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Applied Sciences
Special Issues
The Physics of Joining and Additive Manufacturing
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The Physics of Joining and Additive Manufacturing

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

Deadline for manuscript submissions: closed (30 September 2023) | Viewed by 2898

Special Issue Editors

Dr. Amin Ebrahimi

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Delft University of Technology, Mekelweg 2, 2628 CD Delft, The Netherlands
Interests: additive manufactueing; fusion welding; high-fidelity numerical simulations; transport phenomena in materials processing; data- and physics-driven design and optimisation
Dr. Marcel J.M. Hermans

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Delft University of Technology, Mekelweg 2, 2628 CD Delft, The Netherlands
Interests: joining and additive manufacturing; materials characterization; microstructure development; residual stress and distortion mitigation
Dr. Vera Popovich

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Delft University of Technology, Mekelweg 2, CD 2628 Delft, The Netherlands
Interests: design of materials through additive manufacturing; additively manufactured smart materials; fracture and fatigue; microstructure-damage evolution
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The development, control, monitoring, and optimisation of advanced joining and additive manufacturing rely on our understanding of the involved physical phenomena. Similarly, the deposition of materials to form (near) net shapes requires a deep understanding of the processes and materials in order to control shape and properties. The properties of materials depend on their composition and thermal-mechanical history. Microstructures and properties can be affected by processing. The comprehensive scope of this Special Issue includes all physical aspects of advanced joining and additive manufacturing processes of all materials. It aims at collating aspects of applied physics, engineering, materials science, and chemistry, which are crucial for the development of efficient and cost-effective joining and additive manufacturing technologies. Topics of interest include but are not limited to:

  • The physical properties of fluids at elevated temperatures;
  • Plasma flow and mass transfer in welding and additive manufacturing;
  • Heat and fluid flow in melt pools;
  • Microstructure design and control;
  • Residual stresses and distortion;
  • Numerical simulations of welding and additive manufacturing;
  • Topology optimisation;
  • Applications of artificial intelligence.

The categories of manuscript types that will be considered for publication include full-length original research articles, short communications, reviews, and perspectives. Manuscripts submitted to this Special Issue should contain new insights into the relationship between the processing, structure, and properties of materials.

Dr. Amin Ebrahimi
Dr. Marcel J.M. Hermans
Dr. Vera Popovich
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

  • joining and additive manufacturing
  • heat and mass transfer
  • materials characterization
  • microstructure development
  • residual stress and distortion mitigation
  • mechanical behavior
  • defect formation in welding and additive manufacturing
  • numerical modelling
  • topology optimisation
  • artificial intelligence and machine learning

Published Papers (1 paper)

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Research

13 pages, 3145 KiB  
Article
Impact of the Power-Dependent Beam Diameter during Electron Beam Additive Manufacturing: A Case Study with γ-TiAl
by Marcel Reith, Christoph Breuning, Martin Franke and Carolin Körner
Appl. Sci. 2022, 12(21), 11300; https://doi.org/10.3390/app122111300 - 07 Nov 2022
Cited by 8 | Viewed by 2052
Abstract
The development of process parameters for electron beam powder bed fusion (PBF-EB) is usually made with simple geometries and uniform scan lengths. The transfer to complex parts with various scan lengths can be achieved by adapting beam parameters such as beam power and [...] Read more.
The development of process parameters for electron beam powder bed fusion (PBF-EB) is usually made with simple geometries and uniform scan lengths. The transfer to complex parts with various scan lengths can be achieved by adapting beam parameters such as beam power and scan speed. Under ideal conditions, this adaption results in a constant energy input into the powder bed despite of the local scan length. However, numerous PBF-EB machines show deviations from the ideal situation because the beam diameter is subject to significant changes if the beam power is changed. This study aims to demonstrate typical scaling issues when applying process parameters to scan lengths up to 45 mm using a fourth generation γ-TiAl alloy. Line energy, area energy, return time, and lateral velocity are kept constant during the additive manufacturing process by adjusting beam power and beam velocity to various scan lengths. Samples produced in this way are examined by light microscopy regarding lateral melt pool extension, melt pool depth, porosity, and microstructure. The process-induced aluminum evaporation is measured by electron probe microanalysis. The experiments reveal undesired changes in melt pool geometry, gas porosity, and aluminum evaporation by increasing the beam power. In detail, beam widening is identified as the reason for the change in melt pool dimensions and microstructure. This finding is supported by numerical calculations from a semi-analytic heat conduction model. This study demonstrates that in-depth knowledge of the electron beam diameter is required to thoroughly control the PBF-EB process, especially when scaling process parameters from simply shaped geometries to complex parts with various scan lengths. Full article
(This article belongs to the Special Issue The Physics of Joining and Additive Manufacturing)
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