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Metals
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Laser Processing and Additive Manufacturing of Metallic Materials
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Laser Processing and Additive Manufacturing of Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (29 February 2024) | Viewed by 5294

Special Issue Editors

Dr. Xin Chen

E-Mail Website
Guest Editor
Welding Engineering and Laser Processing Centre, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield MK43 0AL, UK
Interests: welding; additive manufacturing; laser processing; magnetically assisted welding; multiphysics modelling; numerical simulation; heat transfer and fluid flow; monitoring and control
Special Issues, Collections and Topics in MDPI journals
Dr. Tao Zhang

E-Mail Website
Guest Editor
Light Alloy Research Institute, Central South University, Changsha 410083, China
Interests: additive manufacturing; hybrid additive manufacturing and forming process; residual stress; materials science
Dr. Yongle Sun

E-Mail Website
Guest Editor
Welding Engineering and Laser Processing Centre, School of Aerospace, Manufacturing and Transport, Cranfield University, Cranfield MK43 0AL, UK
Interests: additive manufacturing; welding; coatings; cellular materials; applied mechanics; metals processing technology; multi-physics modelling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Laser processing and additive manufacturing are revolutionary techniques for the advanced manufacturing of a broad range of materials, especially metallic materials used in structural applications. Because of their significant advantages of high efficiency, high quality, automation and customization, laser processing and additive manufacturing have been widely applied in many industrial sectors, such as aerospace, energy, transport, and healthcare. However, the requirements of manufacturing technology in the industry are constantly evolving and becoming increasingly complicated and stringent. Undoubtedly, further research needs to be conducted for a better understanding of process physics, optimizing processes, and novel process development and applications. Therefore, this Special Issue aims to provide a platform for appreciating state-of-the-art advances, inspiring and promoting the new development and applications of laser processing and the additive manufacturing of metallic materials. Both original and review research papers are welcomed from scientists, researchers, engineers and all experts in this field. Topics include but are not limited to the following areas:

  • Laser welding;
  • Laser cladding;
  • Laser cutting;
  • Laser-arc hybrid welding and additive manufacturing;
  • Laser-based additive manufacturing;
  • Wire arc additive manufacturing (WAAM);
  • Electron beam-based additive manufacturing;
  • Modelling and simulation of laser processing and additive manufacturing;
  • AI and machine learning for laser processing and additive manufacturing;
  • Monitoring and control of laser processing and additive manufacturing;
  • Quality inspection of laser processing and additive manufacturing;
  • Micro and nano laser welding and additive manufacturing.

Dr. Xin Chen
Dr. Tao Zhang
Dr. Yongle Sun
Guest Editors

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. Metals is an international peer-reviewed open access monthly 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

  • laser processing
  • additive manufacturing
  • metallic materials
  • welding, cladding and cutting
  • WAAM
  • electron beam
  • modelling and simulation
  • AI and machine learning
  • monitoring and control
  • quality inspection
  • micro and nano processing.

Published Papers (5 papers)

