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Crystals
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Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling
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Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling

A special issue of Crystals (ISSN 2073-4352). This special issue belongs to the section "Crystalline Metals and Alloys".

Deadline for manuscript submissions: closed (20 March 2024) | Viewed by 14239

Special Issue Editors

Dr. Muhammad Arif Mahmood

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Guest Editor
Mechanical Engineering Program, Texas A&M University at Qatar, Doha P.O. Box 34110, Qatar
Interests: additive manufacturing; laser-material interaction; tribology; process automation, modelling
Special Issues, Collections and Topics in MDPI journals
Dr. Asif Ur Rehman

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Guest Editor
ERMAKSAN, Bursa 16065, Turkey
Interests: additive manufacturing; laser-material interaction; laser powder bed fusion; laser metal deposition; process development; binder jetting technology; process modelling; modelling
Prof. Dr. Marwan Khraisheh

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Guest Editor
Mechanical Engineering Program, Texas A&M University at Qatar, Doha P.O. Box 34110, Qatar
Interests: sustainable and smart manufacturing; materials for energy applications; materials processing; integration of mechanics and materials in manufacturing
Prof. Dr. Metin U. Salamci

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Guest Editor
1. Department of Mechanical Engineering, Gazi University, Ankara 06570, Turkey
2. Additive manufacturing technologies research and application center-EKTAM, Gazi University, Ankara 06560, Turkey
3. Manufacturing Technologies Center of Excellence-URTEMM A.S., Ankara 06980, Turkey
Interests: non-traditional manufacturing methods; machine; theory and dynamics; machine dynamics; system dynamics and control; mechatronics; modelling and simulation of dynamic systems; mechanical vibrations
Dr. Rashid Ur Rehman

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Guest Editor
Singapore Membrane Technology Centre, Nanyang Environment and Water Research Institute, Nanyang Technological University, 1 Cleantech Loop, Singapore 637141, Singapore
Interests: organic/inorganic membranes applications; surface modification of nanoparticles; bioconversion
Dr. Uzair Sajjad

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Guest Editor
Department of Mechanical Engineering, National Yang Ming Chiao Tung University, Hsinchu 300, Taiwan
Interests: developing mechanical and energy technologies for various applications
Special Issues, Collections and Topics in MDPI journals
Dr. Carmen Ristoscu

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Guest Editor
“Laser-Surface-Plasma Interactions” Laboratory, Lasers Department, National Institute for Lasers, Plasma and Radiation Physics, Institute of Atomic Physics, P.O. Box MG-36 RO-77125 Magurele, Bucharest, Romania
Interests: experimental optics; spectroscopy; lasers and plasma; surface studies and processing with lasers; laser interactions; lasers and plasma physics; nanostructured thin-film technology (PLD, MAPLE, and combinatorial); surface physics and engineering; biophysics and biomedicine; nano-biotechnologies; gas- and biosensors; plasma and laser theory
Special Issues, Collections and Topics in MDPI journals
Dr. Andrei C. Popescu

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Guest Editor
Center for Advanced Laser Technologies (CETAL), National Institute for Lasers, Plasma and Radiation Physics, 077125 Magurele, Romania
Interests: additive manufacturing; laser metal processing; biocompatible materials; surface microstructuring; deposition and modification of thin solid structures via high intensity laser irradiation
Special Issues, Collections and Topics in MDPI journals
Dr. Mihai Oane

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Guest Editor
National Institute for Laser, Plasma and Radiation Physics, 077125 Măgurele, Romania
Interests: laser processing; nuclear physics and relativity
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Ion N. Mihailescu

