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Applied Sciences
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Materials Development by Additive Manufacturing Techniques
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Materials Development by Additive Manufacturing Techniques

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (31 March 2020) | Viewed by 38376

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editors

Prof. Dr. Paolo Fino

E-Mail Website
Guest Editor
DISAT - Department of Applied Science and Technology, Politecnico di Torino, 10129 Turin, Italy
Interests: research and development of new alloys for additive manufacturing processes
Special Issues, Collections and Topics in MDPI journals
Dr. Alberta Aversa

E-Mail Website
Guest Editor
Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
Interests: metallic materials; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Nowadays, metal additive manufacturing (AM) processes have a great impact on several industrial production processes. The reasons for the success of these technologies are mainly related to their possibility to build complex shapes, customized parts, and lightweight components.

However, AM technologies also bring many advantages from a material perspective. The high cooling rate causes the solidification of peculiar microstructures, as well as interesting mechanical properties. Nonetheless, some high-strength alloys are not processable by AM. It is therefore fundamental to develop high-strength alloys that can be processed by AM and can take advantage of the unique solidification conditions that arise during the building process.

This Special Issue will address the advancements in AM alloys’ design and characterization.

Potential topics include, but are not limited to, the following:

  • New methodology for materials additive manufacturing development;
  • New materials for additive manufacturing;
  • Advanced characterizations of AM materials;
  • Microstructural features of AM materials;
  • Properties of AM materials;
  • Materials modeling for AM development

Prof. Paolo Fino
Dr. Alberta Aversa
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. Applied Sciences is an international peer-reviewed open access semimonthly 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 2400 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

  • Metal additive manufacturing
  • Mechanical properties
  • Alloys development
  • Powder production
  • Microstructure

Published Papers (7 papers)

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Editorial

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4 pages, 168 KiB  
Editorial
Special Issue on Materials Development by Additive Manufacturing Techniques
by Alberta Aversa and Paolo Fino
Appl. Sci. 2020, 10(15), 5119; https://0-doi-org.brum.beds.ac.uk/10.3390/app10155119 - 25 Jul 2020
Cited by 11 | Viewed by 1892
Abstract
Additive manufacturing (AM) processes are steadily gaining attention from many industrial fields, as they are revolutionizing components’ designs and production lines. However, the full application of these technologies to industrial manufacturing has to be supported by the study of the AM materials’ properties [...] Read more.
Additive manufacturing (AM) processes are steadily gaining attention from many industrial fields, as they are revolutionizing components’ designs and production lines. However, the full application of these technologies to industrial manufacturing has to be supported by the study of the AM materials’ properties and their correlations with the feedstock and the building conditions. Furthermore, nowadays, only a limited number of materials processable by AM are available on the market. It is, therefore, fundamental to widen the materials’ portfolio and to study and develop new materials that can take advantage of these unique building processes. The present special issue collects recent research activities on these topics. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)

