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Additive Manufacturing: Technology, Applications and Research Need
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Additive Manufacturing: Technology, Applications and Research Need

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 September 2022) | Viewed by 15810

Special Issue Editors

Prof. Seung-Kyum Choi

E-Mail Website
Guest Editor
G. W. Woodruff School of Mechanical Engineering, Georgia Insitute of Technology, 813 Ferst Drive, Atlanta, GA 30332, USA
Interests: additive manufacturing (AM); printing process; advanced materials; computer-aided design; experimental models; certification; characterization
Special Issues, Collections and Topics in MDPI journals
Dr. Hae-Jin Choi

E-Mail Website
Guest Editor
School of Mechanical Engineering, Chung-Ang University, 84 Heukseok-Ro, Dongjak-Gu, Seoul 06974, Korea
Interests: additive manufacturing (AM); printing process; advanced materials; computer-aided design; experimental models; certification; characterization

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) technologies enable a great amount of flexibility in design and functionality of products through their capabilities of placing any material at any geometric position in a product. Ultimately, they can produce unprecedented products which could drastically outperform today’s ordinary products. Advanced AM technologies will be the foundation for new capabilities and tools that meet urgent societal needs in future energy, automotive, aerospace, national security, and human welfare engineering systems. Therefore, this Special Issue of Materials aims to collect novel articles covering additive manufacturing technologies, applications, and corresponding design methods. Topics of interest include (but are not strictly limited to) the following:

  • New printing processes and modeling;
  • Design methods for multifunctional, lightweight, and heterogeneous structures;
  • New materials for AM;
  • Process–structure–property relationships for AM materials;
  • Certification processes for AM-fabricated parts

Prof. Seung-Kyum Choi
Dr. Hae-Jin Choi
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. 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

  • additive manufacturing (AM)
  • printing process
  • advanced materials
  • computer-aided design
  • experimental models
  • certification
  • characterization

Published Papers (6 papers)

