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Advances in Additive Manufacturing
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Advances in Additive Manufacturing

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

Deadline for manuscript submissions: closed (28 February 2021) | Viewed by 23244

Special Issue Editor

Prof. Dr. Rainer J. Hebert

E-Mail Website
Guest Editor
Department of Materials Science & Engineering, University of Connecticut, Storrs, CT, USA
Interests: rapid solidification; aluminum alloys; amorphous alloys
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear colleagues,

Additive manufacturing has taken academia, government agencies, and academia by storm and for good reasons. Opportunities for applications seem to abound, only to be matched by the challenges that could potentially slow down the transformative opportunities of additive manufacturing. These challenges are manifold but mostly revolve around an arch-nemesis of all manufacturing—variations in product attributes, often without a clear understanding of causes. To address this critical challenge, increasingly, modeling and simulations are used to identify potential sources for variations in microstructures and properties of additively manufactured parts. Advanced charaterization techniques both in operandi and post-built complement modeling and simulation efforts. Significant progress has been made using this diverse set of process analysis methods to identify sources of variations.

This Special Issue highlights the current state of the art in understanding sources and causes of process variations in additive manufacturing using a diverse set of tools. Contributions are sought that cover topics of variations in starting materials and their effects on the additive manufacturing process and part properites, including but not limited to powder pedigree and their effects on the additive manufacturing process and part properties; variations in powder delivery and in case of powder-bed additive manufacturing, powder beds and their variations with powder spreading and ramifications on powder bed melting and solidification. Also of interest are variations in energy source characteristics; variations in build chamber gas flows and gas species or other relevant variations of the additive manufacturing process. Modeling and simulation approaches are relevant as well as experimental studies, the use of sensors, and other diagnostic tools.

We invite full length papers with original research contributions, review papers, and communications with significant novel research content.

Prof. Dr. Rainer J. Hebert
Guest Editor

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

  • powders
  • additive manufacturing
  • microstructures and properties
  • laser- or electron beams
  • design for variation
  • uncertainty quantification

Related Special Issue

Published Papers (6 papers)

