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Developments in Additive Manufacturing and 3D Printing
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Developments in Additive Manufacturing and 3D Printing

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

Deadline for manuscript submissions: closed (30 September 2023) | Viewed by 4982

Special Issue Editor

Dr. Ludmila Kučerová

E-Mail Website
Guest Editor
Regional Technological Institute, University of West Bohemia, Univerzitni 8, 30614 Plzen, Czech Republic
Interests: the relationship between processing parameter microstructures and the mechanical properties of metals; microstructure analysis of metals with light and scanning electron microscopy; additively manufactured metals; advanced high-strength steels; in situ testing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With steadily increasing application possibilities, the additive manufacturing (AM) and 3D printing of materials are very late additions to the family of metal and composite production methods. Despite the higher cost of the production of metal AM products and size limitations of commercial printers, AM parts offer novel design solution opportunity with more complex inner geometries than can be achieved through the use of conventional production methods. Due to the high in-built residual stresses and specific microstructure features produced with AM, a postprocessing heat treatment is commonly required. However, AM material heat treatment parameters generally do not correspond to those used for conventionally produced alloys with the same chemical composition, and require optimizing. In terms of chemical composition, alloys traditionally produced with conventional technologies have recently been tested for additive manufacturing; simultaneously, novel materials have been developed, particularly for additive technologies. Novel or improved additive manufacturing methods still appear on the market, enabling the production of parts with already improved mechanical, physical, chemical, or functional properties.

This Special Issue is dedicated to the mapping of the latest developments in the dynamically growing field of metal and composite additive manufacturing. Therefore, it is my pleasure to invite you to submit a manuscript on topics including, but not limited to:

  • The research and development of novel alloys for additive manufacturing;
  • The application of novel AM production or postprocessing methods;
  • Improvements in the mechanical and/or functional properties of printed parts through the optimization of AM and/or the postprocessing treatment;
  • The effect of heat treatment parameters on the microstructure and mechanical properties of AM materials;
  • Increasing the wear and corrosion resistance of AM materials;
  • The creep and fatigue resistance of AM materials;
  • The in-depth microstructure characterization of AM materials.

Dr. Ludmila Kučerová
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. 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

  • additive manufacturing
  • heat treatment
  • metals
  • mechanical properties
  • microstructure analysis
  • composites with a plastic matrix

Published Papers (3 papers)

