace, marine, and other industries. Full article
(This article belongs to the Special Issue 3D & 4D Printing in Engineering Applications, 2nd Edition)
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28 pages, 10098 KiB  
Review
A Short Review of Advancements in Additive Manufacturing of Cemented Carbides
by Zhe Zhao, Xiaonan Ni, Zijian Hu, Wenxin Yang, Xin Deng, Shanghua Wu, Yanhui Li, Guanglin Nie, Haidong Wu, Jinyang Liu and Yong Huang
Crystals 2025, 15(2), 146; https://doi.org/10.3390/cryst15020146 - 30 Jan 2025
Cited by 1 | Viewed by 1316
Abstract
Cemented carbides, renowned for their exceptional strength, hardness, elastic modulus, wear resistance, corrosion resistance, low coefficient of thermal expansion, and chemical stability, have long been indispensable tooling materials in metal cutting, oil drilling, and engineering excavation. The advent of additive manufacturing (AM), commonly [...] Read more.
Cemented carbides, renowned for their exceptional strength, hardness, elastic modulus, wear resistance, corrosion resistance, low coefficient of thermal expansion, and chemical stability, have long been indispensable tooling materials in metal cutting, oil drilling, and engineering excavation. The advent of additive manufacturing (AM), commonly known as “3D printing”, has sparked considerable interest in the processing of cemented carbides. Among the various AM techniques, Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Selective Electron Beam Melting (SEBM), and Binder Jetting Additive Manufacturing (BJAM) have garnered frequent attention. Despite the great application potential of AM, no single AM technique has been universally adopted for the large-scale production of cemented carbides yet. The SLM and SEBM processes confront substantial challenges, such as a non-uniform sintering temperature field, which often result in uneven sintering and frequent post-solidification cracking. SLS notably struggles with achieving a high relative density of carbides. While BJAM yields WC-Co samples with a lower incidence of cracking, it is not without flaws, including abnormal WC grain growth, coarse WC clustering, Co-rich pool formation, and porosity. Three-dimensional gel-printing, though possessing certain advantages from its sintering performance, falls short in dimensional and geometric precision control, as well as fabrication efficiency. Cemented carbides produced via AM processes have yet to match the quality of their traditionally prepared counterparts. To date, the specific densification and microstructure evolution mechanisms during the AM process, and their interrelationship with the feedstock carbide material design, printing/sintering process, and resulting mechanical behavior, have not been thoroughly investigated. This gap in our knowledge impedes the rapid advancement of AM for carbide processing. This article offers a succinct overview of additive manufacturing of cemented carbides, complemented by an analysis of the current research landscape. It highlights the benefits and inherent challenges of these techniques, aiming to provide clarity on the present state of the AM processing of cemented carbides and to offer insights into potential future research directions and technological advancements. Full article
(This article belongs to the Special Issue High-Performance Metallic Materials)
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16 pages, 76542 KiB  
Article
Low-Energy High-Current Pulsed Electron Beam Surface Treatment on the Tribological Behavior of 17-4PH Steel Produced via Binder Jetting
by Lorenza Fabiocchi, Marco Mariani, Andrea Lucchini Huspek, Matteo Pozzi, Massimiliano Bestetti and Nora Lecis
Lubricants 2025, 13(2), 42; https://doi.org/10.3390/lubricants13020042 - 21 Jan 2025
Cited by 1 | Viewed by 1194
Abstract
Stainless steel 17-4PH is valued for its high strength and corrosion resistance but poses machining challenges due to rapid tool wear. This research investigates the use of pulsed electron beam surface treatment to enhance the surface properties of components fabricated by binder jetting [...] Read more.
