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Additive Manufacturing and Innovative Welding Technologies for Light Alloys

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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 May 2021) | Viewed by 12467

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Prof. Dr. Lucjan Śnieżek

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Faculty of Mechanical Engineering, Military University and Technology, 2 Kaliskiego Street, 00-908 Warsaw, Poland
Interests: fatigue strength; friction stir welding; additive manufacturing technologies
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Prof. Dr. Grzegorz Budzik

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Faculty of Mechanical Engineering and Aeronautic, Rzeszow University of Technology, Powstancow Warszawy 12, 35-959 Rzeszow, Poland
Interests: additively manufactured polymers; additive manufacturing; rapid prototyping; aeronautical gears
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Prof. Dr. Grzegorz Królczyk

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Department of Manufacturing Engineering and Production Automation, Faculty of Mechanical Engineering, Opole University of Technology, 5 Mikolajczyka Street, 45-271 Opole, Poland
Interests: surface metrology; optimization of difficult-to-cut materials; sensor technology; metrology; measurement uncertainty; environmental measurement; optimization of geometrical and physical parameters of surface integrity
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Special Issue Information

Dear Colleagues,

Advanced welding and additive manufacturing technologies are characterized by tremendous industrial and academic interest. One of the most important issues connected with the usage of the aforementioned technologies is their capacity of production of lightweight components with high geometrical complexity and very good mechanical properties in comparison with conventional processes. Technologies, which are the main topic of the issue, provide significantly higher design freedom, especially for single or low series production. All these advantages go hand in hand with optimal design theory, very often based on topological optimization. However, the mechanical performance of the elements obtained using innovative welding technologies or produced using additive manufacturing technologies has not been clarified yet.

The main scope of this Special Issue is to provide specialistic, scientific knowledge from all fields involving mainly mechanical properties and structural analysis. The issue is dedicated to a wide range of applications, including mechanical engineering, biomedical engineering, civil engineering, material science, manufacturing, nanotechnology, tribology, and others.

Prof. Lucjan Śnieżek
Prof. Grzegorz Budzik
Prof. Grzegorz Królczyk
Guest Editor

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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

Addictive manufacturing
Welding technologies
Light alloys
High geometrical complexity
Topological optimization

Published Papers (5 papers)

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Research

20 pages, 10371 KiB

Open AccessArticle

Corrosion Resistance Measurement of 316L Stainless Steel Manufactured by Selective Laser Melting

by Rigoberto Guzmán-Nogales, Francisco Estupiñán-López, Citlalli Gaona-Tiburcio, Omar E. Lopez-Botello, Juan G. Ramírez-Rodríguez and Patricia C. Zambrano-Robledo

Materials 2021, 14(16), 4509; https://doi.org/10.3390/ma14164509 - 11 Aug 2021

Cited by 6 | Viewed by 1821

Abstract

Selective laser melting (SLM) technology is ushering in a new era of advanced industrial production of metal components. It is of great importance to understand the relationship between the surface features and electrochemical properties of manufactured parts. This work studied the influence of surface orientation on the corrosion resistance of 316L stainless-steel (SS) components manufactured with SLM. The corrosion resistance of the samples was measured using linear polarization resistance (LPR) and electromechanical noise (EN) techniques under three different environments, H₂O, 3.5 wt.% NaCl, and 20% H₂SO₄, analyzing the horizontal (XY) and vertical (XZ) planes. The microstructure and morphology of the samples were obtained by optical (OM) and scanning electron microscopy (SEM). The obtained microstructure showed the grains growing up from the fusion line to the melt pool center and, via SEM-EDS, the presence of irregular and spherical pores was observed. The highest corrosion rate was identified in the H₂SO₄ solution in the XZ plane with 2.4 × 10⁻² mm/year and the XY plane with 1.31 × 10⁻³ mm/year. The EN technique along with the skewness factor were used to determine the type of corrosion that the material developed. Localized corrosion was observed in the NaCl electrolyte, for the XY and XZ planes (−1.65 and −0.012 skewness factors, respectively), attacking mainly the subgrains of the microstructure and, in some cases, the pores, caused by Cl ions. H₂O and H₂SO₄ solutions presented a uniform corrosion mechanism for the two observed orientations. The morphology identified by SEM was correlated with the results obtained from the electrochemical techniques. Full article

(This article belongs to the Special Issue Additive Manufacturing and Innovative Welding Technologies for Light Alloys)

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16 pages, 5717 KiB

Open AccessArticle

Mechanical Properties Analysis of the AA2519-AA1050-Ti6Al4V Explosive Welded Laminate

by Ireneusz Szachogluchowicz, Lucjan Sniezek, Tomasz Slezak, Janusz Kluczyński, Krzysztof Grzelak, Janusz Torzewski and Teresa Fras

Materials 2020, 13(19), 4348; https://doi.org/10.3390/ma13194348 - 30 Sep 2020

Cited by 7 | Viewed by 1825

Abstract

Explosively welded layered materials made of (a) an AA2519 aluminum alloy (AlCuMgMn + ZrSc), (b) titanium alloy Ti6Al4V and (c) an intermediate layer composed of a thin aluminum alloyed AA1050 layer are considered herein. This study presents test results connected to measurement science including microstructural observations of the material combined with the explosive method, and a basic analysis of the strength properties based on microhardness and tensile tests. Owing to the joint’s special manufacturing conditions, the laminate was subjected to deformation measurements with the digital image correlation (DIC) method. The research was supplemented by the residual stress measurements with the sin2ψ X-ray method based on the diffraction–reflection analysis that was verified by the bore trepanation method. Full article

