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Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications

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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: closed (31 December 2021) | Viewed by 14285

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Prof. Dr. Aniello Riccio

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Department of Engineering, University of Campania Luigi Vanvitelli, Via Roma 29, 81031 Aversa (CE), Italy
Interests: composite materials; damage tolerance; delamination; fatigue; impact damage; crashworthiness; fuselages
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Special Issue Information

Dear Colleagues,

The proposed Special Issue (SI) publishes original research articles, review articles, and short communications regarding the design, production, and performance of metal, polymer, and hybrid structures and concepts, for engineering applications, achievable through additive manufacturing (AM) techniques.

Additive manufacturing is an innovative technique that allows the production of complex shaped and light components without compromising on mechanical performance. This technique, starting from a numerical CAD design phase (which must be considered as an integral part of the manufacturing process), can allow the production of structural components layer by layer or by filament deposition. Both metals and composites can be involved in this manufacturing process, allowing to tailor the compositions of specific alloys and specific composite systems. These characteristics suggest applications to a wide range of engineering problems where lightness, stiffness, and manufacturability are of main concern. The possibility to create hybrid metal/composite solutions, where possible, can amplify the benefits of metal and composite components, leading to a new class of hybrid structural components with a stunning integration capability with the surrounding structure.

However, although the use of additive manufacturing is becoming increasingly widespread, many challenges still need to be overcome to extend all the benefits of this technology to engineering applications. Composite-inherent failure mechanisms, superficial rugosity for metals, and production of large volumes are only a few examples of the main challenges related to the adoption of this new class of fascinating manufacturing techniques. The objective of this Special Issue is to address these challenges. The topics of interest include, but are not limited to:

Additive manufacturing for engineering applications;
Hybrid metal /composite structures;
Nanocharged composites for additive applications;
Short fiber composites for additive applications;
Lightweight structures;
Design for additive manufacturing;
Tailoring of metallic alloy composition by additive;
Tailoring processing parameters for additive manufactured components;
Numerical prediction of mechanical performances of additive manufactured components;
Numerical simulation of the additive manufacturing process;
Testing of additive manufactured components;
Nondestructive inspection (NDI) techniques applied to additive manufactured components.

Prof. Dr. Aniello Riccio
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

additive manufacturing
hybrid structures
short fiber composites
nanocharged composites
testing
NDI techniques

Published Papers (5 papers)

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Research

18 pages, 10562 KiB

Open AccessArticle

Flexural Behavior of Polyurethane Concrete Reinforced by Carbon Fiber Grid

by Hongjian Ding, Quansheng Sun, Yanqi Wang, Dongzhe Jia, Chunwei Li, Ce Ji and Yuping Feng

Materials 2021, 14(18), 5421; https://doi.org/10.3390/ma14185421 - 19 Sep 2021

Cited by 14 | Viewed by 2304

Abstract

In view of the problems of traditional repair materials for anchorage concrete of expansion joints, such as ease of damage and long maintenance cycles, the design of polyurethane concrete was optimized in this article, which could be used for rapid repair of concrete in anchorage zone of expansion joints. A new type of carbon fiber grid–polyurethane concrete system was designed, which makes the carbon fiber grid have an excellent synergistic effect with the quick-hardening and high-strength polyurethane concrete, and improved the flexural bearing capacity of the polyurethane concrete. Through the four-point bending test, the influence of the parameters such as the number of grid layers, grid width, and grid density on the flexural bearing capacity of polyurethane concrete beams was tested. The optimum preparation process parameters of carbon fiber grid were obtained to improve the flexural performance of polyurethane concrete. Compared with the Normal specimen, C-80-1’s average flexural strength increased by 47.7%, the failure strain along the beam height increased by 431.1%, and the failure strain at the bottom of the beam increased by 68.9%. The best width of the carbon fiber grid was 80 mm, and the best number of reinforcement layers was one layer. The test results show that the carbon fiber grid could improve the flexural bearing capacity of polyurethane concrete. The carbon fiber grid–polyurethane concrete system provides a new idea for rapid repair of the anchorage zone of bridge expansion joints, and solves the problems such as ease of damage and long maintenance cycles of traditional repair materials, which can be widely used in the future. Full article

(This article belongs to the Special Issue Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications)

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24 pages, 11139 KiB

Open AccessArticle

Computational Approaches of Quasi-Static Compression Loading of SS316L Lattice Structures Made by Selective Laser Melting

by Ondřej Červinek, Benjamin Werner, Daniel Koutný, Ondřej Vaverka, Libor Pantělejev and David Paloušek

Materials 2021, 14(9), 2462; https://doi.org/10.3390/ma14092462 - 10 May 2021

Cited by 16 | Viewed by 5209

Abstract

Additive manufacturing methods (AM) allow the production of complex-shaped lattice structures from a wide range of materials with enhanced mechanical properties, e.g., high strength to relative density ratio. These structures can be modified for various applications considering a transfer of a specific load or to absorb a precise amount of energy with the required deformation pattern. However, the structure design requires knowledge of the relationship between nonlinear material properties and lattice structure geometrical imperfections affected by manufacturing process parameters. A detailed analytical and numerical computational investigation must be done to better understand the behavior of lattice structures under mechanical loading. Different computational methods lead to different levels of result accuracy and reveal various deformational features. Therefore, this study focuses on a comparison of computational approaches using a quasi-static compression experiment of body-centered cubic (BCC) lattice structure manufactured of stainless steel 316L by selective laser melting technology. Models of geometry in numerical simulations are supplemented with geometrical imperfections that occur on the lattice structure’s surface during the manufacturing process. They are related to the change of lattice struts cross-section size and actual shape. Results of the models supplemented with geometrical imperfections improved the accuracy of the calculations compared to the nominal geometry. Full article