Stainless steel 17-4PH is valued for its high strength and corrosion resistance but poses machining challenges due to rapid tool wear. This research investigates the use of pulsed electron beam surface treatment to enhance the surface properties of components fabricated by binder jetting additive manufacturing. The aim is to improve the tribological performance compared to the as-sintered condition and the H900 aging process, which optimizes hardness and wear resistance. Printed samples were sintered in a reducing atmosphere and superficially treated with an electron beam by varying the voltage and the pulse count. Results showed that the voltage affects the roughness and thickness of the treated layer, while the number of pulses influences the hardening of the microstructure and, consequently, the wear resistance. A reciprocating linear pin-on-disk wear test was conducted at 2 N and 10 Hz. Surface-treated samples exhibited lower coefficients of friction, though the values approached those of aged samples after the abrasion of the melted layer, indicating a deeper heat-affected zone formation. Still, the friction remained lower than that of as-printed specimens. This study demonstrates that optimizing electron beam parameters is vital for achieving surface performance comparable to bulk aging treatments, with significant implications for long-term wear resistance. Full article
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23 pages, 2467 KiB  
Review
3D-Printed Customized Cages for Foot Arthrodesis
by Iozefina Botezatu, Dan Lăptoiu, Diana Popescu and Rodica Marinescu
Appl. Sci. 2025, 15(2), 969; https://doi.org/10.3390/app15020969 - 20 Jan 2025
Cited by 1 | Viewed by 1346
Abstract
In recent years, the application of 3D-printed implant cages or trusses for foot arthrodesis has emerged as a personalized approach to address complex bone defects and deformities. Twenty studies involving different regions of the foot, such as the ankle and subtalar joints, were [...] Read more.
In recent years, the application of 3D-printed implant cages or trusses for foot arthrodesis has emerged as a personalized approach to address complex bone defects and deformities. Twenty studies involving different regions of the foot, such as the ankle and subtalar joints, were reviewed to document the 3D-printed custom solutions. The design of these implants is also discussed, including custom titanium trusses and lattice structures, which can promote osseointegration and fit the bone geometries. From a mechanical perspective, these implants proved to be stable and compatible with natural bone, aiming to reduce stress shielding while offering the mechanical strength needed for optimal outcomes. This systematic survey also addresses the additive manufacturing processes involved, namely EBM, SLM, or DMLS. Clinical cases were focused on patients with large bone loss, failed prior fusions, and deformity corrections, with the follow-up results showing high rates of fusion and functional improvement. Of the analyzed studies, three provide level III evidence, while the rest provide level IV or V, consisting of case series or reports. Since 2015, 148 patients have been reported to receive such implants. This review addresses the question, “how effective are 3D-printed titanium cage implants in foot arthrodesis in addressing large bone defects and deformities?” It is the first review to gather data on the use of such customized implants in foot arthrodesis, providing critical insights to enhance their application, including amputation avoidance. This study highlights the advantages of personalized 3D-printed implants in achieving a better anatomical fit, improving clinical outcomes, and ensuring faster recovery times, while also addressing considerations such as the cost and the need for long-term clinical data. Full article
(This article belongs to the Special Issue Feature Review Papers in Additive Manufacturing Technologies)
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15 pages, 6243 KiB  
Article
Metallic Ion Release Behaviors from Cobalt–Chromium Alloys Fabricated by Additive Manufacturing with Mechanical Grinding in an Acidic Saline Solution
by Naoto Sakurai, Tomofumi Sawada, Yukinori Kuwajima, Kenta Yamanaka, Naoyuki Nomura, Masaaki Kasahara, Akihiko Chiba, Kazuro Satoh and Shinji Takemoto
Materials 2025, 18(2), 432; https://doi.org/10.3390/ma18020432 - 17 Jan 2025
Cited by 1 | Viewed by 1269
Abstract
This study aimed to investigate the release of metallic ions from cobalt–chromium (Co-Cr) alloys fabricated by additive manufacturing (AM) for comparison with dental casting. Co-Cr alloys were fabricated via AM using selective laser melting (SLM) and electron beam melting (EBM) in powder-bed fusion. [...] Read more.
