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3D Printing Technology with Metal Materials
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3D Printing Technology with Metal Materials

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

Deadline for manuscript submissions: 20 September 2024 | Viewed by 5315

Special Issue Editors

Prof. Dr. Piotr Kurylo

E-Mail Website
Guest Editor
Professor DSC PhD Eng., Department of Mechanical Engineering and Safety, University of Zielona Gora, 65-417 Zielona Góra, Poland
Interests: 3D printing; constructions materials; surface layer; production technology; accuracy of details; titanium; medical materials
Prof. Dr. Radovan Hudák

E-Mail Website
Guest Editor
Head of Laboratory of Additive Technologies in Medicine, Department of Biomedical Engineering and Measurement, Faculty of Mechanical Engineering, Technical University of Kosice, Košice, Slovakia
Interests: biomedical engineering; biomaterials; scaffold; bioinspired engineering and biomimetic design; biomaterial science; additive technologies in medicine
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The modern state of technology allows for the manufacturing products and devices, thanks to which automatization and also simplification of the whole manufacturing process is possible. The current development of 3D printing technology brings with it possibilities of very fast prototyping of intricate constructions as well as those constructions which previously were considered as impossible to produce using earlier technologies. Thus, 3D printing technology enables us to start to produce details in piece or small-lot production with a very high accuracy. Instead of a production line, multiple materials for the processing of non-standard dimensions, and a large amount of post-processing waste, in 3D printing technology it is possible to use one printing device—a printer and material in the form of metal powder.

Thanks to 3D printing technology, it is possible to manufacture almost any element. It is possible to print a prototype of a new construction in a very short time. The only limitation is the printing technology, i.e., the volume of the printing workspace and the type of material with which the product is printed (properties, granulation, price).

The 3D printing technology allows us to optimize the construction in terms of mass reduction while maintaining the strength of the printed products, which is required by the constructor.

Software supporting CAD design combined with the possibilities of 3D printing allow the optimization of filling details as well as optimizing their mass while maintaining the criterion of their mechanical strength. For example, the technology of Selective Laser Melting (SLM) allows us to produce precise and homogeneous elements from metal powders. During the SLM printing, metal parts are created based on computer spatial data from CAD applications in a layered, incremental manufacturing process. Generally, there are no limits in the design, and 3D printing ensures high speed and high accuracy.

This Special Issue is an invitation to submit original articles on the following topics:

  • Printing parameters.
  • Accuracy of shape and dimensions of printed products.
  • Application of 3D printing in medicine/industry.
  • 3D printing in scientific research.
  • Hazards in 3D printing.
  • Heat treatment after 3D printing.
  • Design for 3D printing, DfAM (Design for Additive Manufacturing).
  • Low-emission 3D printing technology.
  • Prototyping with the use of 3D printing.
  • Optimization of mass and mechanical strength.
  • Tribological research.
  • Economics of using 3D printing technology.
  • Metal powders and their properties.
  • Postprocessing.
  • Design and optimization of cellular and frame structures printed in 3d technology.
  • Data formats for 3D printing.
  • Surface layer in products printed in 3D technology.

Prof. Dr. Piotr Kurylo
Prof. Dr. Radovan Hudák
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. 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

  • 3D printing
  • construction materials
  • prototyping for 3D printing
  • printing technology
  • powder metallic materials
  • printing parameters
  • properties of printing materials
  • mechanical technological and chemical properties of printed details
  • standardization in 3D printing
  • hazards of 3D metal printing

Published Papers (5 papers)