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Guest Editor
Lasers Department, National Institute for Lasers, Plasma and Radiation Physics, 077125 Magurele, Romania
Interests: pulsed laser deposition; modification and characterization of nanostructured thin coatings; matrix-assisted pulsed laser evaporation (MAPLE); laser surface studies and processing; biomaterials thin layers; tissue engineering; biomimetic metallic implants; optoelectronics and sensors
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) utilizes a layer-upon-layer technique to produce three-dimensional (3D) components via a computer-aided design (CAD) model, promising manufacturing advantages compared to conventional approaches, such as manufacturing intricate geometries, controlling the heat-affected zone and removing numerous technological steps; thus, reducing the final manufacturing cost. AM has been explored in automotive, biomedical, aerospace and industrial applications based on the facts mentioned above, and has been widely applied to various materials, including metals, ceramics, polymers and ceramic-reinforced metal matrix composites (CMMCs), a mixture of metals and ceramics. In AM, operating conditions influence the properties of the manufactured parts and the in-service life. One way to determine the optimum operating conditions is to conduct a series of experiments by utilizing the trial-and-error method, increasing the manufacturing direct and indirect costs. On the other hand, this can be performed by using an experimentally validated simulation model linked with data-driven models (machine learning), leading towards smart manufacturing.

The primary purpose of this Special Issue of Crystals, titled “Additive Manufacturing: Experiments, Simulations and Data-driven Modelling”, is to deliver an intercontinental forum for ground-breaking research on the process parameters optimization, development of new alloys and compounds, ceramics and CMMCs for AM experiments, sophisticated simulation model development and the implementation of machine learning in AM processes.

Dr. Muhammad Arif Mahmood
Dr. Asif Ur Rehman
Prof. Dr. Marwan Khraisheh
Prof. Dr. Metin U. Salamci
Dr. Rashid Ur Rehman
Prof. Dr. Uzair Sajjad
Dr. Carmen Ristoscu
Dr. Andrei C. Popescu
Dr. Mihai Oane
Prof. Dr. Ion N. Mihailescu
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. Crystals 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.

Keywords

  • additive manufacturing
  • metals
  • ceramics
  • ceramic-reinforced metal matrix composites
  • experiments
  • simulations
  • machine learning
  • process parameters optimization
  • smartification of additive manufacturing

Published Papers (8 papers)

