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Research on Additive Manufacturing of Novel Alloy Materials

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

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 8210

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Special Issue Editors

Prof. Dr. Wojciech Zębala

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Guest Editor

Department of Production Engineering, Cracow University of Technology, Cracow, Poland
Interests: Production engineering; construction and operation of machines; physical aspects of the cutting process; precision machining; cutting of difficult-to-cut materials; modeling and simulation of machining processes; additive manufacturing; numerical calculation methods (FEM); CNC machine tools; CAD/CAM systems; measurements of the geometric surface structure and modern manufacturing techniques (HSC, HPC, Hard machining, 3D printing)
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Dr. Grzegorz Struzikiewicz

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Guest Editor

Politechnika Krakowska, Krakow, Poland
Interests: manufacturing techniques; machining and additive manufacturing; numerically controlled machine tool programming; cutting of difficult-to-cut materials; CAx systems; vision systems in machining processes; cutting tools
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive Manufacturing (AM) builds the part layer by layer from a material supplied as a fine powder and could be an alternative to milling a workpiece from the solid block. AM uses computer aided design (CAD) software or 3D object scanners to direct hardware to deposit material layer by layer.

The fundamental benefit of additive manufacturing is the combination of productivity with low volume, high complexity and frequently changing parts.

Over the past few years, we have seen the rapid development of additive manufacturing of machine parts using novel alloy materials as the industry is still waiting for materials which enable the technology to fully realize its true potential. Various metals, plastics and composite materials can be used in AM. Advanced alloy manufacturers are generally able to control the proportion of the elements in the alloy composition with an accuracy of 0.1%, but even small changes in the concentrations of individual elements can lead to large non-linear changes in the material behavior.

To meet today's high demands on the accuracy and efficiency of production, it is necessary to develop precise physical models to predict the properties of new alloy materials depending on their chemical composition, and to use computer methods to design and optimize the process. Understanding the fundamental relationship between materials and the processing environment is important for additive manufacturing in sectors such as automotive, aerospace and medicine.

This Special Issue aims to present the latest advances in additive manufacturing and trends in new material development. We encourage to publish research on optimization of the process for modern manufacturing engineering, in particular modeling and computer simulation of material behavior during sintering powders and removing machining allowances after AM products.

We are pleased to invite you to submit original, high-quality scientific articles, short communications, and state-of-the-art reviews for this Special Issue. Both theoretical and experimental contribiutions can be submitted.

Prof. Dr. Wojciech Zębala
Dr. Grzegorz Struzikiewicz
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
3D printing
AM
materials engineering
optimization
computer simulation

Published Papers (4 papers)

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Research

11 pages, 4080 KiB

Open AccessArticle

Effect of Holding Time on Densification, Microstructure and Selected Properties of Spark Plasma Sintered AA7075-B₄C Composites

by Anna Wąsik, Beata Leszczyńska-Madej, Marcin Madej, Rafał Rubach and Dariusz Garbiec

Materials 2022, 15(6), 2065; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15062065 - 11 Mar 2022

Cited by 4 | Viewed by 1635

Abstract

The paper presents the effect of the holding time, varying between 1 min 15 s and 10 min, on the microstructure evolution and development of selected properties of spark plasma sintered AA7075-based composites reinforced with 3, 5 and 10 wt% sub-micro B₄C powder. The sintering temperature and the compaction pressure were 500 °C and 80 MPa, respectively. Composites with a near full density of 96–97% were obtained. Microstructure studies were performed employing the techniques of light microscopy and scanning electron microscopy, along with an analysis of the chemical composition in micro-areas. Additionally, the phase composition was investigated by means of X-ray diffraction. In addition, hardness and flexural strength tests were performed. It was found that the holding time did not significantly influence the microstructures of the examined materials nor the hardness or flexural strength. The sintered composites had a fine-grained microstructure with a strengthening phase located at the grain boundaries. As a result of the spark plasma sintering process, fine precipitates of intermetallic phases were also observed in the aluminum grains, suggesting partial supersaturation, which occurred during fast cooling. Full article

(This article belongs to the Special Issue Research on Additive Manufacturing of Novel Alloy Materials)

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21 pages, 13335 KiB

Open AccessArticle

A Comparative Study on the Structure and Quality of SLM and Cast AISI 316L Samples Subjected to WEDM Processing

by Magdalena Machno, Emilia Franczyk, Rafał Bogucki, Andrzej Matras and Wojciech Zębala

Materials 2022, 15(3), 701; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15030701 - 18 Jan 2022