(This article belongs to the Special Issue Additive Manufacturing and Innovative Welding Technologies for Light Alloys)

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16 pages, 22457 KiB

Open AccessArticle

Comparison of Different Heat Treatment Processes of Selective Laser Melted 316L Steel Based on Analysis of Mechanical Properties

by Janusz Kluczyński, Lucjan Śnieżek, Krzysztof Grzelak, Artur Oziębło, Krzysztof Perkowski, Janusz Torzewski, Ireneusz Szachogłuchowicz, Krzysztof Gocman, Marcin Wachowski and Bogusz Kania

Materials 2020, 13(17), 3805; https://doi.org/10.3390/ma13173805 - 28 Aug 2020

Cited by 16 | Viewed by 2286

Abstract

In this study, we analyzed the mechanical properties of selectively laser melted (SLM) steel obtained via different modifications during and after the manufacturing process. The aim was to determine the effects of precipitation heat treatment on the mechanical properties of elements additively manufactured using three different process parameters. Some samples were additionally obtained using hot isostatic pressing (HIP), while some were treated using two different types of heat treatment and a combination of those two processes. From each manufactured sample, a part of the material was taken for structural analysis including residual stress analysis and microstructural investigations. In the second part of the research, the mechanical properties were studied to define the scleronomic hardness of the samples. Finally, tensile tests were conducted using a digital image correlation (DIC) test and fracture analysis. The treated samples were found to be significantly elongated, thus indicating the advantages of using precipitation heat treatment. Additionally, precipitation heat treatment was found to increase the porosity of samples, which was the opposite compared to HIP-treated samples. Full article

(This article belongs to the Special Issue Additive Manufacturing and Innovative Welding Technologies for Light Alloys)

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14 pages, 15212 KiB

Open AccessArticle

Crack Growth Behavior of Additively Manufactured 316L Steel—Influence of Build Orientation and Heat Treatment

by Janusz Kluczyński, Lucjan Śnieżek, Krzysztof Grzelak, Janusz Torzewski, Ireneusz Szachogłuchowicz, Marcin Wachowski and Jakub Łuszczek

Materials 2020, 13(15), 3259; https://doi.org/10.3390/ma13153259 - 22 Jul 2020

Cited by 21 | Viewed by 2728

Abstract

The effects of build orientation and heat treatment on the crack growth behavior of 316L stainless steel (SS) fabricated via a selective laser melting additive manufacturing process were investigated. Available research results on additively manufactured metallic parts still require a substantial expansion. The most important issue connected with the metal properties after additive manufacturing are the high anisotropy properties, especially from the fatigue point of view. The study examined the crack growth behavior of additively manufactured 316L in comparison to a conventionally made reference material. Both groups of samples were obtained using precipitation heat treatment. Different build orientations in the additively manufactured samples and rolling direction in the reference samples were taken into account as well. Precipitation heat treatment of additively manufactured parts allowed one to achieve microstructure and tensile properties to similar to those of conventionally made pieces. The heat treatment positively affected the fatigue properties. Additionally, precipitation heat treatment of additively manufactured elements significantly affected the reduction of fatigue cracking velocity and changed the fatigue cracking mechanism. Full article

(This article belongs to the Special Issue Additive Manufacturing and Innovative Welding Technologies for Light Alloys)

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14 pages, 6985 KiB

Open AccessArticle

Microstructure and Low Cycle Fatigue Properties of AA5083 H111 Friction Stir Welded Joint

by Janusz Torzewski, Krzysztof Grzelak, Marcin Wachowski and Robert Kosturek

Materials 2020, 13(10), 2381; https://doi.org/10.3390/ma13102381 - 21 May 2020

Cited by 28 | Viewed by 2905

Abstract

The present paper aims to analyze the microstructure, microhardness, tensile properties, and low cycle fatigue (LCF) behavior of friction stir welded (FSW) butt joints. The material used in this study was the 5 mm thick 5083 H111 aluminum alloy sheet. Butt joints of AA 5083 H111 were manufactured at different operating parameters of the FSW process. The effect of the welding parameters on microstructure, microhardness, and tensile properties was investigated. Based on microstructure analysis and strength tests, the most favorable parameters of the FSW process were settled on the point of view of weld quality. Then, LCF tests of base material and friction stir welded specimens made of 5083 H111 were carried out for the examined welded samples under selected friction stir welding parameters. The process of low-cycle fatigue of 5083 H111 aluminum alloy was characterized by cyclic hardening for both: base material and FSW joint. It was revealed by a decrease in the width of the hysteresis loop with the simultaneous significant increase in the values of the range of stress. It was determined that fatigue cracks are initiated by cyclic slip deformation due to local stress concentration from the surface in the corner of the samples for the base material and the heat-affected zone for FSW joints. For all tested strain amplitudes, the fatigue crack propagation region is characterized by the presence of fatigue striation with secondary cracks. Full article

(This article belongs to the Special Issue Additive Manufacturing and Innovative Welding Technologies for Light Alloys)

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