This study aimed to investigate the release of metallic ions from cobalt–chromium (Co-Cr) alloys fabricated by additive manufacturing (AM) for comparison with dental casting. Co-Cr alloys were fabricated via AM using selective laser melting (SLM) and electron beam melting (EBM) in powder-bed fusion. Polished and mechanically ground specimens were prepared. Each specimen was analyzed using an electron probe microanalyzer (EPMA). Each specimen was immersed in an acidic saline solution for 7 days in accordance with ISO 10271: 2020. The EPMA indicated the segregation of some elements in the as-prepared SLM and EBM specimens, whereas the polished and ground specimens exhibited a homogenous elemental distribution. The total amount of ion release from the SLM and EBM specimens was confirmed to be less than 7 μg/cm2, which was less than 42 μg/cm2 for the cast specimen. The polished and ground specimens exhibited an even lower ion release than the as-prepared specimens. The amount of ions released from the Co-Cr alloy was less than the 200 μg/cm² requirement of ISO 22674: 2022. Co-Cr alloys fabricated by SLM and EBM could provide superior corrosion resistance to cast specimens. AM could be a valuable method for fabricating appliances and denture frameworks in dentistry. Full article
(This article belongs to the Special Issue Additive Manufacturing of Alloys and Composites (2nd Edition))
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16 pages, 8305 KiB  
Article
Investigating Fracture Behavior in Titanium Aluminides: Surface Roughness as an Indicator of Fracture Mechanisms in Ti-48Al-2Cr-2Nb Alloys
by Alessia Serena Perna, Lorenzo Savio, Michele Coppola and Fabio Scherillo
Metals 2025, 15(1), 49; https://doi.org/10.3390/met15010049 - 7 Jan 2025
Cited by 1 | Viewed by 820
Abstract
Titanium aluminides, particularly the Ti-48Al-2Cr-2Nb alloy, have drawn significant attention for their potential in high-temperature aerospace and automotive applications due to their exceptional performances and reduced density compared to nickel-based superalloys. However, their intermetallic nature poses challenges such as limited room-temperature ductility and [...] Read more.
Titanium aluminides, particularly the Ti-48Al-2Cr-2Nb alloy, have drawn significant attention for their potential in high-temperature aerospace and automotive applications due to their exceptional performances and reduced density compared to nickel-based superalloys. However, their intermetallic nature poses challenges such as limited room-temperature ductility and fracture toughness, limiting their widespread application. Additive manufacturing, specifically Electron Beam Melting (EBM), has emerged as a promising method for producing complex-shaped components of titanium aluminides, overcoming challenges associated with conventional production methods. This work investigates the fracture behavior of Ti-48Al-2Cr-2Nb specimens with different microstructures, including duplex and equiaxed, under tensile and high-cycle fatigue at elevated temperatures. Fracture surfaces were analyzed to distinguish between static and dynamic fracture modes. A novel method, employing confocal microscopy acquisitions, is proposed to correlate surface roughness parameters with the causes of failure, offering new insights into the fracture mechanisms of titanium aluminides. The results reveal significant differences in roughness values between the propagation and fracture zones for all the temperatures and microstructure tested. At 650 °C, the crack propagation zone exhibits lower Sq values than the fracture zone, with the fracture zone showing more pronounced roughness, particularly for the equiaxed microstructure. However, at 760 °C, the difference in Sq values between the propagation and fracture zones becomes more pronounced, with a more substantial increase in Sq values in the fracture zone. These findings contribute to understanding fracture behavior in titanium aluminides and provide a predictive framework for assessing structural integrity based on surface characteristics. Full article
(This article belongs to the Special Issue Research on Fatigue Behavior of Additively Manufactured Materials)
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18 pages, 9907 KiB  
Article
Effect of Microstructure on Multiscale Mechanical Properties of Scalmalloy Produced by Powder Bed Fusion-Laser Beam
by Huixing (Hannah) Zhang, Caitlin E. R. Green, Maria J. Lodeiro, Peter Woolliams, Ken P. Mingard and Antony T. Fry
Alloys 2025, 4(1), 1; https://doi.org/10.3390/alloys4010001 - 30 Dec 2024
Viewed by 1635
Abstract
For additive manufactured parts, it is important to measure homogeneity and demonstrate representative parts can be printed faster while maintaining key mechanical properties. In this work, a multiscale characterization of microstructural and mechanical properties was carried out to gain a thorough understanding of [...] Read more.
For additive manufactured parts, it is important to measure homogeneity and demonstrate representative parts can be printed faster while maintaining key mechanical properties. In this work, a multiscale characterization of microstructural and mechanical properties was carried out to gain a thorough understanding of a range of powder bed fusion-laser beam (PBF-LB)-manufactured Scalmalloy for future optimization of the processing parameters. The relationship between microstructure, including porosity, grain structure, and precipitates, and mechanical properties, is investigated. The stress-relieved samples were characterized mainly using scanning electron microscopy (SEM) suite, uniaxial tensile tests and nanoindentation. The results show the multiple strengthening mechanisms in Scalmalloy, including solid solution strengthening, grain size, precipitates and dislocations strengthening, demonstrated through a combination of the nanoindentation measurements with microstructural analysis at the local scale. The current work suggests potential mechanisms for further improvement of the strength and ductility in PBF-LB-Scalmalloy. Full article
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14 pages, 6220 KiB  
Article
Post-Processing of AM-EBM Ti6Al4V for Biomedical Applications: Evolution of Mechanical Properties as a Function of Surface Roughness
by Andrea Valencia-Cadena, Ude Hangen and Joan Josep Roa Rovira
Metals 2024, 14(12), 1423; https://doi.org/10.3390/met14121423 - 12 Dec 2024
Viewed by 1173
Abstract
Post-processing, and particularly the dry electropolishing process, is essential for improving the surface quality of 3D-printed Ti6Al4V samples, with specific emphasis on reducing roughness over extended polishing times while preserving mechanical properties. Reducing surface roughness enhances the reliability of hardness measurements and improves [...] Read more.
