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High-Performance Additive Manufacturing and Welding of Metals and Alloys
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High-Performance Additive Manufacturing and Welding of Metals and Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: 20 February 2025 | Viewed by 3207

Special Issue Editors

Dr. Junmiao Shi

E-Mail Website
Guest Editor
School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai 200237, China
Interests: additive manufacturing; welding; microstructural evolution; diffusion bonding; residual stress; fatigue strength
Special Issues, Collections and Topics in MDPI journals
Dr. Ran Liu

E-Mail Website
Guest Editor
The Institute of Scientific and Industrial Research, Osaka University,Osaka 565-0871, Japan
Interests: advanced packaging; copper paste; die attach; pressureless sintering; high-pressure
Dr. Guangjie Feng

E-Mail Website
Guest Editor
College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China
Interests: material processing; composites; alloys; advanced materials; microstructures; nanomaterials; combustion synthesis
Special Issues, Collections and Topics in MDPI journals
Dr. Qian Wang

E-Mail Website
Guest Editor
Joining and Welding Research Institute, Osaka University, Osaka 565-0871, Japan
Interests: cold spray; laser; brazing; additive manufacturing; large deformation; grain refinement; mechanical property; modeling
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is a key technique driving Industry 4.0. In the era of Industry 4.0, AM/Welding is emerging as a valuable digital technique that offers virtually limitless possibilities for manufacturing (from tools to mass customization) in all industries. To date, AM and welding have been extensively researched. Various fusion-based AM/welding techniques that feature electric arcs, lasers, or electron beams as the heat source to build objects through material melting/solidification have become mainstream. In order to minimize solidification-related problems, in recent years, many solid-state AM/welding techniques (e.g., based on cold spraying or friction processing) have been proposed, attracting great attention from both scientific and industrial communities. Moreover, AM/welding focusing on the metals and alloys is also of great interest.

There is an increasing focus on the research and development of novel die attach materials that exhibit high-temperature reliability and can be specifically tailored to the unique requirements of WBG devices.

This Special Issue will consist of high-quality original research papers related to the following overlapping fields:

  • High-performance computing;
  • Artificial intelligence, machine learning, and deep learning;
  • Microstructure evolution;
  • Mechanical properties;
  • The measurement and analysis of residual stress;
  • Process–microstructure–performance relationships;
  • Modeling;
  • Additive manufacturing and the welding of high-performance parts;
  • The future prospects of additive manufacturing and welding.
  • Developing and enhancing the properties of copper pastes;
  • Processes for 3D high-density packaging.

Dr. Junmiao Shi
Dr. Ran Liu
Dr. Guangjie Feng
Dr. Qian Wang
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

  • additive manufacturing
  • welding
  • arc
  • laser
  • cold spray
  • friction
  • brazing
  • microstructure
  • mechanical property
  • residual stress
  • modeling
  • wide bandgap (WBG)
  • advanced packaging
  • power device

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (3 papers)

