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Coatings
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Recent Progress in Metal Additive Manufacturing
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Recent Progress in Metal Additive Manufacturing

A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Corrosion, Wear and Erosion".

Deadline for manuscript submissions: closed (31 October 2023) | Viewed by 7299

Special Issue Editors

Dr. Chaoqun Zhang

E-Mail Website
Guest Editor
Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: metal additive manufacturing; laser powder bed fusion; multi-material additive manufacturing; dissimilar welding
Special Issues, Collections and Topics in MDPI journals
Dr. Samuel Tammas-Williams

E-Mail Website
Guest Editor
School of Engineering, University of Edinburgh, Scotland EH9 3FB, UK
Interests: additive manufacture of metal components; X-ray computed tomography; materials integrity; functionally graded materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) of metal parts with no geometric limitations has enabled new product design possibilities and opportunities, improved product performance, reduced part weight, quick response in part production, increased heat transfer performance, multi-materials in one part, etc. As a result, AM technologies have attracted significant industrial and academic interest. Many new metal AM technologies are emerging to reduce costs or to solve the problems of conventional AM technologies. For example, in the past few years, sinter-based metal additive manufacturing technologies, such as binder jetting additive manufacturing (BJAM) and fused deposition modeling (FDM), have raised users’ expectations to enable new large-scale applications by significantly reducing costs.

This Special Issue is devoted to publishing original research and high-quality review articles relevant to recent advances in metal additive manufacturing. Potential topics for this Special Issue will include, but are not limited to, the following:

  • Sinter-based additive manufacturing technologies;
  • Binder jetting additive manufacturing of various metals;
  • Emerging metal additive manufacturing technologies;
  • Multi-material additive manufacturing technologies;
  • High speed additive manufacturing technologies;
  • Surface treatment and coatings for additively manufactured parts
  • Tribological behaviors and corrosion behaviors of additively manufactured metallic parts
  • Cold spray and solid-state additive manufacturing
  • Additive manufacturing of titanium, copper, magnesium and their alloys;
  • Additive manufacturing in aerospace.

Dr. Chaoqun Zhang
Dr. Samuel Tammas-Williams
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. Coatings is an international peer-reviewed open access monthly 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.

 

Published Papers (6 papers)

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Editorial

Jump to: Research

3 pages, 187 KiB  
Editorial
Fabrication of Multi-Material Components by Wire Arc Additive Manufacturing
by Chaoqun Zhang, Hongying Yu, Dongbai Sun and Wen Liu
Coatings 2022, 12(11), 1683; https://doi.org/10.3390/coatings12111683 - 05 Nov 2022
Cited by 2 | Viewed by 1570
Abstract
Complex and harsh service environments in the aerospace industry, power industry, automotive industry, injection molding industry and medical industry require components to have spatially tailored properties [...] Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)