Post-processing, and particularly the dry electropolishing process, is essential for improving the surface quality of 3D-printed Ti6Al4V samples, with specific emphasis on reducing roughness over extended polishing times while preserving mechanical properties. Reducing surface roughness enhances the reliability of hardness measurements and improves the consistency of elastic modulus measurements, as prolonged polishing time stabilizes the full width at half maximum values, thereby minimizing variability due to uniaxial indentation. This stability is crucial for maintaining the structural integrity and uniformity of mechanical properties, facilitating better performance and reliability in biomedical applications. Additionally, under service-like working conditions, solid electrolyte particles undergo dehydration due to the Joule effect, introducing a dynamic aspect to the system as the particle structure degrades with thermal cycling. EDX cross-sectional analysis reveals that TiO2 informs the particle’s surface, with an oxygen-to-titanium ratio that confirms the oxide’s composition. This TiO2 oxide layer demonstrates the progressive surface oxidation occurring under the post-processing process, further modifying the particle’s surface chemistry. This dual effect of roughness reduction and controlled surface chemistry highlights the role of dry electropolishing in enhancing the functional lifespan and mechanical reliability of Ti6Al4V components. Full article
(This article belongs to the Special Issue Novel Materials and Techniques for Dental Implants)
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13 pages, 16022 KiB  
Article
Effects of Anisotropic Microstructure and Load Ratio on Fatigue Crack Propagation Rate in Additively Manufactured Ti-6Al-4V Alloy
by Elad Chakotay, Roni Z. Shneck, Oz Golan, Rami Carmi, Mor Mega, Igal Alon, Raziel Yakov and Arie Busiba
Metals 2024, 14(12), 1405; https://doi.org/10.3390/met14121405 - 9 Dec 2024
Viewed by 975
Abstract
Additive manufacturing (AM) refers to advanced technologies for building 3D objects by adding material layer upon layer using either electron beam melting (EBM) or selective laser melting. AM allows us to produce lighter and more complex parts. However, various defects are created during [...] Read more.
Additive manufacturing (AM) refers to advanced technologies for building 3D objects by adding material layer upon layer using either electron beam melting (EBM) or selective laser melting. AM allows us to produce lighter and more complex parts. However, various defects are created during the AM process, which severely affect fatigue behavior. In the current research, the effects of the anisotropic microstructure in the in-plane and out-of-plane orientations and defects on the fatigue crack propagation rate (FCPR) and crack path were studied. A resonance machine was used to determine the fatigue crack propagation rate (da/dN vs. ΔK) from the near-threshold up to the final fracture, accompanied by in situ Acoustic Emission (AE) monitoring. Micro-Computerized Tomography (µCT) enabled us to characterize surface and microstructural defects. Metallography was used to determine the microstructure vs. orientations and fractography to classify the fatigue fracture propagation modes. Calculations of the local stress distribution were performed to determine the interactions of the cracks with the defects. In the out-of-plane direction, the material exhibited high fatigue fracture toughness accompanied by a slightly lower fatigue crack propagation rate as compared to in-plane orientations. The near-threshold stress intensity factor was slightly higher in the out-of-plane orientation as compared to that in the in-plane one, accompanied by a lower exponent of the Paris law regime. The threshold decreased with an increasing load ratio as expected for both orientations. The crack propagation direction that crosses the elongated grains plays an important role in increasing fatigue resistance in the out-of-plane direction. In the in-plane directions, the crack propagates parallel to the grain boundary, interacts with more defects and exhibits more brittle striations on the fracture surface, resulting in lower fatigue resistance. Full article
(This article belongs to the Special Issue Additive Manufacturing of Metallic Materials)
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