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Research

14 pages, 4085 KiB  
Article
Complementary Methods for the Assessment of the Porosity of Laser Additive-Manufactured Titanium Alloy
by Silviu Mihai Petrișor, Adriana Savin, Mariana Domnica Stanciu, Zdenek Prevorovsky, Marian Soare, František Nový and Rozina Steigmann
Materials 2023, 16(19), 6383; https://doi.org/10.3390/ma16196383 - 24 Sep 2023
Viewed by 1166
Abstract
The method of making parts through additive manufacturing (AM) is becoming more and more widespread due to the possibility of the direct manufacturing of components with complex geometries. However, the technology’s capacity is limited by the appearance of micro-cracks/discontinuities during the layer-by-layer thermal [...] Read more.
The method of making parts through additive manufacturing (AM) is becoming more and more widespread due to the possibility of the direct manufacturing of components with complex geometries. However, the technology’s capacity is limited by the appearance of micro-cracks/discontinuities during the layer-by-layer thermal process. The ultrasonic (US) method is often applied to detect and estimate the location and size of discontinuities in the metallic parts obtained by AM as well as to identify local deterioration in structures. The Ti6Al4V (Ti64) alloy prepared by AM needed to acquire a high-quality densification if remarkable mechanical properties were to be pursued. Ultrasonic instruments employ a different type of scanning for the studied samples, resulting in extremely detailed images comparable to X-rays. Automated non-destructive testing with special algorithms is widely used in the industry today. In general, this means that there is a trend towards automation and data sharing in various technological and production sectors, including the use of intelligent systems at the initial stage of production that can exclude defective construction materials, prevent the spread of defective products, and identify the causes of certain instances of damage. Placing the non-destructive testing on a completely new basis will create the possibility for a broader analysis of the primary data and thus will contribute to the improvement of both inspection reliability and consistency of the results. The paper aims to present the C-scan method, using ultrasonic images in amplitude or time-of-flight to emphasize discontinuities of Ti64 samples realized by laser powder-bed fusion (L-PBF) technology. The analysis of US maps offers the possibility of information correlation, mainly as to flaws in certain areas, as well as distribution of a specific flaw in the volume of the sample (flaws and pores). Final users can import C-scan results as ASCII files for further processing and comparison with other methods of analysis (e.g., non-linear elastic wave spectroscopy (NEWS), multi-frequency eddy current, and computer tomography), leading to specific results. The precision of the flight time measurement ensures the possibility of estimating the types of discontinuities, including volumetric ones, offering immediate results of the inspection. In situ monitoring allows the detection, characterization, and prediction of defects, which is suitable for robotics. Detailing the level of discontinuities at a certain location is extremely valuable for making maintenance and management decisions. Full article
(This article belongs to the Special Issue Developments in Additive Manufacturing and 3D Printing)
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17 pages, 6515 KiB  
Article
Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS
by Frantisek Sedlacek, Tomas Kalina and Martin Stepanek
Materials 2023, 16(15), 5422; https://doi.org/10.3390/ma16155422 - 2 Aug 2023
Cited by 5 | Viewed by 2060
Abstract
This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. [...] Read more.
This paper presents a novel design methodology that validates and utilizes the results of topology optimization as the final product shape. The proposed methodology aims to streamline the design process by eliminating the need for remodeling and minimizing printing errors through process simulation. It also eliminates the repeated export and import of data between software tools. The study includes a case study involving the steering column housing of a racing car, where Siemens NX Topology Optimization was used for optimization, and verification analysis was conducted using the NX Nastran solver. The final solution was fabricated using AlSi10Mg via direct metal laser sintering on a 3D printer and successfully validated under real conditions. In conclusion, this paper introduces a comprehensive design methodology for the direct utilization of topology optimization, which was validated through a case study, yielding positive results. Full article
(This article belongs to the Special Issue Developments in Additive Manufacturing and 3D Printing)
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16 pages, 9830 KiB  
Article
Additive Manufacturing of WC-Co Specimens with Internal Channels
by Jindrich Sykora, Michael Sedlmajer, Tim Schubert, Markus Merkel, Lubos Kroft, Ludmila Kucerova and Jan Rehor
Materials 2023, 16(11), 3907; https://doi.org/10.3390/ma16113907 - 23 May 2023
Cited by 4 | Viewed by 1275
Abstract
Most material removal in modern manufacturing is currently performed using tools with indexable inserts. Additive manufacturing allows for the creation of new, experimental insert shapes and, more importantly, internal structures, such as channels for coolant. This study deals with developing a process for [...] Read more.
Most material removal in modern manufacturing is currently performed using tools with indexable inserts. Additive manufacturing allows for the creation of new, experimental insert shapes and, more importantly, internal structures, such as channels for coolant. This study deals with developing a process for efficiently manufacturing WC-Co specimens with internal coolant channels with a focus on obtaining a suitable microstructure and surface finish, especially inside the channels. The first part of this study covers the development of process parameters to achieve a microstructure without cracks and with minimal porosity. The next stage focuses solely on improving the surface quality of the parts. Special attention is given to the internal channels, where true surface area and surface quality are evaluated, as these characteristics greatly influence coolant flow. To conclude, WC-Co specimens were successfully manufactured and a microstructure with low porosity and no cracks was achieved and an effective parameter set was found. We have developed a process that produces parts with a surface roughness comparable to those of standard SLS manufacturing of steel parts, while still providing a high-quality internal microstructure. The most suitable parameter set resulted in a profile surface roughness of Ra 4 μm and Rz 31 μm and areal surface roughness of Sa 7 µm and Sz 125 µm. Full article
(This article belongs to the Special Issue Developments in Additive Manufacturing and 3D Printing)
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