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Advances in Metal Additive Manufacturing
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Advances in Metal Additive Manufacturing

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (30 November 2021) | Viewed by 12655

Special Issue Editor

Dr. Patrycja Szymczyk-Ziółkowska

E-Mail Website
Guest Editor
Department of Laser Technology, Automation and Production Organization, Faculty of Mechanical Engineering, Wrocław University of Science and Technology, 50-370 Wroclaw, Poland
Interests: additive manufacturing; biomechanics; bioengineering; materials science; materials characterization; biomaterials; titanium alloys; surface modifications; biopolymers; hydrogels
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

New trends of international development require the creation and implementation of new technologies that will make it possible to introduce new products in new prospective markets. Additive manufacturing (AM), due to its high potential for forming complex shapes in an almost unrestricted manner, allows the production of individualized products and fully functional parts for a wide range of engineering materials, including components used in challenging operating conditions (thermal, mechanical, and corrosive environment). The ability to locally control process parameters in AM processes or the supply of two or more different materials allow creating objects with different and unique properties.

Additive manufacturing is being approached from numerous industries which require short-batch or one-off products or those with very specific requirements, such as complex internal structures or functionally graded materials. Tailor-made high-technology products in automotive and aerospace will lead to long-term profitable markets based on reliable and affordable customized products. Very important applications may also be found in the medical segment, aiming to respond to the impending societal challenges of an aging society and increasing importance of healthcare.

Within this context, this Special Issue aims to provide an opportunity for researchers to submit high-quality original research papers and comprehensive reviews in the field of additive manufacturing of metals. Specific topics include but are not limited to:

  • Product design and topology optimization for metal AM;
  • New materials and processes that can be applied to producing durable lightweight and complex-shape objects, e.g., for automotive and aerospace sectors;
  • Multifunctional materials for special applications;
  • Design and manufacturing of modern customized implants, both in terms of geometric form, as well as programmed mechanical characteristics;
  • Materials characterization, including fatigue and failure analysis models of metal additive manufacturing;
  • Post-processing of additively manufactured metal parts;
  • Quality control, defect identification, and characterization.

Dr. Patrycja Szymczyk-Ziółkowska
Guest Editor

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. Materials 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 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

  • product design
  • topology optimization
  • advanced structures
  • advanced materials
  • mechanical characterization
  • microstructures and properties
  • surface modifications
  • quality control

Published Papers (5 papers)

