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Metals
Special Issues
Benchmarking and Qualification of Additive Manufactured Metallic Components
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Benchmarking and Qualification of Additive Manufactured Metallic Components

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

Deadline for manuscript submissions: 20 May 2024 | Viewed by 2270

Special Issue Editor

Dr. Johannes Buhl

E-Mail Website
Guest Editor
Chair of Mechanical Design and Manufacturing, Brandenburg University of Technology Cottbus-Senftenberg, Cottbus, Germany
Interests: hybrid manufacturing; additive manufacturing; forming technologies; material characterization; circular economy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Due to their potential for individualized and function-integrated products, AM technologies are attractive for mass production. However, the technologies have difficulties in using high-performance metallic materials with complex geometries, leading to unpredictable material properties under "as-built" conditions.

The thermomechanical history experienced during the additive manufacturing (AM) process has a substantial impact on the ultimate material properties of AM parts. This history primarily contributes to localized variations in the microstructure, resulting in phenomena such as anisotropic behavior. The development of microstructure is significantly influenced by various factors, including process parameters, material properties, and part geometry.

This Special Issue aims to develop industry-relevant benchmark geometries, efficient test sequences and test specifications. The outcomes should establish a correlation between process chains and the ultimate properties of the components, enabling their comparability. The aim of this Special Issue is to evaluate macroscopic tests, from which industry-relevant design elements can be easily calculated. Statistics can be employed to quantify the significance of the observed results. Industrial relevance is achieved with the integration of basic machine elements such as notches, threads, bending plates, gear teeth, shaft–hub connections, etc., in the test geometry.

Consequently, compared to conventional testing, a notable decrease in both time and resource consumption should be observed; thereby, the testing method should be economically advantageous.

Fundamental material tests, including microstructure and void volume examination, as well as tension or compression testing, can be conducted to characterize the material in its "as built" state or as a means of validation.

Major topics are:

  • Scalable and extensible benchmark geometry for AM.
  • Efficient test sequence and test specification.
  • Manufacturing factors for various process chains.
  • Benchmark of different AM materials.
  • Comparison of AM with the traditional manufacturing routes.
  • Calculation of design elements based on simple tests.
  • Statistics to quantify the significance of the observed results.

Yours sincerely,

Dr. Johannes Buhl
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. 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

  • additive manufacturing
  • process chain
  • process qualification
  • benchmark
  • qualification
  • new tests
  • material characterization
  • statistics and significance
  • metallic materials

Published Papers (2 papers)

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Research

49 pages, 27220 KiB  
Article
Design of a Cost-Effective and Statistically Validated Test Specification with Selected Machine Elements to Evaluate the Influence of the Manufacturing Process with a Focus on Additive Manufacturing
by Lennart Grüger, Benjamin Sydow, Ralf Woll and Johannes Buhl
Metals 2023, 13(11), 1900; https://doi.org/10.3390/met13111900 - 17 Nov 2023
Viewed by 1006
Abstract
Due to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure [...] Read more.
Due to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure and thus also the final mechanical properties differ greatly compared to conventional processes. In most cases, only direction-dependent characteristic values from the uniaxial tension are used to qualify a printing process before it is used. The literature, on the other hand, demonstrates that the results are not transferable to other loading conditions. In this work, several engineering tests were integrated into a single test specimen so that they can be determined on the same specimen. The test specimen can be used to test tooth root strength, bending strength, notched bar impact energy, and thread strength depending on the mounting direction, thus representing industrial loading cases. In this study, test specimens were fabricated by conventional manufacturing (machining), L-PBF (Laser Powder Bed Fusion), and WA-DED (Wire Arc Direct Energy Deposition), and the results were compared using statistical methods. Factors to capture manufacturing influence and buildup direction were statistically validated on 316L. The work shows a benchmark with a typical initial microstructure of rolled and milled material, L-PBF, and WA-DED parts on loads close to the application and thus simplifies an industry-oriented evaluation of a new manufacturing process. Full article
(This article belongs to the Special Issue Benchmarking and Qualification of Additive Manufactured Metallic Components)
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14 pages, 19882 KiB  
Article
Correlation of Different Cemented Carbide Starting Powders with the Resulting Properties of Components Manufactured via Binder Jetting
by Christian Berger, Johannes Pötschke, Uwe Scheithauer and Alexander Michaelis
Metals 2023, 13(11), 1848; https://doi.org/10.3390/met13111848 - 04 Nov 2023
Viewed by 1101
Abstract
For several years, researchers have been exploring the use of the binder jetting powder-based additive manufacturing process to produce WC-Co hardmetals. Compared to other additive manufacturing processes, binder jetting has the potential for high-volume production. However, due to the powder-based approach, the resulting [...] Read more.
For several years, researchers have been exploring the use of the binder jetting powder-based additive manufacturing process to produce WC-Co hardmetals. Compared to other additive manufacturing processes, binder jetting has the potential for high-volume production. However, due to the powder-based approach, the resulting green bodies typically have low green density, limiting the achievable hardness and requiring higher Co content. Choosing the appropriate starting powder and post-processing can extend previous limitations and allow the selection of a suitable powder based on the application. This investigation focuses on exploring and evaluating the correlation between varying morphologies of WC-Co starting powders, their processability using the BJT method, and the resultant mechanical properties of sintered components. Full article
(This article belongs to the Special Issue Benchmarking and Qualification of Additive Manufactured Metallic Components)
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