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Materials, Processing, and Post-treatment for Metal-Based Additive Manufacturing

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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: 20 October 2024 | Viewed by 7268

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Prof. Dr. Liyuan Sheng

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Guest Editor

Laboratory of Advanced Materials and Processing, Peking University Shenzhen Institute, Shenzhen 518057, China
Interests: magnesium alloy; intermetallic compound; superalloy; metal-based composite; surface coating; laser processing; microstructure; mechanical properties

Prof. Dr. Hui Zhao

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Guest Editor

School of Material Science and Engineering, Xi’an Shiyou University, Xi’an 710065, China
Interests: titanium alloy; explosive welding; surface coating; laser processing

Prof. Dr. Junke Jiao

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Guest Editor

School of Mechanical Engineering, Yangzhou University, Yangzhou 225009, China
Interests: laser welding; laser additive manufacturing; laser cladding; laser micromachining

Special Issue Information

Dear Colleagues,

Recently, additive manufacturing (AM) has been widely investigated because of its advantages in the fabrication of components with irregular and complex shapes. Therefore, AM has been applied to fabricate components in the aerospace, medical and automotive fields. However, the rapid fusion and solidification of feeding materials during AM always lead to the formation of metallurgical defects and influence the mechanical properties. In fact, the materials, processing parameters and post-treatments are the main factors of AM fabrication that could affect the microstructure and mechanical properties of as-fabricated components. Therefore, the exploration on the relationship between them is helpful for further improving AM fabrication.

The main aim of the Special Issue is to discuss the effects of the materials, processing and post-treatments of AM on the microstructure and mechanical properties of the components. Research on AM powder or wire, novel AM processing, post-treatments, simulation and mechanism analyses, laser cladding and remanufacturing technology, laser joining, and other related topics are welcome.

Prof. Dr. Liyuan Sheng
Prof. Dr. Hui Zhao
Prof. Dr. Junke Jiao
Guest Editors

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Keywords

additive manufacturing
post-treatment
laser cladding
laser welding
numerial simulation
powders
coatings

Published Papers (4 papers)

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Research

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21 pages, 15231 KiB

Open AccessArticle

Response Surface Methodology (RSM) Approach for Optimizing the Processing Parameters of 316L SS in Directed Energy Deposition

by Eden Amar, Vladimir Popov, Vyas Mani Sharma, Shir Andreev Batat, Doron Halperin and Noam Eliaz

Materials 2023, 16(23), 7253; https://doi.org/10.3390/ma16237253 - 21 Nov 2023

Viewed by 1300

Abstract

Directed energy deposition (DED) is a crucial branch of additive manufacturing (AM), performing repairs, cladding, and processing of multi-material components. 316L austenitic stainless steel is widely used in applications such as the food, aerospace, automotive, marine, energy, biomedical, and nuclear reactor industries. Nevertheless, there is need for process parameter optimization and a comprehensive understanding of the individual and complex synergistic effects of process parameters on the geometry, microstructure, and properties of the deposited material or component. This is essential for ensuring repeatable manufacturing of parts across a single or series of platforms over time, or for minimizing defects such as porosity. In this study, the response surface methodology (RSM) and central composite design (CCD) were employed to investigate the effects of laser power, laser scan speed, and powder mass flow rate on layer thickness, density, microstructure, and microhardness of 316L steel processed by Laser Engineered Net Shaping (LENS^®) DED. Polynomial empirical prediction models correlating the applied processing parameters and the studied responses were developed. Full article

(This article belongs to the Special Issue Materials, Processing, and Post-treatment for Metal-Based Additive Manufacturing)

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24 pages, 10923 KiB

Open AccessArticle

Effect of Heat Treatment on the Microstructure and Mechanical Properties of 18Ni-300 Maraging Steel Produced by Additive–Subtractive Hybrid Manufacturing

by Mahmoud Osman, Sheida Sarafan, Priti Wanjara, Fabrice Bernier, Sila Ece Atabay, Javad Gholipour, Marjan Molavi-Zarandi, Josh Soost and Mathieu Brochu

Materials 2023, 16(13), 4749; https://doi.org/10.3390/ma16134749 - 30 Jun 2023

Cited by 2 | Viewed by 1472

Abstract

The present work investigates the effectiveness of two heat treatment cycles—solution treatment + aging (STA) and direct aging (DA)—on optimizing the microstructure and enhancing the mechanical properties of 18Ni-300 maraging steel (300 MS) produced by additive–subtractive hybrid manufacturing (ASHM). The STA treatment led to a fully martensitic microstructure with minor remnants of the cellular substructures associated with the solidification conditions in ASHM. DA resulted in some reverted austenite and partial dissolution of the cellular morphologies into shorter fragments. Despite the contrasting microstructures, the tensile strength and the macro- and micro-hardness were comparable between STA and DA conditions. By contrast, the potential for improving the ductility was higher with the DA heat treatment. This is attributed to the higher reverted austenite content in the samples treated by DA, i.e., up to a maximum of 13.4% compared to less than 3.0% in the STA samples. For the DA sample with the highest reverted austenite content of 13.4%, the highest local and global fracture strain values of 30.1 and 5.9 ± 0.6% were measured, while the respective values were 23.4 and 4.4 ± 0.1% for the corresponding STA sample. This work suggests that DA of 300 MS produced by ASHM is sufficient to achieve comparable hardness and tensile strength to STA, whilst maintaining reasonable ductility. Avoiding the solution treatment cycle, with its appreciably higher temperatures, could benefit the dimensional stability and surface quality that are important for ASHM of 300 MS parts. Full article