Research

Jump to: Editorial

14 pages, 3864 KiB  
Article
Effect of Ca Addition on Inclusions of Welding Heat-Affected Zone in Pressure Vessel Steels
by Yan Liu, Bo Li, Kai Wang and Anna Du
Coatings 2023, 13(12), 2009; https://doi.org/10.3390/coatings13122009 - 27 Nov 2023
Viewed by 679
Abstract
Pressure vessel steels are used in the manufacture of tanks for the storage of gases, chemical materials and oil. To meet the increasing production demands, high-wire-energy welding is widely used in the manufacture of pressure vessel steels. This means that the weldability of [...] Read more.
Pressure vessel steels are used in the manufacture of tanks for the storage of gases, chemical materials and oil. To meet the increasing production demands, high-wire-energy welding is widely used in the manufacture of pressure vessel steels. This means that the weldability of pressure vessel steels needs to be improved. Therefore, in order to reveal the microalloying effect of Ca in pressure vessel steel, this study took a commonly used pressure vessel steel as the research object, and three groups of experimental steels with different Ca mass fractions were prepared using vacuum metallurgy, controlled rolling and controlled cooling. Welding heat simulation technology was used to simulate the welding heat of experimental steel and the welding heat-affected zone (HAZ) was investigated. The inclusions of the welding HAZ in the experimental steels were observed by using a metallographic microscope and scanning electron microscope (SEM). The mechanism of intragranular acicular ferrite (IAF) nucleation induced by the inclusions containing Ca elements in the welding HAZ of pressure vessel steels was also discussed. The research results show that the addition of Ca increased the number density of effective inclusions in the welding HAZ of the experimental steel up to 535.60 pieces/mm2. The addition of the Ca element was beneficial for producing more pinning inclusions in the experimental steel welding HAZ under the experimental conditions, and the inclusions were mainly elliptical oxide complex inclusions of Ca-Si with a size of about 2 μm. Meanwhile, Al2O3 and MnS were precipitated. After the addition of Ca elements, Mn-poor regions appeared around the inclusions containing Ca in the welding HAZ. IAF nucleation was mainly induced by the local compositional change mechanism and supplemented by the stress–strain energy mechanism and inert interface energy mechanism. This study provides a valuable reference for optimizing the welding process of pressure vessel steels and is of great importance for understanding the IAF nucleation mechanism of Ca-containing inclusions in the welding HAZ of pressure vessel steels. Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)
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13 pages, 3106 KiB  
Article
The Effect of TIG Welding Heat Input on the Deformation of a Thin Bending Plate and Its Weld Zone
by Nan Guo, Hao Hu, Xiaojie Tang, Xiqiang Ma and Xiao Wang
Coatings 2023, 13(12), 2008; https://doi.org/10.3390/coatings13122008 - 27 Nov 2023
Viewed by 839
Abstract
Heat input is a crucial parameter in the process of welding thin plates. It has a direct impact on the quality of the weld and the degree of deformation caused during welding. This study investigates the impact of heat input on the deformation [...] Read more.
Heat input is a crucial parameter in the process of welding thin plates. It has a direct impact on the quality of the weld and the degree of deformation caused during welding. This study investigates the impact of heat input on the deformation of a thin bending plate and its weld zone using the thermoelastic–plastic finite element method. The accuracy of the model is ascertained using the non-contact inspection method utilizing digital image correlation technology. The welding deformation patterns of thin bending plates with a radius of 500 mm were analyzed at various welding heat inputs ranging from 173 J/mm to 435 J/mm. The results indicate that the finite element prediction model proposed in this paper is highly accurate. It has been observed that, under this range of thermal input, the thin bent plates undergo saddle deformation. By examining the correlation between heat input and the maximum deformation outside of the plane, it has been determined that a heat input of at least 50 J/mm is required for the thin bending plate to experience out-of-plane deformation. Additionally, as the level of heat input increases, so too does the out-of-plane deformation of the thin bending plate. After the completion of the welding cooling process, the transverse shrinkage at the weld seam of the thin bend plate is twice that of the longitudinal shrinkage. However, the transverse deformation of the bend plate is not significantly different from the longitudinal deformation. Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)
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14 pages, 3825 KiB  
Article
Quality of Low-Carbon Steel as a Distribution of Pollution and Fatigue Strength Heated in Oxygen Converter
by Tomasz Lipiński
Coatings 2023, 13(7), 1275; https://doi.org/10.3390/coatings13071275 - 20 Jul 2023
Viewed by 753
Abstract
The works available in the literature presenting the influence of impurities on the properties (mainly fatigue strength) of material give an answer with a high degree of probability for hard steels and large precipitations (usually above 10 µm). The impact of non-metallic impurities [...] Read more.