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Research

17 pages, 6895 KiB  
Article
Effect of Spatter Behavior on Mechanical Properties and Surface Roughness of Printed Parts during PBF-LM of 316L
by Xiaoxuan Chen, Jialei Song, Wei Zhang, Xin Shang, Yizhe Li, Shenggui Chen, Jiahao Lin and Zirong Zhou
Materials 2024, 17(4), 860; https://doi.org/10.3390/ma17040860 - 12 Feb 2024
Viewed by 639
Abstract
The spatter generated by the interaction between laser and powder during Powder Bed Fusion-Laser Melting (PBF-LM) can significantly affect the quality of printed parts. A high-speed camera is used to observe the dynamic process of spatter’s behavior under different layer thickness and laser [...] Read more.
The spatter generated by the interaction between laser and powder during Powder Bed Fusion-Laser Melting (PBF-LM) can significantly affect the quality of printed parts. A high-speed camera is used to observe the dynamic process of spatter’s behavior under different layer thickness and laser powers during the printing process, and to analyze the printed samples’ surface roughness, microstructure, and mechanical properties. In terms of spatter image processing, employing an optical flow approach to track and quantify the number of spatters efficiently eliminates statistical redundancy and improves statistical correctness. It is found that under the same laser power, the number of spatters produced by the laser scan direction with the gas flow (LSD-W) is more than that by the laser scan direction against the gas flow (LSD-A), and the number of spatters produced increases with the increase of laser power. Analyzing the mechanical properties and surface roughness of the printed samples under different process parameters quantitatively reveals that differences in the spatter amount generated under different process parameters in the PBF-LM process is not the determining factor affecting the difference in tensile strength of printed parts. During LSD-W, the number of spatters generated at laser power of 170 W and layer thickness of 0.03 mm is 87, and the tensile strength of the printed sample is 618 MPa. During LSD-W, the number of spatters generated at laser power of 320 W and layer thickness of 0.05 mm is 211, and the tensile strength of the printed sample is 680 MPa. Instead, spatter generation has a more direct impact on the surface roughness of printed parts. The layer thickness is 0.03 mm, the laser power is 170 W, and (Ra = 2.372 μm) is the surface roughness of the sample. The layer thickness is 0.05 mm, the laser power is 320 W, and (Ra = 8.163 μm) is the surface roughness of the sample. Full article
(This article belongs to the Special Issue 3D Printing Technology with Metal Materials)
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16 pages, 3881 KiB  
Article
Precision Control in Vat Photopolymerization Based on Pure Copper Paste: Process Parameters and Optimization Strategies
by Weiqu Wang, Mengzhao Feng, Zhiwei Wang, Yanlin Jiang, Bohang Xing and Zhe Zhao
Materials 2023, 16(16), 5565; https://doi.org/10.3390/ma16165565 - 10 Aug 2023
Cited by 2 | Viewed by 823
Abstract
Vat photopolymerization (VPP) presents new opportunities for metals to achieve the design freedom of components. However, the material properties of copper powder and the inherent defects of the technology seriously hinder its application in high-precision metal additive manufacturing. Precision control is the key [...] Read more.
Vat photopolymerization (VPP) presents new opportunities for metals to achieve the design freedom of components. However, the material properties of copper powder and the inherent defects of the technology seriously hinder its application in high-precision metal additive manufacturing. Precision control is the key to obtaining minimal precision metal parts when copper is prepared by reduction photopolymerization. This paper employed variance analysis (ANOVA) and root mean square deviation (RMSD) to determine the significant parameters affecting dimensional accuracy and their optimal regions. The results show that printing accuracy is improved by optimizing exposure time, intensity, layer thickness, and sweeper moving speed. When the exposure time is 21 s, and the exposure intensity is 220 mW/cm2, a hole with a height of 1 mm and a diameter of 200 μm can be printed with a minimum size deviation of 51 μm. In addition, RMSD and ANOVA provide an effective method for realizing high-precision stereolithography 3D printing metal copper, expanding the material adaptation in the 3D printing metals field. The study highlights the potential of VPP as a method for preparing metals in future studies. Full article
(This article belongs to the Special Issue 3D Printing Technology with Metal Materials)
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15 pages, 7703 KiB  
Article
A Comparative Investigation of Properties of Metallic Parts Additively Manufactured through MEX and PBF-LB/M Technologies
by Janusz Kluczyński, Katarzyna Jasik, Jakub Łuszczek, Bartłomiej Sarzyński, Krzysztof Grzelak, Tomáš Dražan, Zdeněk Joska, Ireneusz Szachogłuchowicz, Paweł Płatek and Marcin Małek
Materials 2023, 16(14), 5200; https://doi.org/10.3390/ma16145200 - 24 Jul 2023
Cited by 3 | Viewed by 835
Abstract
In this study, the research on 316L steel manufactured additively using two commercially available techniques, Material Extrusion (MEX) and Laser Powder Bed Fusion of Metals (PBF-LB/M), were compared. The additive manufacturing (AM) process based on powder bed synthesis is of great interest in [...] Read more.