(This article belongs to the Special Issue Materials, Processing, and Post-treatment for Metal-Based Additive Manufacturing)

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15 pages, 4439 KiB

Open AccessArticle

Effect of Synchronized Laser Shock Peening on Decreasing Defects and Improving Microstructures of Ti-6Al-4V Laser Joint

by Li Zhang, Wentai Ouyang, Di Wu, Liyuan Sheng, Chunhai Guo, Licheng Ma, Zhihao Chen, Zhenkai Zhu, Yongxiao Du, Peijuan Cui, Zhanlin Hou and Wenwu Zhang

Materials 2023, 16(13), 4570; https://doi.org/10.3390/ma16134570 - 24 Jun 2023

Cited by 2 | Viewed by 1095

Abstract

Repairing processing is a significant method for damaged high-cost Ti-6Al-4V components to decrease economic loss, which usually utilizes a welding technique. For a large-size structural component, welding processing is commonly completed in air conditioning, which makes it difficult to avoid welding defects. To this end, an appropriate matching technique is important for improving welding performance. In the present research, asynchronized laser shock peening (ALSP) and synchronized laser shock peening (SLSP) techniques were utilized to decrease the influence of macro welding defects on laser-welded Ti-6Al-4V joints. The results show that SLSP has a greater effect on inducing surface plastic deformation on Ti-6Al-4V joints with a pitting depth of more than 25 microns while ALSP can lead to a pitting depth of about 15 microns. Through micro-CT observation a long hot crack exists in the central area of as-welded joints with a length of about 2.24 mm, accompanied by lots of pores in different sizes on double sides. After ALSP processing, some pores are eliminated while others are enlarged, and one-side crack tips present closure morphology. However, some microcracks exist on the side-wall of hot cracks. With the influence of SLSP, significant shrinkage of pores can be observed and both sides of crack tips tend to be closed, which presents a better effect than ALSP processing. Moreover, greater effects of grain refinement and thermal stress release could be achieved by SLSP processing than ALSP, which can be ascribed to dynamic recrystallization. For the as-welded joint, the ultimate tensile strength (UTS) and elongation (EL) values are 418 MPa and 0.73%, respectively. The values of UTS and EL in the ALSP processed joint are increased to 437 MPa and 1.07%, which are 4.55% and 46.48% higher than the as-welded joint, respectively. Such values after SLSP processing are 498 MPa and 1.23%, which are 19.14% and 68.49% higher than the as-welded joint, respectively. Full article

(This article belongs to the Special Issue Materials, Processing, and Post-treatment for Metal-Based Additive Manufacturing)

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Review

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41 pages, 6840 KiB

Open AccessReview

Research Progress of Laser Cladding on the Surface of Titanium and Its Alloys

by Hui Zhao, Chaochao Zhao, Weixin Xie, Di Wu, Beining Du, Xingru Zhang, Min Wen, Rui Ma, Rui Li, Junke Jiao, Cheng Chang, Xingchen Yan and Liyuan Sheng

Materials 2023, 16(8), 3250; https://doi.org/10.3390/ma16083250 - 20 Apr 2023

Cited by 12 | Viewed by 2826

Abstract

Titanium (Ti) and its alloys have been widely employed in aeronautical, petrochemical, and medical fields owing to their fascinating advantages in terms of their mechanical properties, corrosion resistance, biocompatibility, and so on. However, Ti and its alloys face many challenges, if they work in severe or more complex environments. The surface is always the origin of failure for Ti and its alloys in workpieces, which influences performance degradation and service life. To improve the properties and function, surface modification becomes the common process for Ti and its alloys. The present article reviews the technology and development of laser cladding on Ti and its alloys, according to the cladding technology, cladding materials, and coating function. Generally, the laser cladding parameters and auxiliary technology could influence the temperature distribution and elements diffusion in the molten pool, which basically determines the microstructure and properties. The matrix and reinforced phases play an important role in laser cladding coating, which can increase the hardness, strength, wear resistance, oxidation resistance, corrosion resistance, biocompatibility, and so on. However, the excessive addition of reinforced phases or particles can deteriorate the ductility, and thus the balance between functional properties and basic properties should be considered during the design of the chemical composition of laser cladding coatings. In addition, the interface including the phase interface, layer interface, and substrate interface plays an important role in microstructure stability, thermal stability, chemical stability, and mechanical reliability. Therefore, the substrate state, the chemical composition of the laser cladding coating and substrate, the processing parameters, and the interface comprise the critical factors which influence the microstructure and properties of the laser cladding coating prepared. How to systematically optimize the influencing factors and obtain well-balanced performance are long-term research issues. Full article

(This article belongs to the Special Issue Materials, Processing, and Post-treatment for Metal-Based Additive Manufacturing)

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