The works available in the literature presenting the influence of impurities on the properties (mainly fatigue strength) of material give an answer with a high degree of probability for hard steels and large precipitations (usually above 10 µm). The impact of non-metallic impurities on the durability of high-ductility steels causes much greater problems and is much more difficult to explain. The results of the existing studies rarely take into account the diameter of the impurities in relation to the distance between the impurities. This paper presents the results of tests carried out on a low-carbon steel heated in a 100-tonne oxygen converter and deoxidized under vacuum. The fatigue strength test was carried out on cylindrical samples using rotational bending for different tempering temperatures of the steel. The quotient of the average size of the inclusions and the average distance between the inclusions were analyzed. Based on the obtained results, it was found that steel annealed in the converter and vacuum degassed has a content of both phosphorus and sulfur below 0.02% and a total volume of impurities of 0.086%. The main fraction of impurities are oxide inclusions with a diameter below 2 µm. An increase in fatigue strength was found along with an increase in the number of impurities, mainly of small diameters. Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)
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17 pages, 7677 KiB  
Article
Finite Element Analysis of Renewable Porous Bones and Optimization of Additive Manufacturing Processes
by Hailong Ma, Shubo Xu, Xiaoyu Ju, Aijun Tang and Xinzhi Hu
Coatings 2023, 13(5), 912; https://doi.org/10.3390/coatings13050912 - 12 May 2023
Viewed by 1070
Abstract
Three-dimensional printing technology has a precise manufacturing process that can control tiny pores and can design individualized prostheses based on the patient’s own conditions. Different porous structures were designed by controlling different parameters such as porosity, using UG NX to establish models with [...] Read more.
Three-dimensional printing technology has a precise manufacturing process that can control tiny pores and can design individualized prostheses based on the patient’s own conditions. Different porous structures were designed by controlling different parameters such as porosity, using UG NX to establish models with different porosities and using ANSYS to simulate stress and strain. Unidirectional compression and stretching simulations were carried out to obtain stress, strain, and deformation. Based on these data, a porosity was found to approximate the elastic modulus of the humeral bone scaffold. As the porosity increased, the equivalent elastic modulus decreased significantly in the lateral direction, and the maximum stress formed by the porous structure and deformation increased significantly. Four different finite element models and geometric models of cubic, face-centered cubic, honeycomb, and body-centered cubic unit structures were selected. Then these porous structures were simulated for tensile and compression experiments, and the simulation results were analyzed. The forming simulation of the finite element model was carried out, and the evolution of mechanical properties of the porous structure during the 3D printing process was analyzed. The results showed that designing the humeral bone scaffold as a porous structure could reduce the stiffness of the prosthesis, alleviate stress shielding around the prosthesis after surgery, enhance its stability, and prolong its service life. The study provides reference values and scientific guidance for the feasibility of porous humeral bone scaffolds and provides a basis for the research and design of clinical humeral bone scaffolds. Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)
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15 pages, 2429 KiB  
Article
Intelligent Metal Welding Defect Detection Model on Improved FAST-PNN
by Jinxin Liu and Kexin Li
Coatings 2022, 12(10), 1523; https://doi.org/10.3390/coatings12101523 - 11 Oct 2022
Cited by 1 | Viewed by 1273
Abstract
In order to solve the problem of accurate and efficient detection of welding defects in the process of batch welding of metal parts, an improved Probabilistic Neural Network (PNN) algorithm was proposed to build an automatic identification model of welding defects. Combined with [...] Read more.
In order to solve the problem of accurate and efficient detection of welding defects in the process of batch welding of metal parts, an improved Probabilistic Neural Network (PNN) algorithm was proposed to build an automatic identification model of welding defects. Combined with the characteristics of the PNN model, the structure and algorithm flow of the FAST-PNN algorithm model are proposed. Extraction of welding defect image texture features of metal welded parts by a Gray Level Co-occurrence Matrix (GLCM) screens out the characteristic indicators that can effectively characterize welding defects. Weld defect texture features are used as input to build a defect classification model with FAST-PNN, for accurate and efficient classification of welding defects. The results show that the improved FAST-PNN model can effectively identify the types of welding defects such as burn-through, pores and cracks, etc. The classification recognition accuracy and recognition efficiency have been significantly improved. The proposed defect welding identification method can accurately and effectively identify the damage types of welding defects based on a small number of defect sample images. Welding defects can be quickly identified and classified by simply collecting weld images, which helps to solve the problem of intelligent, high-precision, fast real-time online detection of welding defects in modern metal structures; it provides corresponding evidence for formulating response strategies, with a certain theoretical basis and numerical reference. Full article
(This article belongs to the Special Issue Recent Progress in Metal Additive Manufacturing)
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