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Research

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21 pages, 8274 KiB  
Article
Direct Metal Laser Sintering of the Ti6Al4V Alloy from a Powder Blend
by Lekhetho Ambition Ramosena, Thywill Cephas Dzogbewu and Willie du Preez
Materials 2022, 15(22), 8193; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15228193 - 18 Nov 2022
Cited by 8 | Viewed by 1510
Abstract
Additively manufactured Ti6Al4V parts have only seen major application in industries such as the aerospace and medical industries, mainly due to the high cost of production of the feedstock powder. In this article, the feasibility of in situ alloying a powder blend of [...] Read more.
Additively manufactured Ti6Al4V parts have only seen major application in industries such as the aerospace and medical industries, mainly due to the high cost of production of the feedstock powder. In this article, the feasibility of in situ alloying a powder blend of elemental Ti and an Al–V master alloy to produce the Ti6Al4V alloy through direct metal laser sintering is presented and discussed. In a previous study, single track formation from this powder blend was studied and analyzed to determine the optimum principal process parameters suitable for this powder blend. These process parameters were employed in this study to produce single and double layers where the effects of varied hatch distance and the employment of a rescanning strategy on the surface morphology and alloy homogeneity were investigated. Lastly, in the current study, three-dimensional specimens were produced and analyzed to determine the alloy microstructure, homogeneity, part porosity and mechanical properties. The analyses revealed that a Ti6Al4V alloy with a density of up to 99.9% and corresponding tensile strength and ductility values of up to 942.9 MPa and 17% was produced. Furthermore, a minimum Al evaporation value of 7.2% was recorded. Therefore, in situ alloying can indeed be employed to produce high-quality Ti6Al4V parts from an elemental Ti and an Al–V master alloy powder blend. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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22 pages, 3689 KiB  
Article
Changes in Synthetic Soda Ash Production and Its Consequences for the Environment
by Marcin Cichosz, Urszula Kiełkowska, Kazimierz Skowron, Łukasz Kiedzik, Sławomir Łazarski, Marian Szkudlarek, Beata Kowalska and Damian Żurawski
Materials 2022, 15(14), 4828; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15144828 - 11 Jul 2022
Cited by 6 | Viewed by 2201
Abstract
This publication presents a series of data of one of the most difficult chemical processes to implement in industrial conditions. Obtaining soda using the Solvay technique is a process with a world volume of about 28 Tg per year. The process is extremely [...] Read more.
This publication presents a series of data of one of the most difficult chemical processes to implement in industrial conditions. Obtaining soda using the Solvay technique is a process with a world volume of about 28 Tg per year. The process is extremely physico-chemically complex and environmentally burdensome. The paper presents information on a multi-component system containing three phases with a chemical reaction. Calculations for such systems and their engineering are very complicated, but the authors show how the results of this work can be applied. This paper also describes modifications of the soda process to minimize the environmental burden and minimize the production input of Na2CO3. The modifications were beneficial in reducing CO2 emissions and increased the efficiency of the soda process, resulting in a measurable financial benefit. At the scale of the plant where the experiment was carried out, this reduction in CO2 emissions amounts to 7.93 Gg per year. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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10 pages, 3573 KiB  
Article
Glass Frit Jetting for Advanced Wafer-Level Hermetic Packaging
by Ali Roshanghias, Jochen Bardong and Alfred Binder
Materials 2022, 15(8), 2786; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15082786 - 11 Apr 2022
Cited by 7 | Viewed by 1931
Abstract
Glass frit bonding is a widely used technology to cap and seal micro-electromechanical systems on the wafer level using a low melting point glass. Screen printing is the main method to apply glass frit paste on wafers. Screen printing of glass frit paste [...] Read more.
Glass frit bonding is a widely used technology to cap and seal micro-electromechanical systems on the wafer level using a low melting point glass. Screen printing is the main method to apply glass frit paste on wafers. Screen printing of glass frit paste is usually performed on less sensitive, less critical wafers, normally the capping wafer, because screen printing is a rough process involving the mechanical contact of the screen printing mesh and the wafer. However, for some applications in which contactless patterning of glass frit materials on the device wafers are preferred (e.g., 3D topographies, micro-lens and optics integration) jet dispensing could be a promising approach. Consequently, in this study, wafer-level jetting of glass frit materials on silicon wafers was proposed and investigated. The jetting parameters such as jetting distance, power and temperature were optimized for a glass frit paste. Additionally, the effect of jetted pitch size on the bond-line thickness was assessed. The wafers with jetted glass frit pastes were conclusively bonded in low vacuum and characterized. As a single-step (non-contact) additive approach, the jet printing of glass frit was revealed to be a straightforward, cost-effective and flexible approach with several implications for hermetic packaging. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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19 pages, 3925 KiB  
Article
Bonding widths of Deposited Polymer Strands in Additive Manufacturing
by Cheng Luo, Manjarik Mrinal, Xiang Wang and Ye Hong
Materials 2021, 14(4), 871; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14040871 - 11 Feb 2021
Cited by 7 | Viewed by 2120
Abstract
In this study, we explore the deformation of a polymer extrudate upon the deposition on a build platform, to determine the bonding widths between stacked strands in fused-filament fabrication. The considered polymer melt has an extremely high viscosity, which dominates in its deformation. [...] Read more.
In this study, we explore the deformation of a polymer extrudate upon the deposition on a build platform, to determine the bonding widths between stacked strands in fused-filament fabrication. The considered polymer melt has an extremely high viscosity, which dominates in its deformation. Mainly considering the viscous effect, we derive analytical expressions of the flat width, compressed depth, bonding width and cross-sectional profile of the filament in four special cases, which have different combinations of extrusion speed, print speed and nozzle height. We further validate the derived relations, using our experimental results on acrylonitrile butadiene styrene (ABS), as well as existing experimental and numerical results on ABS and polylactic acid (PLA). Compared with existing theoretical and numerical results, our derived analytic relations are simple, which need less calculations. They can be used to quickly predict the geometries of the deposited strands, including the bonding widths. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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Review