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Research

26 pages, 32433 KiB  
Article
Benchmarking L-PBF Systems for Die Production: Powder, Dimensional, Surface, Microstructural and Mechanical Characterisation
by Jose Manuel Costa, Elsa Wellenkamp Sequeiros, Ruben Filipe Santos and Manuel Fernando Vieira
Metals 2024, 14(5), 520; https://doi.org/10.3390/met14050520 - 29 Apr 2024
Viewed by 466
Abstract
While conventional die manufacturing techniques often lead to limitations in production speed and design intricacy due to labour-intensive procedures like machining and casting, Additive Manufacturing (AM) emerges as a key player offering substantial potential for cost reduction and process improvement in mass production. [...] Read more.
While conventional die manufacturing techniques often lead to limitations in production speed and design intricacy due to labour-intensive procedures like machining and casting, Additive Manufacturing (AM) emerges as a key player offering substantial potential for cost reduction and process improvement in mass production. This study benchmarks four leading Laser Powder Bed Fusion (L-PBF) systems for producing maraging steel (EN 1.2709) dies. Despite the shared material and technology, variations in dimensional accuracy, surface finish, and microstructure were observed among the maraging steel parts. SEM/EDS, EBSD, hardness testing, and dimensional analysis revealed system-specific performance differences. Additionally, select parts underwent heat treatment and tensile testing, demonstrating the impact of post-processing on mechanical properties. These results offer valuable guidance for industrial stakeholders considering AM, highlighting the importance of supplier selection and process optimisation for achieving consistent part quality and unlocking the full potential of AM technologies. Full article
(This article belongs to the Special Issue Laser Processing and Additive Manufacturing of Metallic Materials)
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19 pages, 3393 KiB  
Article
Genetic Algorithm-Based Framework for Optimization of Laser Beam Path in Additive Manufacturing
by Primož Potočnik, Andrej Jeromen and Edvard Govekar
Metals 2024, 14(4), 410; https://doi.org/10.3390/met14040410 - 29 Mar 2024
Viewed by 631
Abstract
In this study, a genetic algorithm-based laser beam (LB) path optimization method is presented to improve laser-based additive manufacturing (LBAM). To emulate the LBAM process, LB irradiation of a thin metal substrate is applied. The LB path generation is formulated as the search [...] Read more.
In this study, a genetic algorithm-based laser beam (LB) path optimization method is presented to improve laser-based additive manufacturing (LBAM). To emulate the LBAM process, LB irradiation of a thin metal substrate is applied. The LB path generation is formulated as the search for the optimal sequence of LB irradiation into the cells on the substrate that minimizes the fitness function, which is composed of two components, i.e., thermal fitness and process fitness. The thermal fitness is expressed by the average thermal gradient, and a simple thermal model is developed to simulate the effects of laser-induced heat input on the temperature distribution in the substrate. The process fitness regulates the suitability of the proposed LB path for the implementation of the LBAM process. In addition to standardized tool paths (i.e., raster, spiral, etc.), novel LB path generators are proposed to define the initial population of LB path solutions. To implement a genetic algorithm-based LB path optimization, a framework is proposed, and custom initialization, crossover, and mutation operators are developed for application in LBAM. The effectiveness of the proposed approach is demonstrated through a simulation case study aiming to identify LB paths that minimize the fitness function and thus provide more suitable LB path solutions with respect to the defined fitness function. Compared with the traditional trial-and-error LB path formulations, the proposed approach provides an improved and automated method for an efficient laser beam path selection in LBAM. Full article
(This article belongs to the Special Issue Laser Processing and Additive Manufacturing of Metallic Materials)
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14 pages, 16845 KiB  
Article
Effects of Contaminations on Electric Arc Behavior and Occurrence of Defects in Wire Arc Additive Manufacturing of 316L-Si Stainless Steel
by Joyce Ingrid Venceslau de Souto, Jefferson Segundo de Lima, Walman Benício de Castro, Renato Alexandre Costa de Santana, Antonio Almeida Silva, Tiago Felipe de Abreu Santos and João Manuel R. S. Tavares
Metals 2024, 14(3), 286; https://doi.org/10.3390/met14030286 - 29 Feb 2024
Viewed by 946
Abstract
Additive Manufacturing is a manufacturing process that consists of obtaining a three-dimensional object from the deposition of material layer by layer, unlike conventional subtractive manufacturing methods. Wire Arc Additive Manufacturing stands out for its high productivity among the Additive Manufacturing technologies for manufacturing [...] Read more.