(This article belongs to the Special Issue Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications)

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16 pages, 7366 KiB

Open AccessEditor’s ChoiceArticle

Effect of Stirring Pin Rotation Speed on Microstructure and Mechanical Properties of 2A14-T4 Alloy T-Joints Produced by Stationary Shoulder Friction Stir Welding

by Haifeng Yang, Hongyun Zhao, Xinxin Xu, Li Zhou, Huihui Zhao and Huijie Liu

Materials 2021, 14(8), 1938; https://doi.org/10.3390/ma14081938 - 13 Apr 2021

Cited by 7 | Viewed by 1728

Abstract

In this study, 2A14-T4 Al-alloy T-joints were prepared via stationary shoulder friction stir welding (SSFSW) technology where the stirring pin’s rotation speed was set as different values. In combination with the numerical simulation results, the macro-forming, microstructure, and mechanical properties of the joints under different welding conditions were analyzed. The results show that the thermal cycle curves in the SSFSW process are featured by a steep climb and slow decreasing variation trends. As the stirring pin’s rotation speed increased, the grooves on the weld surface became more obvious. The base and rib plates exhibit W- or N-shaped hardness distribution patterns. The hardness of the weld nugget zone (WNZ) was high but was lower than that of the base material. The second weld’s annealing effect contributed to the precipitation and coarsening of the precipitated phase in the first weld nugget zone (WNZ1). The hardness of the heat affect zone (HAZ) in the vicinity of the thermo-mechanically affected zone (TMAZ) dropped to the minimum. As the stirring pin's rotation speed increased, the tensile strengths of the base and rib plates first increased and then dropped. The base and rib plates exhibited ductile and brittle/ductile fracture patterns, respectively. Full article

(This article belongs to the Special Issue Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications)

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13 pages, 22748 KiB

Open AccessArticle

Residual Stress Reduction Technology in Heterogeneous Metal Additive Manufacturing

by Myoung-Pyo Hong and Young-Suk Kim

Materials 2020, 13(23), 5516; https://doi.org/10.3390/ma13235516 - 03 Dec 2020

Cited by 5 | Viewed by 1643

Abstract

Metal additive manufacturing (AM) is a low-cost, high-efficiency functional mold manufacturing technology. However, when the functional section of the mold or part is not a partial area, and large-area additive processing of high-hardness metal is required, cracks occur frequently in AM and substrate materials owing to thermal stress and the accumulation of residual stresses. Hence, research on residual stress reduction technologies is required. In this study, we investigated the effect of reducing residual stress due to thermal deviation reduction using a real-time heating device as well as changes in laser power in the AM process for both high-hardness cold and hot work mold steel. The residual stress was measured using an X-ray stress diffraction device before and after AM. Compared to the AM processing conditions at room temperature (25 °C), residual stress decreased by 57% when the thermal deviation was reduced. The microstructures and mechanical properties of AM specimens manufactured under room-temperature and real-time preheating and heating conditions were analyzed using an optical microscope. Qualitative evaluation of the effect of reducing residual stress, which was quantitatively verified in a small specimen, confirmed that the residual stress decreased for a large-area curved specimen in which concentrated stress was generated during AM processing. Full article

(This article belongs to the Special Issue Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications)

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20 pages, 7024 KiB

Open AccessArticle

Estimation of the Adhesion Interface Performance in Aluminum-PLA Joints by Thermographic Monitoring of the Material Extrusion Process

by Stephan Bechtel, Mirko Meisberger, Samuel Klein, Tobias Heib, Steven Quirin and Hans-Georg Herrmann

Materials 2020, 13(15), 3371; https://doi.org/10.3390/ma13153371 - 29 Jul 2020

Cited by 9 | Viewed by 2577

Abstract

Using additive manufacturing to generate a polymer–metal structure offers the potential to achieve a complex customized polymer structure joined to a metal base of high stiffness and strength. A tool to evaluate the generated interface during the process is of fundamental interest, as the sequential deposition of the polymer as well as temperature gradients within the substrate lead to local variations in adhesion depending on the local processing conditions. On preheated aluminum substrates, 0.3 and 0.6 mm high traces of polylactic acid (PLA) were deposited. Based on differential scanning calorimetry (DSC) and rheometry measurements, the substrate temperature was varied in between 150 and 200 °C to identify an optimized manufacturing process. Decreasing the layer height and increasing the substrate temperature promoted wetting and improved the adhesion interface performance as measured in a single lap shear test (up to 7 MPa). Thermographic monitoring was conducted at an angle of 25° with respect to the substrate surface and allowed a thermal evaluation of the process at any position on the substrate. Based on the thermographic information acquired during the first second after extrusion and the preset shape of the polymer trace, the resulting wetting and shear strength were estimated. Full article

(This article belongs to the Special Issue Additive Manufactured Metals, Polymers and Hybrid Materials for Engineering Applications)

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