Research

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15 pages, 5282 KiB  
Article
Qualification of a Ni–Cu Alloy for the Laser Powder Bed Fusion Process (LPBF): Its Microstructure and Mechanical Properties
by Iris Raffeis, Frank Adjei-Kyeremeh, Uwe Vroomen, Elmar Westhoff, Sebastian Bremen, Alexandru Hohoi and Andreas Bührig-Polaczek
Appl. Sci. 2020, 10(10), 3401; https://0-doi-org.brum.beds.ac.uk/10.3390/app10103401 - 14 May 2020
Cited by 15 | Viewed by 3236
Abstract
As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni–Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of [...] Read more.
As researchers continue to seek the expansion of the material base for additive manufacturing, there is a need to focus attention on the Ni–Cu group of alloys which conventionally has wide industrial applications. In this work, the G-NiCu30Nb casting alloy, a variant of the Monel family of alloys with Nb and high Si content is, for the first time, processed via the laser powder bed fusion process (LPBF). Being novel to the LPBF processes, optimum LPBF parameters were determined, and hardness and tensile tests were performed in as-built conditions and after heat treatment at 1000 °C. Microstructures of the as-cast and the as-built condition were compared. Highly dense samples (99.8% density) were achieved after varying hatch distance (80 µm and 140 µm) with scanning speed (550 mm/s–1500 mm/s). There was no significant difference in microhardness between varied hatch distance print sets. Microhardness of the as-built condition (247 HV0.2) exceeded the as-cast microhardness (179 HV0.2.). Tensile specimens built in vertical (V) and horizontal (H) orientations revealed degrees of anisotropy and were superior to conventionally reported figures. Post heat treatment increased ductility from 20% to 31% (V), as well as from 16% to 25% (H), while ultimate tensile strength (UTS) and yield strength (YS) were considerably reduced. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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15 pages, 4953 KiB  
Article
Methods for the Characterization of Polyetherimide Based Materials Processed by Fused Deposition Modelling
by Claudio Tosto, Lorena Saitta, Eugenio Pergolizzi, Ignazio Blanco, Giovanni Celano and Gianluca Cicala
Appl. Sci. 2020, 10(9), 3195; https://0-doi-org.brum.beds.ac.uk/10.3390/app10093195 - 03 May 2020
Cited by 18 | Viewed by 3493
Abstract
Fused deposition modelling (FDM™) is one of the most promising additive manufacturing technologies and its application in industrial practice is increasingly spreading. Among its successful applications, FDM™ is used in structural applications thanks to the mechanical performances guaranteed by the printed parts. Currently, [...] Read more.
Fused deposition modelling (FDM™) is one of the most promising additive manufacturing technologies and its application in industrial practice is increasingly spreading. Among its successful applications, FDM™ is used in structural applications thanks to the mechanical performances guaranteed by the printed parts. Currently, a shared international standard specifically developed for the testing of FDM™ printed parts is not available. To overcome this limit, we have considered three different tests aimed at characterizing the mechanical properties of technological materials: tensile test (ASTM D638), flexural test (ISO 178) and short-beam shear test (ASTM D2344M). Two aerospace qualified ULTEMTM 9085 resins (i.e., tan and black grades) have been used for printing all specimens by means of an industrial printer (Fortus 400mc). The aim of this research was to improve the understanding of the efficiency of different mechanical tests to characterize materials used for FDM™. For each type of test, the influence on the mechanical properties of the specimen’s materials and geometry was studied using experimental designs. For each test, 22 screening factorial designs were considered and analyzed. The obtained results demonstrated that the use of statistical analysis is recommended to ascertain the real pivotal effects and that specific test standards for FDM™ components are needed to support the development of materials in the additive manufacturing field. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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15 pages, 1442 KiB  
Article
Mechanical and Thermal Behavior of Ultem® 9085 Fabricated by Fused-Deposition Modeling
by Elisa Padovano, Marco Galfione, Paolo Concialdi, Gianni Lucco and Claudio Badini
Appl. Sci. 2020, 10(9), 3170; https://0-doi-org.brum.beds.ac.uk/10.3390/app10093170 - 01 May 2020
Cited by 25 | Viewed by 4911
Abstract
Fused-deposition modeling (FDM) is an additive manufacturing technique which is widely used for the fabrication of polymeric end-use products in addition to the development of prototypes. Nowadays, there is an increasing interest in the scientific and industrial communities for new materials showing high [...] Read more.
Fused-deposition modeling (FDM) is an additive manufacturing technique which is widely used for the fabrication of polymeric end-use products in addition to the development of prototypes. Nowadays, there is an increasing interest in the scientific and industrial communities for new materials showing high performance, which can be used in a wide range of applications. Ultem 9085 is a thermoplastic material that can be processed by FDM; it recently emerged thanks to such good properties as excellent flame retardancy, low smoke generation, and good mechanical performance. A deep knowledge of this material is therefore necessary to confirm its potential use in different fields. The aim of this paper is the investigation of the mechanical and thermal properties of Ultem 9085. Tensile strength and three-point flexural tests were performed on samples with XY, XZ, and ZX building orientations. Moreover, the influence of different ageing treatments performed by varying the maximum reached temperature and relative humidity on the mechanical behavior of Ultem 9085 was then investigated. The thermal and thermo-oxidative behavior of this material was also determined through thermal-gravimetric analyses. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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14 pages, 4257 KiB  
Article
Dense, Strong, and Precise Silicon Nitride-Based Ceramic Parts by Lithography-Based Ceramic Manufacturing
by Altan Alpay Altun, Thomas Prochaska, Thomas Konegger and Martin Schwentenwein
Appl. Sci. 2020, 10(3), 996; https://0-doi-org.brum.beds.ac.uk/10.3390/app10030996 - 03 Feb 2020
Cited by 49 | Viewed by 9854
Abstract
Due to the high level of light absorption and light scattering of dark colored powders connected with the high refractive indices of ceramic particles, the majority of ceramics studied via stereolithography (SLA) have been light in color, including ceramics such as alumina, zirconia [...] Read more.
Due to the high level of light absorption and light scattering of dark colored powders connected with the high refractive indices of ceramic particles, the majority of ceramics studied via stereolithography (SLA) have been light in color, including ceramics such as alumina, zirconia and tricalcium phosphate. This article focuses on a lithography-based ceramic manufacturing (LCM) method for β-SiAlON ceramics that are derived from silicon nitride and have excellent material properties for high temperature applications. This study demonstrates the general feasibility of manufacturing of silicon nitride-based ceramic parts by LCM for the first time and combines the advantages of SLA, such as the achievable complexity and low surface roughness (Ra = 0.50 µm), with the typical properties of conventionally manufactured silicon nitride-based ceramics, such as high relative density (99.8%), biaxial strength (σf = 764 MPa), and hardness (HV10 = 1500). Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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17 pages, 3746 KiB  
Article
Filament Extrusion and Its 3D Printing of Poly(Lactic Acid)/Poly(Styrene-co-Methyl Methacrylate) Blends
by Luis Enrique Solorio-Rodríguez and Alejandro Vega-Rios
Appl. Sci. 2019, 9(23), 5153; https://doi.org/10.3390/app9235153 - 28 Nov 2019
Cited by 12 | Viewed by 3408
Abstract
Herein, we report the melt blending of amorphous poly(lactide acid) (PLA) with poly(styrene-co-methyl methacrylate) (poly(S-co-MMA)). The PLAx/poly(S-co-MMA)y blends were made using amorphous PLA compositions from 50, 75, and 90wt.%, namely PLA50/poly(S-co [...] Read more.
Herein, we report the melt blending of amorphous poly(lactide acid) (PLA) with poly(styrene-co-methyl methacrylate) (poly(S-co-MMA)). The PLAx/poly(S-co-MMA)y blends were made using amorphous PLA compositions from 50, 75, and 90wt.%, namely PLA50/poly(S-co-MMA)50, PLA75/poly(S-co-MMA)25, and PLA90/poly(S-co-MMA)10, respectively. The PLAx/poly(S-co-MMA)y blend pellets were extruded into filaments through a prototype extruder at 195 °C. The 3D printing was done via fused deposition modeling (FDM) at the same temperature and a 40 mm/s feed rate. Furthermore, thermogravimetric curves of the PLAx/poly(S-co-MMA)y blends showed slight thermal decomposition with less than 0.2% mass loss during filament extrusion and 3D printing. However, the thermal decomposition of the blends is lower when compared to amorphous PLA and poly(S-co-MMA). On the contrary, the PLAx/poly(S-co-MMA)y blend has a higher Young’s modulus (E) than amorphous PLA, and is closer to poly(S-co-MMA), in particular, PLA90/poly(S-co-MMA)10. The PLAx/poly(S-co-MMA)y blends proved improved properties concerning amorphous PLA through mechanical and rheological characterization. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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Review

