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Advanced Technology for Materials Synthesis and Processing - Series II

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

Deadline for manuscript submissions: closed (10 December 2022) | Viewed by 7471

Special Issue Editor


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Guest Editor
Mechanical and Manufacturing Engineering, Dublin City University, Dublin, Ireland
Interests: laser processing; material processing; material functionalisation; nanostructured materials; rapid prototyping; chromatography
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue of Materials is focused on recent developments in the area of additive manufacturing (AM) processing methods, materials, and related implementation. AM production technologies have developed significantly in recent years. We have seen the development and implementation of new metals, polymers, and ceramics; multi-material printing; shape memory alloys; nano and multi-scale material design; composites; and metamaterials. Relevant production technologies for this Special Issue are those for metals, polymers, and ceramics, and include PBF, DED, ink jetting, STL, SLS, and FDM. The sustainability of AM has been noted as an advantage of this production method compared to alternative conventional production methods and assembly technologies, yet this remains an under-examined area and while correct in the case of some part designs, it is not correct for all part designs. It is important to control the AM pre-processing and post-processing steps. New breakthroughs for better in-situ monitoring and control of AM is an ever-pressing issue in order to improve part quality while maintaining part production rates. Papers are encouraged in these areas and also invited more broadly from the rapidly developing areas of advanced materials synthesis and processing.

Prof. Dr. Dermot Brabazon
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
  • 3D printing
  • rapid prototyping
  • solid freeform fabrication
  • composites
  • shape memory alloys
  • nano and multiscale material design
  • multi-material printing

Published Papers (3 papers)

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Research

17 pages, 10100 KiB  
Article
Processing and Properties of Tungsten-Steel Composites and FGMs Prepared by Spark Plasma Sintering
by Jiří Matějíček, Radek Mušálek, Zdeněk Dlabáček, Veronika Klevarová and Lenka Kocmanová
Materials 2022, 15(24), 9037; https://doi.org/10.3390/ma15249037 - 17 Dec 2022
Cited by 2 | Viewed by 1476
Abstract
Tungsten is the prime candidate material for the plasma-facing components of fusion reactors. For the joining of tungsten armor to the cooling system or support structure, composites or graded interlayers can be used to reduce the stress concentration at the interface. These interlayers [...] Read more.
Tungsten is the prime candidate material for the plasma-facing components of fusion reactors. For the joining of tungsten armor to the cooling system or support structure, composites or graded interlayers can be used to reduce the stress concentration at the interface. These interlayers can be produced by several technologies. Among these, spark plasma sintering appears advantageous because of its ability to fabricate fully dense parts at lower temperatures and in a shorter time than traditional powder metallurgy techniques, thanks to the concurrent application of temperature, pressure, and electrical current. In this work, spark plasma sintering of tungsten-steel composites and functionally graded layers (FGMs) was investigated. As a first step, pure tungsten and steel powders of different sizes were sintered at a range of temperatures to find a suitable temperature window for fully dense compacts. Characterization of the sintered compacts included structure (by SEM); porosity (by the Archimedean method and image analysis); thermal diffusivity (by the flash method) and mechanical properties (microhardness and flexural strength). Compacts with practically full density and fine grains were obtained; while the temperature needed to achieve full sintering decreased with decreasing powder size (down to about 1500 °C for the 0.4 μm powder). For fully sintered compacts, the hardness and thermal diffusivity increased with decreasing powder size. Composites with selected tungsten/steel ratios were produced at several conditions and characterized. At temperatures of 1100 °C or above, intermetallic formation was observed in the composites; nevertheless, without a detrimental effect on the mechanical strength. Finally, the formation of graded layers and tungsten-steel joints in various configurations was demonstrated. Full article
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10 pages, 2146 KiB  
Article
Residual Stresses Measurements in Laser Powder Bed Fusion Using Barkhausen Noise Analysis
by Alexandre Staub, Muriel Scherer, Pascal Zehnder, Adriaan Bernardus Spierings and Konrad Wegener
Materials 2022, 15(7), 2676; https://doi.org/10.3390/ma15072676 - 05 Apr 2022
Cited by 5 | Viewed by 2177
Abstract
In recent years, the advancement of technology brought the laser powder bed fusion process to its industrialisation step. Despite all the advancements in process repeatability and general quality control, many challenges remain unsolved due to the intrinsic difficulties of the process, notably the [...] Read more.
In recent years, the advancement of technology brought the laser powder bed fusion process to its industrialisation step. Despite all the advancements in process repeatability and general quality control, many challenges remain unsolved due to the intrinsic difficulties of the process, notably the residual stresses issue. This work aimed to assess the usability of Barkhausen noise analysis (BNA) for the residual stress in situ monitoring of laser powder bed fusion on Maraging steel 300 (18Ni-300/1.2709). After measuring the evolution of grain size distribution over process parameter changes, two series of experiments were designed. First, a setup with an external force allows to validate the working principle of BNA on the chosen material processed using LPBF. The second experiment uses on-plates samples with different residual stress states. The results show a good stability in microstructure, a prerequisite for BNA. In addition, the external load setup acknowledges that signal variation correlates with the induced stress state. Finally, the on-plate measurement shows a similar signal variation to what has been observed in the literature for residual stress variation. It is shown that BNA is a suitable method for qualitative residual stresses variation monitoring developed during the LPBF process and underlines that BNA is a promising candidate as an in situ measurement method. Full article
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19 pages, 10016 KiB  
Article
316L Stainless Steel Powders for Additive Manufacturing: Relationships of Powder Rheology, Size, Size Distribution to Part Properties
by Robert Groarke, Cyril Danilenkoff, Sara Karam, Eanna McCarthy, Bastien Michel, Andre Mussatto, John Sloane, Aidan O’ Neill, Ramesh Raghavendra and Dermot Brabazon
Materials 2020, 13(23), 5537; https://doi.org/10.3390/ma13235537 - 04 Dec 2020
Cited by 19 | Viewed by 3143
Abstract
Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powders produced using the gas atomization process [...] Read more.
Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powders produced using the gas atomization process is presented. In particular, the effects of the powder properties (particle size and shape) on the powder rheology were examined. The results presented suggest that the powder properties strongly influence the powder rheology and are important factors in the selection of suitable powder for use in an additive manufacturing (AM) process. Both of the powders exhibited a strong correlation between the particle size and shape parameters and the powder rheology. Optical microscope images of melt pools of parts printed using the powders in an L-PBF machine are presented, which demonstrated further the significance of the powder morphology parameters on resulting part microstructures. Full article
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