Cited by 6 | Viewed by 1485

Abstract

Additive manufacturing technologies are increasingly used in the production of semi-finished workpieces intended for further processing. This entails the need to investigate the machinability and final properties of such products. Comparative research on wire electrical discharge machining (WEDM) processes performed with two kinds of AISI 316L stainless steel workpieces is presented in this paper. The first workpiece was made by selective laser melting (SLM), while the second one was casting. Both working materials were cut with current values ranging from 8 to 72 amps. A comparison of roughness, structure and chemical composition of machined surfaces was performed between the two kinds of specimens. For the SLM sample, parameters of the cutting process that provide relatively low surface roughness (Ra ≤ 10 µm) with the simultaneous maximization of the process efficiency were determined. It was found that in the case of applying high current values (72 amp.), more favorable properties of the treated surface were obtained for the SLM sample than for the cast one. Full article

(This article belongs to the Special Issue Research on Additive Manufacturing of Novel Alloy Materials)

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22 pages, 34796 KiB

Open AccessEditor’s ChoiceArticle

Cutting Forces and Tool Wear Investigation during Turning of Sintered Nickel-Cobalt Alloy with CBN Tools

by Wojciech Zębala, Grzegorz Struzikiewicz and Ksenia Rumian

Materials 2021, 14(7), 1623; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14071623 - 26 Mar 2021

Cited by 13 | Viewed by 1666

Abstract

This article describes issues related to the machining of parts made of sintered nickel-cobalt alloy. Longitudinal turning with a CBN (cubic boron nitride) tool was analyzed. The results of experiments showed the influence of cutting parameters in the field of finishing machining on the values of cutting forces and specific cutting force, taking into account the wear of the cutting edge. Measurements and analysis of the topography and roughness parameters of the machined surface, as well as the cutting tool wear, were presented. The microscopic examination showed that the average grain size of the sintered nickel-cobalt alloy was 3.22 ± 0.1 (μm). The presence of the hardening state variability of the material during machining, as well as the value of the cutting force fluctuation as a function of the tool wear VB, were stated. The specific cutting force values increased to a small degree for the tool wear in the range of VB = 0–0.2 mm, and reached similar values in the range k_c = 5500–7500 N/mm². The specific cutting force values increased significantly for wear VB > 0.2 mm and were characterized by a large variability. The occurring phenomena were analyzed and several explanations were proposed. A recommendation was developed for the machining of parts made of sintered nickel-cobalt alloy. The Taguchi method was used in the experiment methodology. Full article

(This article belongs to the Special Issue Research on Additive Manufacturing of Novel Alloy Materials)

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16 pages, 23210 KiB

Open AccessArticle

Yttrium’s Effect on the Hot Cracking and Creep Properties of a Ni-Based Superalloy Built Up by Additive Manufacturing

by Santhosh Banoth, Thaviti Naidu Palleda, Sota Shimazu and Koji Kakehi

Materials 2021, 14(5), 1143; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14051143 - 28 Feb 2021

Cited by 11 | Viewed by 2651

Abstract

We studied the effects of the rare earth element yttrium (Y) on the hot cracking and creep properties of Hastelloy-X processed by selective laser melting. We used two different alloys to study hot cracking in Hastelloy-X: one with 0.12 mass% yttrium added and one with no yttrium. Y-free Hastelloy-X exhibited less cracks, mainly due to the segregation of Si, W, and C resulting in SiC- and W₆C-type carbides at the grain boundary and interdendritic regions. On the other hand, more cracks formed in the Y-added Hastelloy-X specimen because of segregation of Y, resulting in the formation of yttrium-rich carbide (YC). Post-heat treatment was conducted at 1177 °C for 2 h, followed by air cooling, to obtain good creep properties. We carried out a creep test along the vertical and horizontal directions. Despite having more cracks, the Y-added as-built Hastelloy-X specimen showed longer creep life and ductility than the Hastelloy-X specimen. This was mainly because of the formation of Y₂O₃ and SiO₂ inside the grains. After solution treatment, the Y-added specimen’s creep life was eight times longer than that of the Y-free solution-treated specimen. This was mainly because of the maintenance of the columnar grain morphology even after solution treatment. In addition, the formation of M₆C carbides, Y₂O₃, and SiO₂ improved creep life. To summarize the effect of Y, Y addition promoted the formation of cracks, which brought about creep anisotropy; however, it improved creep properties through the stabilization of oxygen and the promotion of discrete carbide precipitation, which prohibited the migration and sliding of grain boundary. Full article

(This article belongs to the Special Issue Research on Additive Manufacturing of Novel Alloy Materials)

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