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23 pages, 15513 KiB  
Review
Microstructure and Mechanical Properties of AISI 316L Produced by Directed Energy Deposition-Based Additive Manufacturing: A Review
by Abdollah Saboori, Alberta Aversa, Giulio Marchese, Sara Biamino, Mariangela Lombardi and Paolo Fino
Appl. Sci. 2020, 10(9), 3310; https://0-doi-org.brum.beds.ac.uk/10.3390/app10093310 - 09 May 2020
Cited by 104 | Viewed by 10568
Abstract
Directed energy deposition (DED) as a metal additive manufacturing technology can be used to produce or repair complex shape parts in a layer-wise process using powder or wire. Thanks to its advantages in the fabrication of net-shape and functionally graded components, DED could [...] Read more.
Directed energy deposition (DED) as a metal additive manufacturing technology can be used to produce or repair complex shape parts in a layer-wise process using powder or wire. Thanks to its advantages in the fabrication of net-shape and functionally graded components, DED could attract significant interest in the production of high-value parts for different engineering applications. Nevertheless, the industrialization of this technology remains challenging, mainly because of the lack of knowledge regarding the microstructure and mechanical characteristics of as-built parts, as well as the trustworthiness/durability of engineering parts produced by the DED process. Hence, this paper reviews the published data about the microstructure and mechanical performance of DED AISI 316L stainless steel. The data show that building conditions play key roles in the determination of the microstructure and mechanical characteristics of the final components produced via DED. Moreover, this review article sheds light on the major advancements and challenges in the production of AISI 316L parts by the DED process. In addition, it is found that in spite of different investigations carried out on the optimization of process parameters, further research efforts into the production of AISI 316L components via DED technology is required. Full article
(This article belongs to the Special Issue Materials Development by Additive Manufacturing Techniques)
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