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Research

14 pages, 8913 KiB  
Article
The Influence of Layer Thickness on the Microstructure and Mechanical Properties of M300 Maraging Steel Additively Manufactured by LENS® Technology
by Natalia Rońda, Krzysztof Grzelak, Marek Polański and Julita Dworecka-Wójcik
Materials 2022, 15(2), 603; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15020603 - 14 Jan 2022
Cited by 8 | Viewed by 1527
Abstract
This work investigates the effect of layer thickness on the microstructure and mechanical properties of M300 maraging steel produced by Laser Engineered Net Shaping (LENS®) technique. The microstructure was characterized using light microscopy (LM) and scanning electron microscopy (SEM). The mechanical [...] Read more.
This work investigates the effect of layer thickness on the microstructure and mechanical properties of M300 maraging steel produced by Laser Engineered Net Shaping (LENS®) technique. The microstructure was characterized using light microscopy (LM) and scanning electron microscopy (SEM). The mechanical properties were characterized by tensile tests and microhardness measurements. The porosity and mechanical properties were found to be highly dependent on the layer thickness. Increasing the layer thickness increased the porosity of the manufactured parts while degrading their mechanical properties. Moreover, etched samples revealed a fine cellular dendritic microstructure; decreasing the layer thickness caused the microstructure to become fine-grained. Tests showed that for samples manufactured with the chosen laser power, a layer thickness of more than 0.75 mm is too high to maintain the structural integrity of the deposited material. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing)
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19 pages, 2326 KiB  
Article
Impact of the Allowed Compositional Range of Additively Manufactured 316L Stainless Steel on Processability and Material Properties
by Felix Großwendt, Louis Becker, Arne Röttger, Abootorab Baqerzadeh Chehreh, Anna Luise Strauch, Volker Uhlenwinkel, Jonathan Lentz, Frank Walther, Rainer Fechte-Heinen, Sebastian Weber and Werner Theisen
Materials 2021, 14(15), 4074; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14154074 - 22 Jul 2021
Cited by 6 | Viewed by 2135
Abstract
This work aims to show the impact of the allowed chemical composition range of AISI 316L stainless steel on its processability in additive manufacturing and on the resulting part properties. ASTM A276 allows the chromium and nickel contents in 316L stainless steel to [...] Read more.
This work aims to show the impact of the allowed chemical composition range of AISI 316L stainless steel on its processability in additive manufacturing and on the resulting part properties. ASTM A276 allows the chromium and nickel contents in 316L stainless steel to be set between 16 and 18 mass%, respectively, 10 and 14 mass%. Nevertheless, the allowed compositional range impacts the microstructure formation in additive manufacturing and thus the properties of the manufactured components. Therefore, this influence is analyzed using three different starting powders. Two starting powders are laboratory alloys, one containing the maximum allowed chromium content and the other one containing the maximum nickel content. The third material is a commercial powder with the chemical composition set in the middle ground of the allowed compositional range. The materials were processed by laser-based powder bed fusion (PBF-LB/M). The powder characteristics, the microstructure and defect formation, the corrosion resistance, and the mechanical properties were investigated as a function of the chemical composition of the powders used. As a main result, solid-state cracking could be observed in samples additively manufactured from the starting powder containing the maximum nickel content. This is related to a fully austenitic solidification, which occurs because of the low chromium to nickel equivalent ratio. These cracks reduce the corrosion resistance as well as the elongation at fracture of the additively manufactured material that possesses a low chromium to nickel equivalent ratio of 1.0. A limitation of the nickel equivalent of the 316L type steel is suggested for PBF-LB/M production. Based on the knowledge obtained, a more detailed specification of the chemical composition of the type 316L stainless steel is recommended so that this steel can be PBF-LB/M processed to defect-free components with the desired mechanical and chemical properties. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing)
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18 pages, 7379 KiB  
Article
Influence of Different Alloying Strategies on the Mechanical Behavior of Tool Steel Produced by Laser-Powder Bed Fusion
by Abootorab Baqerzadeh Chehreh, Anna Strauch, Felix Großwendt, Arne Röttger, Rainer Fechte-Heinen, Werner Theisen and Frank Walther
Materials 2021, 14(12), 3344; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14123344 - 17 Jun 2021
Cited by 2 | Viewed by 1561
Abstract
Additive manufacturing is a high-potential technique that allows the production of components with almost no limitation in complexity. However, one of the main factors that still limits the laser-based additive manufacturing is a lack of processable alloys such as carbon martensitic hardenable tool [...] Read more.
Additive manufacturing is a high-potential technique that allows the production of components with almost no limitation in complexity. However, one of the main factors that still limits the laser-based additive manufacturing is a lack of processable alloys such as carbon martensitic hardenable tool steels, which are rarely investigated due to their susceptibility to cold cracking. Therefore, this study aimed to expand the variety of steels for laser powder bed fusion (L-PBF) by investigating an alternative alloying strategy for hot work tool steel powder. In this study, a comprehensive investigation was performed on the powder and L-PBF processed specimen properties and their correlation with the existing defects. Cubical specimens were created using the following two alloying strategies by means of L-PBF: conventional pre-alloyed gas-atomized powder and a mixture of gas-atomized powder with mechanically crushed pure elements and ferroalloys. The influence of the particle parameters such as morphology were correlated to the defect density and resulting quasi-static mechanical properties. Micromechanical behavior and damage evolution of the processed specimens were investigated using in situ computed tomography. It was shown that the properties of the L-PBF processed specimens obtained from the powder mixture performs equal or better compared to the specimens produced from conventional powder. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing)
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13 pages, 9703 KiB  
Article
Air Permeability of Maraging Steel Cellular Parts Made by Selective Laser Melting
by Annadurai Dhinakar, Bai-En Li, Yo-Cheng Chang, Kuo-Chi Chiu and Jhewn-Kuang Chen
Materials 2021, 14(11), 3118; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14113118 - 06 Jun 2021
Cited by 4 | Viewed by 2289
Abstract
Additive manufacturing, such as selective laser melting (SLM), can be used to manufacture cellular parts. In this study, cellular coupons of maraging steels are prepared through SLM by varying hatch distance. Air flow and permeability of porous maraging steel blocks are obtained for [...] Read more.
Additive manufacturing, such as selective laser melting (SLM), can be used to manufacture cellular parts. In this study, cellular coupons of maraging steels are prepared through SLM by varying hatch distance. Air flow and permeability of porous maraging steel blocks are obtained for samples of different thickness based on the Darcy equation. By reducing hatch distance from 0.75 to 0.4 mm, the permeability decreases from 1.664 × 10−6 mm2 to 0.991 × 10−6 mm2 for 4 mm thick coupons. In addition, by increasing the thickness from 2 to 8 mm, the permeability increases from 0.741 × 10−6 mm2 to 1.345 × 10−6 mm2 at 16.2 J/mm3 energy density and 0.14 MPa inlet pressure. Simulation using ANSYS-Fluent is conducted to observe the pressure difference across the porous coupons and is compared with the experimental results. Surface artifacts and the actual morphology of scan lines can cause the simulated permeability to deviate from the experimental values. The measured permeability of maraging steel coupons is regression fit with both energy density and size of samples which provide a design guideline of porous mold inserts for industry applications such as injection molding. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing)
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27 pages, 10307 KiB  
Article
Evaluation of Inconel 718 Metallic Powder to Optimize the Reuse of Powder and to Improve the Performance and Sustainability of the Laser Powder Bed Fusion (LPBF) Process
by Konrad Gruber, Irina Smolina, Marcin Kasprowicz and Tomasz Kurzynowski
Materials 2021, 14(6), 1538; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14061538 - 21 Mar 2021
Cited by 31 | Viewed by 4270
Abstract
In this paper, a detailed assessment of Inconel 718 powder, with varying degrees of degradation due to repeated use in the Laser Powder Bed Fusion (LPBF) process, has been undertaken. Four states of IN718 powder (virgin, used, overflow and spatter) were characterized in [...] Read more.
In this paper, a detailed assessment of Inconel 718 powder, with varying degrees of degradation due to repeated use in the Laser Powder Bed Fusion (LPBF) process, has been undertaken. Four states of IN718 powder (virgin, used, overflow and spatter) were characterized in terms of their morphology, flowability and physico-chemical properties. Studies showed that used and overflow powders were almost identical. The fine particle-size distribution of the virgin powder, in which 50% of particles were found to be below the nominal particle-size distribution (PSD), was recognized as the main reason for its lower flowability and the main cause of the differentiation between virgin, used and overflow powders. Only spatter powder was found to be degraded enough to preclude its direct LPBF reuse. The oxygen content in the spatter powder exceeded the limit value for IN718 by 290 ppm, and aluminum oxide spots were found on the spatter particles surfaces. Laser absorption analysis showed 10 pp higher laser absorption compared to the other powders. The results of evaluation showed that IN718 powder is resistant to multiple uses in the LPBF process. Due to the low degradation rate of IN718 powder, overflow powder can be re-enabled for multiple uses with a proper recycling strategy. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing)
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