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Research

16 pages, 4736 KiB  
Article
Ti6Al4V-0.72H on the Establishment of Flow Behavior and the Analysis of Hot Processing Maps
by Jian-Hua Sun, Hai Gu, Jie Zhang, Jie Jiang, Guo-Qing Wu and Zhong-Gang Sun
Crystals 2024, 14(4), 345; https://doi.org/10.3390/cryst14040345 - 03 Apr 2024
Viewed by 358
Abstract
Significant columnar grains usually occur in the metallurgical microstructure of laser additive manufacturing, and plastic deformation introduced into additive manufacturing can significantly refine grain size. Due to the high deformation resistance and difficult deformation of titanium alloys, reducing the high-temperature deformation resistance of [...] Read more.
Significant columnar grains usually occur in the metallurgical microstructure of laser additive manufacturing, and plastic deformation introduced into additive manufacturing can significantly refine grain size. Due to the high deformation resistance and difficult deformation of titanium alloys, reducing the high-temperature deformation resistance of additive manufacturing titanium alloys is essential to facilitating the implementation of online rolling processes. High-temperature compression of titanium alloys was performed on a Gleeble-3800. It was found that the flow stress of the alloy decreased when the strain of the alloy decreased or the deformation temperature increased. The flow behavior of titanium alloys at high temperatures was investigated with the help of a Z-parameter flow model and multiple linear regression model. A positive correlation was found between the experimental and predicted values of the alloy under the multiple linear regression model, with a correlation coefficient of 0.98 and its error of 13.5%, which could better predict the flow stress values. In addition, hot processing maps were established, and the optimal deformation conditions were determined to provide some theoretical guidance for subsequent experiments. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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14 pages, 5562 KiB  
Article
Effect of Particle Concentration on the Microstructure and Properties of Electrodeposited Nickel–Diamond Composite Coatings
by Zhiyuan Yang, Kunxiang Ge, Wen Cai, Shenqiang Liu, Shitao Zhang, Zhengyang Pan, Jianing Zhang, Yuantao Zhao, Wenge Li and Yanbo Liu
Crystals 2024, 14(4), 308; https://doi.org/10.3390/cryst14040308 - 27 Mar 2024
Viewed by 431
Abstract
For the purpose of improving the wear properties of Ni composite coatings, diamond particles were co-electrodeposited into Ni–diamond composite coatings. The effect of diamond particle concentration in the electrolyte on the surface morphology, microstructure, and wear properties of Ni–diamond composite coatings was investigated. [...] Read more.
For the purpose of improving the wear properties of Ni composite coatings, diamond particles were co-electrodeposited into Ni–diamond composite coatings. The effect of diamond particle concentration in the electrolyte on the surface morphology, microstructure, and wear properties of Ni–diamond composite coatings was investigated. The electrodeposition behaviors of the composite coatings were simulated by COMSOL5.6. The results showed that the content of diamond particles in the coating was elevated by increasing the particle concentration in the electrolyte. The formation of [200] fiber texture was blocked and concurrently brought about crystallite refinement of the Ni deposits by the embedded particles. The COMSOL simulation findings indicated that embedded particles influenced the microstructure of the Ni deposits through processes such as heterogeneous nucleation, rearrangement, and concentration of local current density. The synergistic effect of the tailored microstructure and embedded particles substantially enhanced the wear resistance of the coating. By increasing the particle concentration in the electrolyte, the wear resistance of the coating was gradually enhanced, and the coating electrodeposited at 16 g/L possessed the lowest friction coefficient and the smallest profile of wear scratch owning to the strengthened synergistic effect. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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17 pages, 8261 KiB  
Article
Advancing PLA 3D Printing with Laser Polishing: Improving Mechanical Strength, Sustainability, and Surface Quality
by Ray Tahir Mushtaq, Asif Iqbal, Yanen Wang, Aqib Mashood Khan and Mohammad Iskandar Petra
Crystals 2023, 13(4), 626; https://doi.org/10.3390/cryst13040626 - 05 Apr 2023
Cited by 12 | Viewed by 2146
Abstract
Three-dimensional (3D) printing of polylactic acid using the fused filament fabrication approach is a widely used additive manufacturing method in various fields, despite the historical issue of substantial surface roughness in fused filament fabrication products. Several strategies have been utilized to minimize the [...] Read more.
Three-dimensional (3D) printing of polylactic acid using the fused filament fabrication approach is a widely used additive manufacturing method in various fields, despite the historical issue of substantial surface roughness in fused filament fabrication products. Several strategies have been utilized to minimize the surface roughness of 3D-printed items. However, laser polishing is a novel technique for reducing surface roughness and improving other material qualities. In this study, polylactic acid was examined using the laser polishing method for surface roughness and mechanical properties, such as tensile and flexural strength and laser scan time. Several trials were conducted to determine how changing the laser’s characteristics may affect the materials’ surface quality and mechanical qualities. Before the final test, preliminary tests were performed to determine the lowest potential heat-affected zone. Laser polishing reduced surface roughness by more than 88.8% (from 7.8 µm to 0.87 µm). The tensile strength of the specimen increased by 14.03%, from 39.2 MPa to 44.7 MPa. Polylactic acid had a constant flexural strength of 70.1 MPa before and after polishing, and the laser scan time for samples was 19.4 s. Polished morphologies were studied to learn more about the microstructure. These findings show that laser polishing can improve and modify the surface properties of a fused filament fabrication product, which can benefit the industry and researchers. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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20 pages, 8944 KiB  