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Research

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13 pages, 4862 KiB  
Article
Advanced Surface Color Quality Assessment in Paper-Based Full-Color 3D Printing
by Jieni Tian, Jiangping Yuan, Hua Li, Danyang Yao and Guangxue Chen
Materials 2021, 14(4), 736; https://doi.org/10.3390/ma14040736 - 04 Feb 2021
Cited by 9 | Viewed by 1743
Abstract
Color 3D printing allows for 3D-printed parts to represent 3D objects more realistically, but its surface color quality evaluation lacks comprehensive objective verification considering printing materials. In this study, a unique test model was designed and printed using eco-friendly and vivid paper-based full-color [...] Read more.
Color 3D printing allows for 3D-printed parts to represent 3D objects more realistically, but its surface color quality evaluation lacks comprehensive objective verification considering printing materials. In this study, a unique test model was designed and printed using eco-friendly and vivid paper-based full-color 3D printing as an example. By measuring the chromaticity, roughness, glossiness, and whiteness properties of 3D-printed surfaces and by acquiring images of their main viewing surfaces, this work skillfully explores the correlation between the color representation of a paper-based 3D-printed coloring layer and its attached underneath blank layer. Quantitative analysis was performed using ΔE*ab, feature similarity index measure of color image (FSIMc), and improved color-image-difference (iCID) values. The experimental results show that a color difference on color-printed surfaces exhibits a high linear correlation trend with its FSIMc metric and iCID metric. The qualitative analysis of microscopic imaging and the quantitative analysis of the above three surface properties corroborate the prediction of the linear correlation between color difference and image-based metrics. This study can provide inspiration for the development of computational coloring materials for additive manufacturing. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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19 pages, 6011 KiB  
Article
Crack Detection during Laser Metal Deposition by Infrared Monochrome Pyrometer
by Yin Wu, Bin Cui and Yao Xiao
Materials 2020, 13(24), 5643; https://doi.org/10.3390/ma13245643 - 10 Dec 2020
Cited by 8 | Viewed by 2362
Abstract
Laser metal deposition (LMD) is an advanced technology of additive manufacturing which involves sophisticated processes. However, it is associated with high risks of failure due to the possible generation of cracks and bubbles. If not identified in time, such defects can cause substantial [...] Read more.
Laser metal deposition (LMD) is an advanced technology of additive manufacturing which involves sophisticated processes. However, it is associated with high risks of failure due to the possible generation of cracks and bubbles. If not identified in time, such defects can cause substantial losses. In this paper, real-time monitoring of LMD samples and online detection of cracks by an infrared monochrome pyrometer (IMP) could mitigate this risk. An experimental platform for crack detection in LMD samples was developed, and the identification of four simulated cracks in a 316L austenitic stainless-steel LMD sample was conducted. Data at temperatures higher than 150 °C were collected by an IMP, and the results indicated that crack depth is an important factor affecting the peak temperature. Based on this factor, the locations of cracks in LMD-316L austenitic stainless-steel samples can be determined. The proposed technique can provide real-time detection of cracks through layers of cladding during large-scale manufacturing, which suggests its relevance for optimizing the technological process and parameters, as well as reducing the possibility of cracks in the LMD process. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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24 pages, 8997 KiB  
Article
Influence of Laser Powder Bed Fusion Process Parameters on Voids, Cracks, and Microhardness of Nickel-Based Superalloy Alloy 247LC
by Olutayo Adegoke, Joel Andersson, Håkan Brodin and Robert Pederson
Materials 2020, 13(17), 3770; https://doi.org/10.3390/ma13173770 - 26 Aug 2020
Cited by 14 | Viewed by 3386
Abstract
The manufacturing of parts from nickel-based superalloy Alloy 247LC by laser powder bed fusion (L-PBF) is challenging, primarily owing to the alloy’s susceptibility to cracks. Apart from the cracks, voids created during the L-PBF process should also be minimized to produce dense parts. [...] Read more.
The manufacturing of parts from nickel-based superalloy Alloy 247LC by laser powder bed fusion (L-PBF) is challenging, primarily owing to the alloy’s susceptibility to cracks. Apart from the cracks, voids created during the L-PBF process should also be minimized to produce dense parts. In this study, samples of Alloy 247LC were manufactured by L-PBF, several of which could be produced with voids and crack density close to zero. A statistical design of experiments was used to evaluate the influence of the process parameters, namely laser power, scanning speed, and hatch distance (inherent to the volumetric energy density) on void formation, crack density, and microhardness of the samples. The window of process parameters, in which minimum voids and/or cracks were present, was predicted. It was shown that the void content increased steeply at a volumetric energy density threshold below 81 J/mm3. The crack density, on the other hand, increased steeply at a volumetric energy density threshold above 163 J/mm3. The microhardness displayed a relatively low value in three samples which displayed the lowest volumetric energy density and highest void content. It was also observed that two samples, which displayed the highest volumetric energy density and crack density, demonstrated a relatively high microhardness; which could be a vital evidence in future investigations to determine the fundamental mechanism of cracking. The laser power was concluded to be the strongest and statistically most significant process parameter that influenced void formation and microhardness. The interaction of laser power and hatch distance was the strongest and most significant factor that influenced the crack density. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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16 pages, 10463 KiB  
Article
Microstructure Evolution, Mechanical Properties and Deformation Behavior of an Additively Manufactured Maraging Steel
by Kanwal Chadha, Yuan Tian, Philippe Bocher, John G. Spray and Clodualdo Aranas, Jr.
Materials 2020, 13(10), 2380; https://doi.org/10.3390/ma13102380 - 21 May 2020
Cited by 37 | Viewed by 3609
Abstract
In this work, the microstructure and mechanical properties of an additively manufactured X3NiCoMoTi18-9-5 maraging steel were determined. Optical and electron microscopies revealed the formation of melt pool boundaries and epitaxial grain growth with cellular dendritic structures after the laser powder bed fusion (LPBF) [...] Read more.
In this work, the microstructure and mechanical properties of an additively manufactured X3NiCoMoTi18-9-5 maraging steel were determined. Optical and electron microscopies revealed the formation of melt pool boundaries and epitaxial grain growth with cellular dendritic structures after the laser powder bed fusion (LPBF) process. The cooling rate is estimated to be around 106 °C/s during solidification, which eliminates the nucleation of any precipitates. However, it allows the formation of austenite with a volume fraction of about 5% and dendritic structures with primary arm spacing of 0.41 ± 0.23 µm. The electron backscatter diffraction analysis showed the formation of elongated grains with significant low-angle grain boundaries (LAGBs). Then, a solutionizing treatment was applied to the as-printed samples to dissolve all the secondary phases, followed by aging treatment. The reverted austenite was evident after heat treatment, which transformed into martensite after tensile testing. The critical plastic stresses for this transformation were determined using the double differentiation method. The tensile strength of the alloy increased from 1214 MPa to 2106 MPa after the aging process due to the formation of eta phase. The experimental data were complemented with thermodynamic and mechanical properties simulations, which showed a discrepancy of less than 3%. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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11 pages, 2605 KiB  
Article
Collaborative Optimization of Density and Surface Roughness of 316L Stainless Steel in Selective Laser Melting
by Yong Deng, Zhongfa Mao, Nan Yang, Xiaodong Niu and Xiangdong Lu
Materials 2020, 13(7), 1601; https://doi.org/10.3390/ma13071601 - 01 Apr 2020
Cited by 41 | Viewed by 2954
Abstract
Although the concept of additive manufacturing has been proposed for several decades, momentum in the area of selective laser melting (SLM) is finally starting to build. In SLM, density and surface roughness, as the important quality indexes of SLMed parts, are dependent on [...] Read more.
Although the concept of additive manufacturing has been proposed for several decades, momentum in the area of selective laser melting (SLM) is finally starting to build. In SLM, density and surface roughness, as the important quality indexes of SLMed parts, are dependent on the processing parameters. However, there are few studies on their collaborative optimization during SLM to obtain high relative density and low surface roughness simultaneously in the literature. In this work, the response surface method was adopted to study the influences of different processing parameters (laser power, scanning speed and hatch space) on density and surface roughness of 316L stainless steel parts fabricated by SLM. A statistical relationship model between processing parameters and manufacturing quality is established. A multi-objective collaborative optimization strategy considering both density and surface roughness is proposed. The experimental results show that the main effects of processing parameters on the density and surface roughness are similar. We observed that the laser power and scanning speed significantly affected the above objective quality, but the influence of the hatch spacing was comparatively low. Based on the above optimization, 316L stainless steel parts with excellent surface roughness and relative density can be obtained by SLM with optimized processing parameters. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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Review