In this study, the research on 316L steel manufactured additively using two commercially available techniques, Material Extrusion (MEX) and Laser Powder Bed Fusion of Metals (PBF-LB/M), were compared. The additive manufacturing (AM) process based on powder bed synthesis is of great interest in the production of metal parts. One of the most interesting alternatives to PBF-LB/M, are techniques based on material extrusion due to the significant initial cost reduction. Therefore, the paper compares these two different methods of AM technologies for metals. The investigations involved determining the density of the printed samples, assessing their surface roughness in two printing planes, examining their microstructures including determining their porosity and density, and measuring their hardness. The tests carried out make it possible to determine the durability, and quality of the obtained sample parts, as well as to assess their strength. The conducted research revealed that samples fabricated using the PBF-LB/M technology exhibited approximately 3% lower porosity compared to those produced using the MEX technology. Additionally, it was observed that the hardness of PBF-LB/M samples was more than twice as high as that of the samples manufactured using the MEX technology. Full article
(This article belongs to the Special Issue 3D Printing Technology with Metal Materials)
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16 pages, 5513 KiB  
Article
Simulation of Wire Arc Additive Manufacturing in the Reinforcement of a Half-Cylinder Shell Geometry
by Xiao Fan Zhao, Avelino Zapata, Christian Bernauer, Siegfried Baehr and Michael F. Zaeh
Materials 2023, 16(13), 4568; https://doi.org/10.3390/ma16134568 - 24 Jun 2023
Cited by 3 | Viewed by 1080
Abstract
Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on gas metal arc welding. It allows the fabrication of large-volume metal components by the controlled deposition and stacking of weld beads. Next to the near-net-shape manufacturing of metal components, WAAM is [...] Read more.
Wire arc additive manufacturing (WAAM) is an additive manufacturing process based on gas metal arc welding. It allows the fabrication of large-volume metal components by the controlled deposition and stacking of weld beads. Next to the near-net-shape manufacturing of metal components, WAAM is also applied in the local reinforcement of structural parts, such as shell geometries. However, this procedure can lead to undesired thermally induced distortions. In this work, the distortion caused by the WAAM reinforcement of half-cylinder shell geometries was investigated through experiments and transient thermo-mechanical finite element simulations. In the experiments, the weld beads were applied to the specimen, while its thermal history was measured using thermocouples. The developing distortions were registered using displacement transducers. The experimental data were used to calibrate and validate the simulation. Using the validated model, the temperature field and the distortions of the specimens could be predicted. Subsequently, the simulation was used to assess different deposition patterns and shell thicknesses with regard to the resulting part distortions. The investigations revealed a non-linear relation between shell thickness and distortion. Moreover, the orientation and the sequence of the weld beads had a significant impact on the formation of distortion. However, those effects diminished with an increasing shell thickness. Full article
(This article belongs to the Special Issue 3D Printing Technology with Metal Materials)
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26 pages, 13093 KiB  
Article
Determination of Johnson–Cook Constitutive of 15-5 PH Steel Processed by Selective Laser Melting
by Xiaojing Zhang, Wenjin Yao, Xintao Zhu, Zhiming Hu, Wei Zhu, Hongxin Huang and Wenbin Li
Materials 2023, 16(2), 800; https://doi.org/10.3390/ma16020800 - 13 Jan 2023
Cited by 1 | Viewed by 1163
Abstract
To obtain a Johnson–Cook model of 15-5 PH steel formed by selective laser melting (SLM), and to determine the difference between the forging process, in this work, mechanical testing, penetration testing and numerical simulations were used to study 15-5 PH steel formed by [...] Read more.
To obtain a Johnson–Cook model of 15-5 PH steel formed by selective laser melting (SLM), and to determine the difference between the forging process, in this work, mechanical testing, penetration testing and numerical simulations were used to study 15-5 PH steel formed by SLM and forging. Finally, the Johnson–Cook model parameters and failure parameters of the 15-5 PH steel formed by SLM and forging were obtained. We found that the SLM process was beneficial for refining the grain size of 15-5 PH steel and for improving the mechanical properties of 15-5 PH steel, where the yield strength of its specimens increased by 13.1% compared with the forged specimens. The error between the numerical simulations and penetration tests was less than 10%, which verified the validity of the numerical model parameters. It was also found that the penetration ability and abrasion resistance of the SLM-shaped projectiles were slightly superior to those of the forged projectiles. Full article
(This article belongs to the Special Issue 3D Printing Technology with Metal Materials)
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