Article
3D Claying: 3D Printing and Recycling Clay
by Javier Alonso Madrid, Guillermo Sotorrío Ortega, Javier Gorostiza Carabaño, Nils O. E. Olsson and José Antonio Tenorio Ríos
Crystals 2023, 13(3), 375; https://doi.org/10.3390/cryst13030375 - 22 Feb 2023
Cited by 3 | Viewed by 2827
Abstract
Clay is of great interest as a 3D printing material thanks to its ease of use, recyclability and reusability. This paper analyses the technical aspects of the whole printing process. The behaviour of 3D printing clay is studied with respect to the environment [...] Read more.
Clay is of great interest as a 3D printing material thanks to its ease of use, recyclability and reusability. This paper analyses the technical aspects of the whole printing process. The behaviour of 3D printing clay is studied with respect to the environment and its specific application as a temporary or definitive formwork system for cement parts. The study addresses the performance of clay and the loss of its properties and characteristics according to the type of protection, whether it is in direct contact with air or cement, or protected with plastics, metal sheets, or combinations of both. A 3D printing system with various printers and 3D models has been considered, observing a direct relationship between the prototype shape, extrusion process and resulting material. The most important variables in 3D printing have been considered: layer height, line thickness, base definition, total model height, overhang angles, overlap between layers, etc. The main technical aspects have been analysed such as raw material properties, kneading, process control, post-treatments and material hardening. As a natural material, clay can be reused indefinitely under certain conditions to be part of a circular economy with low energy consumption and minimal resources. It is concluded that the option of using ceramics in 3D printing for very diverse uses in the architecture, engineering & construction (AEC) sector is very promising due to their ease of implementation, recycling capability and suitability to different environments. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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16 pages, 6183 KiB  
Article
The Influence of Nanoparticle Dispersions on Mechanical and Thermal Properties of Polymer Nanocomposites Using SLA 3D Printing
by Mussadiq Shah, Abid Ullah, Kashif Azher, Asif Ur Rehman, Nizami Akturk, Wang Juan, Celal Sami Tüfekci and Metin Uymaz Salamci
Crystals 2023, 13(2), 285; https://doi.org/10.3390/cryst13020285 - 07 Feb 2023
Cited by 4 | Viewed by 2450
Abstract
The synergistic integration of nanocomposites and 3D printing has opened a gateway to the future and is soon expected to surpass its rivalry with traditional manufacturing techniques. However, there is always a challenge associated with preparing a nanocomposite resin for polymerization-based 3D printing, [...] Read more.
The synergistic integration of nanocomposites and 3D printing has opened a gateway to the future and is soon expected to surpass its rivalry with traditional manufacturing techniques. However, there is always a challenge associated with preparing a nanocomposite resin for polymerization-based 3D printing, which is the agglomeration of nanoparticles. Due to the high surface-area-to-volume ratio, the nanoparticles form clusters in the composite matrix, which affects the final properties. This paper aims to analyze the effects of graphene oxide (GO) dispersion on the mechanical and thermal properties of 3D-printed nanocomposites. In particular, a well-dispersed sonication dispersion route is employed for analyzing high and poor GO dispersions and their effects on different properties. After different microscopic analyses and testing, the optimum sonication condition was 30 min at an amplitude of 70%. In terms of mechanical properties, both tensile and compression strength first increased and then decreased gradually with different dispersions as well as varying GO concentrations. Furthermore, there was less or no effect on thermal stability. GO of 0.05 wt.% had the highest compression and tensile strength, while beyond 0.05 to 0.5 wt.%, both strengths reduced slowly. These 3D-printed nanocomposites have found their application in automotive, sports, and biomedical fields. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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16 pages, 6790 KiB  
Article
Estimation of the Critical Value of the Second-Phase Particles in the Microstructure of AZ31 Mg Alloy by Phase-Field Methods
by Yan Wu, Jinlin Xiong, Qiang Luo, Jibing Chen, Rutie Zeng and Shuo Wang
Crystals 2022, 12(11), 1504; https://doi.org/10.3390/cryst12111504 - 22 Oct 2022
Cited by 4 | Viewed by 1311
Abstract
In this study, phase-field models were employed to simulate the effects of second-phase particles (SPPs) on grain growth of the AZ31 Mg alloy, under realistic spatial and temporal scales, at 350 °C, during annealing. The particle sizes ranged from 0 to 7 μm, [...] Read more.