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28 pages, 3467 KiB  
Review
How Can We Provide Additively Manufactured Parts with a Fingerprint? A Review of Tagging Strategies in Additive Manufacturing
by Antonella Sola, Yilin Sai, Adrian Trinchi, Clement Chu, Shirley Shen and Shiping Chen
Materials 2022, 15(1), 85; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15010085 - 23 Dec 2021
Cited by 8 | Viewed by 3444
Abstract
Additive manufacturing (AM) is rapidly evolving from “rapid prototyping” to “industrial production”. AM enables the fabrication of bespoke components with complicated geometries in the high-performance areas of aerospace, defence and biomedicine. Providing AM parts with a tagging feature that allows them to be [...] Read more.
Additive manufacturing (AM) is rapidly evolving from “rapid prototyping” to “industrial production”. AM enables the fabrication of bespoke components with complicated geometries in the high-performance areas of aerospace, defence and biomedicine. Providing AM parts with a tagging feature that allows them to be identified like a fingerprint can be crucial for logistics, certification and anti-counterfeiting purposes. Whereas the implementation of an overarching strategy for the complete traceability of AM components downstream from designer to end user is, by nature, a cross-disciplinary task that involves legal, digital and technological issues, materials engineers are on the front line of research to understand what kind of tag is preferred for each kind of object and how existing materials and 3D printing hardware should be synergistically modified to create such tag. This review provides a critical analysis of the main requirements and properties of tagging features for authentication and identification of AM parts, of the strategies that have been put in place so far, and of the future challenges that are emerging to make these systems efficient and suitable for digitalisation. It is envisaged that this literature survey will help scientists and developers answer the challenging question: “How can we embed a tagging feature in an AM part?”. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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15 pages, 1587 KiB  
Review
Additive Manufacturing of Ti-Based Intermetallic Alloys: A Review and Conceptualization of a Next-Generation Machine
by Thywill Cephas Dzogbewu and Willie Bouwer du Preez
Materials 2021, 14(15), 4317; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14154317 - 02 Aug 2021
Cited by 31 | Viewed by 3551
Abstract
TiAl-based intermetallic alloys have come to the fore as the preferred alloys for high-temperature applications. Conventional methods (casting, forging, sheet forming, extrusion, etc.) have been applied to produce TiAl intermetallic alloys. However, the inherent limitations of conventional methods do not permit the production [...] Read more.
TiAl-based intermetallic alloys have come to the fore as the preferred alloys for high-temperature applications. Conventional methods (casting, forging, sheet forming, extrusion, etc.) have been applied to produce TiAl intermetallic alloys. However, the inherent limitations of conventional methods do not permit the production of the TiAl alloys with intricate geometries. Additive manufacturing technologies such as electron beam melting (EBM) and laser powder bed fusion (LPBF), were used to produce TiAl alloys with complex geometries. EBM technology can produce crack-free TiAl components but lacks geometrical accuracy. LPBF technology has great geometrical precision that could be used to produce TiAl alloys with tailored complex geometries, but cannot produce crack-free TiAl components. To satisfy the current industrial requirement of producing crack-free TiAl alloys with tailored geometries, the paper proposes a new heating model for the LPBF manufacturing process. The model could maintain even temperature between the solidified and subsequent layers, reducing temperature gradients (residual stress), which could eliminate crack formation. The new conceptualized model also opens a window for in situ heat treatment of the built samples to obtain the desired TiAl (γ-phase) and Ti3Al (α2-phase) intermetallic phases for high-temperature operations. In situ heat treatment would also improve the homogeneity of the microstructure of LPBF manufactured samples. Full article
(This article belongs to the Special Issue Additive Manufacturing: Technology, Applications and Research Need)
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