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Laser Powder Bed Fusion of Metals and Alloys: Microstructure and Mechanical Properties

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Applied Industrial Technologies".

Deadline for manuscript submissions: 20 November 2025 | Viewed by 586

Special Issue Editors


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Guest Editor
1. China Machinery Institute of Advanced Materials Co., Ltd., Zhengzhou 450001, China
2. State Key Laboratory for Advanced Forming Technology and Equipment, China Academy of Machinery Science and Technology, Beijing 100083, China
Interests: additive manufacturing; laser powder bed fusion; crystallographic texture; strengthening and deformation behavior of metals and alloys; powder metallurgy; rapid solidification
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Guest Editor
Mechanical Engineering, School of Engineering, College of Science and Engineering, University of Galway, Galway, Ireland
Interests: additive manufacturing; cyclic plasticity; micromechanics; metal microstructure evolution

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Guest Editor
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
Interests: multi-field-assisted laser welding; laser additive manufacturing and repairing; laser cleaning; welding process monitoring and intelligent control
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Among the different metal additive manufacturing technologies available, laser powder bed fusion (LPBF) has grained significant traction. It has been widely used in the fields of aerospace, energy, and medicine, among others, due to its high design freedom, the ability to produce complex components, and the reduced lead time and material waste. During the LPBF process, focused laser beam(s) irradiate selected regions on the metal powder bed, creating a high cooling rate (105–107 K/s) that can hardly be achieved through other traditional processing methods. The unique heating and cooling conditions offer LPBF materials highly non-equilibrium and heterogenous microstructure features that span across several length scale levels, namely nanometer to millimeter. These novel microstructure features exhibit intriguing mechanical performance such as higher hardness, enhanced strength–ductility synergy, and highly anisotropic damage tolerance. Understanding the underlying mechanisms of the evolution of microstructure in LPBF and harnessing the correlations between microstructure and properties are of great significance for additive manufacturing. This requires a multidisciplinary approach, integrating insights from materials science, mechanical engineering, as well as computational modeling and simulation.

We are pleased to invite you to contribute to our Special Issue, which aims to bring together recent advances from cutting-edge research and comprehensive reviews that advance the understanding of the microstructure evolution and mechanical behaviors of materials processed using LPBF. We invite contributions that explore experimental investigations, theoretical analyses, and computational modeling, with a focus on linking processing to microstructural outcomes and mechanical performance.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but not limited to) the following topics:

  • Development of novel alloys and composites for LPBF;
  • Process monitoring and control;
  • Defect analysis and suppression methods;
  • Microstructural evolution in LPBF;
  • Advances in microstructure and property control;
  • Residual stresses and distortion in LPBF components;
  • Post-processing techniques;
  • Advanced applications of LPBF-processed metals and alloys;
  • Computational modeling and simulation;
  • Anisotropy in LPBF components.

We look forward to receiving your contributions.

Dr. Xianglong Wang
Prof. Dr. Séan B. Leen
Prof. Dr. Zhenglong Lei
Guest Editors

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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. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

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Keywords

  • metals and alloys
  • laser powder bed fusion (LPBF)
  • alloy development
  • process-microstructure–property correlation
  • defect analysis
  • modeling and simulation
  • post-processing
  • process monitoring and control
  • residual stresses and distortion

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Published Papers (1 paper)

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Research

24 pages, 15484 KB  
Article
On the Process Optimization, Microstructure Characterization and Mechanical Performance of Ti65 Titanium Alloy Produced by Laser Powder Bed Fusion
by Yuan Meng, Xianglong Wang, Jinjun Wu, Haojie Wang, Ping Gan, Lei Lu, Chengjie Li, Tongling Ma, Jun Niu and Zhigang Zhang
Appl. Sci. 2025, 15(21), 11717; https://doi.org/10.3390/app152111717 - 3 Nov 2025
Abstract
Ti65 high-temperature titanium alloy, known for its exceptional high-temperature mechanical properties and oxidation resistance, demonstrates considerable potential for aerospace applications. Nevertheless, conventional manufacturing techniques are often inadequate for achieving high design freedom and fabricating complex geometries. This study presents a systematic investigation into [...] Read more.
Ti65 high-temperature titanium alloy, known for its exceptional high-temperature mechanical properties and oxidation resistance, demonstrates considerable potential for aerospace applications. Nevertheless, conventional manufacturing techniques are often inadequate for achieving high design freedom and fabricating complex geometries. This study presents a systematic investigation into the process optimization, microstructure characterization, and mechanical performance of Ti65 alloy produced by laser powder bed fusion (LPBF). Via meticulously designed single-track, multi-track, and bulk sample experiments, the influences of laser power (P), scanning speed (V), and hatch spacing (h) on molten pool behavior, defect formation, microstructural evolution, and surface roughness were thoroughly examined. The results indicate that under optimized parameters, the specimens attain ultra-high dimensional accuracy, with a near-full density (>99.99%) and reduced surface roughness (Ra = 3.9 ± 1.3 μm). Inadequate energy input (low P or high V) led to lack-of-fusion defects, whereas excessive energy (high P or low V) resulted in keyhole porosity. Microstructural analysis revealed that the rapid solidification inherent to LPBF promotes the formation of fine acicular α′-phase (0.236–0.274 μm), while elevated laser power or reduced scanning speed facilitated the development of coarse lamellar α′-martensite (0.525–0.645 μm). Tensile tests demonstrated that samples produced under the optimized parameters exhibit high ultimate tensile strength (1489 ± 7.5 MPa), yield strength (1278 ± 5.2 MPa), and satisfactory elongation (5.7 ± 0.15%), alongside elevated microhardness (446.7 ± 1.7 HV0.2). The optimized microstructure thereby enables the simultaneous achievement of high density and superior mechanical properties. The fundamental mechanism is attributed to precise control over volumetric energy density, which governs melt pool mode, defect generation, and solidification kinetics, thereby tailoring the resultant microstructure. This study offers valuable insights into defect suppression, microstructure control, and process optimization for LPBF-fabricated Ti65 alloy, facilitating its application in high-temperature structural components. Full article
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