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Research

15 pages, 6017 KiB  
Article
Unraveling Residual Stress Distribution Characteristics of 6061-T6 Aluminum Alloy Induced by Laser Shock Peening
by Qian Wang, Yaqiong Ge, Jingjia Chen, Tosei Suzuki, Yoshihiro Sagisaka and Ninshu Ma
Materials 2024, 17(14), 3484; https://doi.org/10.3390/ma17143484 - 14 Jul 2024
Viewed by 676
Abstract
Laser shock peening (LSP) is a powerful technique for improving the fatigue performance of metallic components by customizing compressive residual stresses in the desired near-surface regions. In this study, the residual stress distribution characteristics of 6061-T6 aluminum alloy induced by LSP were identified [...] Read more.
Laser shock peening (LSP) is a powerful technique for improving the fatigue performance of metallic components by customizing compressive residual stresses in the desired near-surface regions. In this study, the residual stress distribution characteristics of 6061-T6 aluminum alloy induced by LSP were identified by the X-ray diffraction method, and their dependent factors (i.e., LSP coverage, LSP energy, and scanning path) were evaluated quantitatively by numerical simulations, exploring the formation mechanism of LSP residual stresses and the key role factor of the distribution characteristics. The results show that LSP is capable of creating anisotropic compressive residual stresses on the specimen surface without visible deformation. Compressive residual stresses are positively correlated with LSP coverage. The greater the coverage, the higher the residual stress, but the longer the scanning time required. Raising LSP energy contributes to compressive residual stresses, but excessive energy may lead to a reduction in the surface compressive residual stress. More importantly, the anisotropy of residual stresses was thoroughly explored, identifying the scanning path as the key to causing the anisotropy. The present work provides scientific guidance for efficiently tailoring LSP-induced compressive residual stresses to improve component fatigue life. Full article
(This article belongs to the Special Issue High-Performance Additive Manufacturing and Welding of Metals and Alloys)
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16 pages, 10891 KiB  
Article
Towards Understanding Formation Mechanism of Cellular Structures in Laser Powder Bed Fused AlSi10Mg
by Xiaoying Zhang, Xingpeng Zhang, Wenbo Liu, Aoke Jiang and Yu Long
Materials 2024, 17(9), 2121; https://doi.org/10.3390/ma17092121 - 30 Apr 2024
Viewed by 1036
Abstract
A new approach is proposed that identifies three different zones of the Si-rich network structure (the cellular structure) in laser powder bed fused (LPBF) AlSi10Mg alloy, based on the variation in morphology, grain growth transition, and melt pool solidification conditions. The three identified [...] Read more.
A new approach is proposed that identifies three different zones of the Si-rich network structure (the cellular structure) in laser powder bed fused (LPBF) AlSi10Mg alloy, based on the variation in morphology, grain growth transition, and melt pool solidification conditions. The three identified zones are denoted in the present work as the liquid solidification zone (LSZ), the mushy solidification zone (MSZ), and the heat affected zone (HAZ). The LSZ is the result of liquid–solid transformation, showing small planar growth at the boundary and large cellular growth in the center, while the MSZ is related to a semisolid reaction, and the HAZ arises from a short-time aging process. The boundary between the LSZ and MSZ is identified by the change of grain growth direction and the Si-rich network advancing direction. The boundary between MSZ and HAZ is identified by the start of the breakdown of the Si-rich network. In addition, it is found that the fracture is generated in and propagates along the HAZ during tensile tests. Full article
(This article belongs to the Special Issue High-Performance Additive Manufacturing and Welding of Metals and Alloys)
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31 pages, 11975 KiB  
Article
Improving Laser Powder Bed Fusion Printability of Tungsten Powders Using Simulation-Driven Process Optimization Algorithms
by Aurore Leclercq and Vladimir Brailovski
Materials 2024, 17(8), 1865; https://doi.org/10.3390/ma17081865 - 18 Apr 2024
Viewed by 999
Abstract
This study applies numerical and experimental techniques to investigate the effect of process parameters on the density, structure and mechanical properties of pure tungsten specimens fabricated by laser powder bed fusion. A numerical model based on the simplified analysis of a thermal field [...] Read more.
This study applies numerical and experimental techniques to investigate the effect of process parameters on the density, structure and mechanical properties of pure tungsten specimens fabricated by laser powder bed fusion. A numerical model based on the simplified analysis of a thermal field generated in the powder bed by a moving laser source was used to calculate the melt pool dimensions, predict the density of printed parts and build a cost-effective plan of experiments. Specimens printed using a laser power of 188 W, a scanning speed of 188 mm/s, a hatching space of 80 µm and a layer thickness of 30 µm showed a maximum printed density of 93.2%, an ultimate compression strength of 867 MPa and a maximum strain to failure of ~7.0%, which are in keeping with the standard requirements for tungsten parts obtained using conventional powder metallurgy techniques. Using the optimized printing parameters, selected geometric artifacts were manufactured to characterize the printability limits. A complementary numerical study suggested that decreasing the layer thickness, increasing the laser power, applying hot isostatic pressing and alloying with rhenium are the most promising directions to further improve the physical and mechanical properties of printed tungsten parts. Full article
(This article belongs to the Special Issue High-Performance Additive Manufacturing and Welding of Metals and Alloys)
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