In this study, phase-field models were employed to simulate the effects of second-phase particles (SPPs) on grain growth of the AZ31 Mg alloy, under realistic spatial and temporal scales, at 350 °C, during annealing. The particle sizes ranged from 0 to 7 μm, and the particles with large volume fractions were used in the paper. The results reveal that the volume fractions and sizes of the SPP affect grain growth and that the volume fractions and sizes of the SPP on pinning exhibited critical values. When the SPP volume fraction is f = 5%, the SPP is at the maximum critical size, rμmmax; when the SPP size is r=1 μm, the SPP minimum critical volume fraction is fmin = 0.25% and the maximum critical volume fraction is fmax = 20%. The critical values increase with the increase of the sizes or volume fractions of the second-phase particles. Finally, the average grain size, particle size, and particle volume fraction obtained from the simulation were fitted according to the Zener relationship, and the obtained results showed that the fitting indices were in the range of 0.33–0.50. The results were compared with the experimental results. The simulation results obtained in this study will provide an important academic reference for understanding the mechanism and law of grain growth, an important reference for accurate control of grain size and properties of the material, a reference for the development of the annealing treatment process of Mg alloy, and a theoretical guide for the use of recrystallization process to control the microstructure of Mg alloy and improve the plastic-forming properties. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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15 pages, 4437 KiB  
Article
Influence of Nano-Sized SiC on the Laser Powder Bed Fusion of Molybdenum
by Nathan E. Ellsworth, Ryan A. Kemnitz, Cayla C. Eckley, Brianna M. Sexton, Cynthia T. Bowers, Joshua R. Machacek and Larry W. Burggraf
Crystals 2022, 12(9), 1276; https://doi.org/10.3390/cryst12091276 - 08 Sep 2022
Cited by 2 | Viewed by 1464
Abstract
Consolidation of pure molybdenum through laser powder bed fusion and other additive manufacturing techniques is complicated by a high melting temperature, thermal conductivity and ductile-to-brittle transition temperature. Nano-sized SiC particles (0.1 wt%) were homogeneously mixed with molybdenum powder and the printing characteristics, chemical [...] Read more.
Consolidation of pure molybdenum through laser powder bed fusion and other additive manufacturing techniques is complicated by a high melting temperature, thermal conductivity and ductile-to-brittle transition temperature. Nano-sized SiC particles (0.1 wt%) were homogeneously mixed with molybdenum powder and the printing characteristics, chemical composition, microstructure, mechanical properties were compared to pure molybdenum for scan speeds of 100, 200, 400, and 800 mm/s. The addition of SiC improved the optically determined density and flexural strength at 400 mm/s by 92% and 80%, respectively. The oxygen content was reduced by an average of 52% over the four scan speeds analyzed. Two mechanisms of oxygen reduction were identified as responsible for the improvements: oxidation of free carbon and the creation of secondary phase nanoparticles. This study illustrates the promising influence of nanoparticle additions to refractory metals in laser powder bed fusion. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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9 pages, 2027 KiB  
Article
Laser Additive Manufacturing of Bulk Silicon Nitride Ceramic: Modeling versus Integral Transform Technique with Experimental Correlation
by Cristian N. Mihailescu, Mihai Oane, Bogdan A. Sava, Andrei C. Popescu, Mihail Elisa, Muhammad Arif Mahmood, Natalia Mihailescu, Ana V. Filip, Sinziana Andreea Anghel, Ion N. Mihailescu and Carmen Ristoscu
Crystals 2022, 12(8), 1155; https://doi.org/10.3390/cryst12081155 - 16 Aug 2022
Viewed by 1453
Abstract
A semi-analytical-numerical solution is theorized to describe the laser additive manufacturing via laser-bulk ceramic interaction modeling. The Fourier heat equation was used to infer the thermal distribution within the ceramic sample. Appropriate boundary conditions, including convection and radiation, were applied to the bulk [...] Read more.
A semi-analytical-numerical solution is theorized to describe the laser additive manufacturing via laser-bulk ceramic interaction modeling. The Fourier heat equation was used to infer the thermal distribution within the ceramic sample. Appropriate boundary conditions, including convection and radiation, were applied to the bulk sample. It was irradiated with a Gaussian spatial continuous mode fiber laser (λ = 1.075 µm) while a Lambert-Beer law was assumed to describe the laser beam absorption. A close correlation between computational predictions versus experimental results was validated in the case of laser additive manufacturing of silicon nitride bulk ceramics. The thermal field value rises but stays confined within the irradiated zone due to heat propagation with an infinite speed, a characteristic of the Fourier heat equation. An inverse correlation was observed between the laser beam scanning speed and thermal distribution intensity. Whenever the laser scanning speed increases, photons interact with and transfer less energy to the sample, resulting in a lower thermal distribution intensity. This model could prove useful for the description and monitoring of low-intensity laser beam-ceramic processing. Full article
(This article belongs to the Special Issue Additive Manufacturing: Experiments, Simulations and Data-Driven Modelling)
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