Additive Manufacturing is a manufacturing process that consists of obtaining a three-dimensional object from the deposition of material layer by layer, unlike conventional subtractive manufacturing methods. Wire Arc Additive Manufacturing stands out for its high productivity among the Additive Manufacturing technologies for manufacturing metal parts. On the other hand, the excessive heat input promotes increased residual stress levels and the occurrence of defects, such as pores, voids, a lack of fusion, and delamination. These defects result in abnormalities during the process, such as disturbances in electrical responses. Therefore, process monitoring and the detection of defects and failures in manufactured items are of fundamental importance to ensure product quality and certify the high productivity characteristic of this process. Thus, this work aimed to characterize the effects of different contaminations on the electric arc behavior of the Wire Arc Additive Manufacturing process and the occurrence of microscopic defects in thin walls manufactured by this process. To investigate the presence of defects in the metal preforms, experimental conditions were used to promote the appearance of defects, such as the insertion of contaminants. To accomplish the electric arc behavior analysis, voltage and current temporal data were represented through histograms and cyclograms, and the arc stability was assessed based on the Vilarinho index for a short circuit. Effectively, the introduction of contaminants caused electric arc disturbances that led to the appearance of manufacturing defects, such as inclusions and porosities, observed through metallographic characterization. The results confirm that the introduction of contaminations could be identified early in the Wire Arc Additive Manufacturing process through electric arc data analysis. Full article
(This article belongs to the Special Issue Laser Processing and Additive Manufacturing of Metallic Materials)
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17 pages, 9418 KiB  
Article
Study on Residual Stresses of 2219 Aluminum Alloy with TIG Welding and Its Reduction by Shot Peening
by Tao Zhang, Junwen Chen, Hai Gong and Huigui Li
Metals 2023, 13(9), 1581; https://doi.org/10.3390/met13091581 - 11 Sep 2023
Cited by 1 | Viewed by 768
Abstract
Large residual stress of 2219 aluminum alloy induced by Tungsten Inert Gas (TIG) welding decreases its service performances. Shot peening was adopted to decrease the residual stress of TIG welding. Numerical models of TIG welding and shot peening were established using the combined [...] Read more.
Large residual stress of 2219 aluminum alloy induced by Tungsten Inert Gas (TIG) welding decreases its service performances. Shot peening was adopted to decrease the residual stress of TIG welding. Numerical models of TIG welding and shot peening were established using the combined discrete and finite element methods (DEM–FEM). The results show that TIG welding induces tensile residual stress due to the heat exchange effect and the longitudinal stress is larger than that in the transverse direction. The maximum tensile stress occurs at a depth of 0.1 mm. The surface tensile stress changes to compressive stress after shot peening as the severe deformation induced by the shots changes the stress state of the plate. The maximum value of compressive stress (σm) and the peened depth with compressive stress (Z0) are adopted to describe the peening effect. The absolute value of σm increases with the increased peening speed and nozzle height. Mixed shots with a diameter of 0.8 mm and 1.2 mm induce larger value of σm than those with only a diameter of 1.2 mm. The value of Z0 increases with the ascending shots diameter and nozzle height, while it varies nonmonotonically with the peening speed. The effect of shot peening on the residual stress in TIG welding is discussed. Full article
(This article belongs to the Special Issue Laser Processing and Additive Manufacturing of Metallic Materials)
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11 pages, 2145 KiB  
Article
Dislocation Density of Electron Beam Powder Bed Fusion Ti–6Al–4V Alloys Determined via Time-Of-Flight Neutron Diffraction Line-Profile Analysis
by Kenta Yamanaka, Manami Mori, Yusuke Onuki, Shigeo Sato and Akihiko Chiba
Metals 2023, 13(1), 86; https://doi.org/10.3390/met13010086 - 30 Dec 2022
Cited by 2 | Viewed by 1921
Abstract
Ti–6Al–4V alloys undergo a multiple phase transformation sequence during electron beam powder bed fusion (EB-PBF) additive manufacturing, forming unique dislocation substructures. Thus, determining the dislocation density is crucial for comprehensively understanding the strengthening mechanisms and deformation behavior. This study performed time-of-flight neutron diffraction [...] Read more.
Ti–6Al–4V alloys undergo a multiple phase transformation sequence during electron beam powder bed fusion (EB-PBF) additive manufacturing, forming unique dislocation substructures. Thus, determining the dislocation density is crucial for comprehensively understanding the strengthening mechanisms and deformation behavior. This study performed time-of-flight neutron diffraction (TOF-ND) measurements of Ti–6Al–4V alloys prepared via EB-PBF and examined the dislocation density in the as-built and post-processed states using convolutional multiple whole profile (CMWP) fitting. The present TOF-ND/CMWP approach successfully determined the bulk-averaged dislocation density (6.8 × 1013 m−2) in the as-built state for the α-matrix, suggesting a non-negligible contribution of dislocation hardening. The obtained dislocation density values were comparable to those obtained by conventional and synchrotron X-ray diffraction (XRD) measurements, confirming the reliability of the analysis, and indicating that the dislocations in the α-matrix were homogeneously distributed throughout the as-built specimen. However, the negative and positive neutron scattering lengths of Ti and Al, respectively, lowered the diffraction intensity for the Ti–6Al–4V alloys, thereby decreasing the lower limit of the measurable dislocation density and making the analysis difficult. Full article
(This article belongs to the Special Issue Laser Processing and Additive Manufacturing of Metallic Materials)
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