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19 pages, 2694 KiB  
Review
Current Status and Prospects of Polymer Powder 3D Printing Technologies
by Yue Wang, Zhiyao Xu, Dingdi Wu and Jiaming Bai
Materials 2020, 13(10), 2406; https://doi.org/10.3390/ma13102406 - 23 May 2020
Cited by 74 | Viewed by 8042
Abstract
3D printing technology, which greatly simplifies the manufacturing of complex parts by a two-dimensional layer-upon-layer process, has flourished in recent years. As one of the most advanced technology, polymer powder 3D printing has many advantages such as high materials utilization rate, free of [...] Read more.
3D printing technology, which greatly simplifies the manufacturing of complex parts by a two-dimensional layer-upon-layer process, has flourished in recent years. As one of the most advanced technology, polymer powder 3D printing has many advantages such as high materials utilization rate, free of support structure, great design freedom, and large available materials, which has shown great potential and prospects in various industry applications. With the launch of the Multi jet Fusion system from HP, polymer powder 3D printing has been attracting more attention from industries and researchers. In this work, a comprehensive review of the main polymer powder-based 3D printing methods including binder jetting, selective laser sintering, high-speed sintering were carried out. Their forming mechanism, advantages and drawbacks, materials, and developments were presented, compared, and discussed respectively. In addition, this paper also gives suggestions on the process selection by comparing typical equipment parameters and features of each technology. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing)
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