Additive Manufacturing of Metallic Alloys and Composite Materials—Process, Structure, Properties and Part Performance: Experimental and Computer Methods

Dear Colleagues,

Additive manufacturing (AM) has, for some time, been experiencing an explosion of research in the field of materials science and non-equilibrium processing aimed at designing novel high-value products for potential new engineering applications. The unique shaping versatility of AM offers an unprecedent advantage in the fabrication of more efficient, sustainable, reliable and durable products. However, although many materials, geometries and fabrication methods have been investigated, our ability to systematically and unambiguously determine the mechanical performances, detect the actual 3D microstructures and, thus, tailor the mechanical properties to specific applications remains fragmented and unsatisfactory. Moreover, the basic principles needed to design and verify the structural performance of such fabricated AM components have not yet been established. Multiscale indentation testing is a promising technique in this direction, as it virtually allows a fully automated assessment to be made of the local properties and quality of AM products in a semi-destructive manner. However, the available international standard guidelines have so far failed to include this form of testing for materials containing residual stresses. Thus, new testing protocols need to be developed to progress in the mechanical characterization of AM products affected by such stresses. Furthermore, harsh operating conditions may prematurely alter or degrade AM components, such as expensive and complex tooling products. Appropriate, quick and effective repair methodologies are also necessary to minimize high-cost manufacturing downtimes. Non-destructive diagnostic and non-intrusive monitoring techniques represent a valuable means of inspecting materials and products in the laboratory, although appropriate adjustments and evaluations are needed for in-line AM processing and the in situ inspection of metallurgical and inherent stress–strain phenomena.

This Special Issue calls for contributions (critical reviews and articles) that focus on advanced AM methods, in combination with new alloy and composite materials; in-line and/or in situ monitoring techniques for process and microstructure control; 3D microstructure characterization to better clarify the non-equilibrium microstructure of AM products and its correlation with process parameters and properties; the elucidation of deformation modes during mechanical testing, with special attention to non-destructive testing; measurement techniques and strategies to discern mechanical properties from residual stresses; the optimization of metallurgical/mechanical properties in additive repair operations; and computer modelling and simulation to verify new theories and optimize the AM process, material properties and performance of components.

Prof. Dr. Giovanni Maizza
Prof. Dr. Dario Croccolo
Guest Editors

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