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Materials for Additive Manufacturing Processes
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Materials for Additive Manufacturing Processes

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

Deadline for manuscript submissions: closed (20 February 2025) | Viewed by 6802

Special Issue Editor

Dr. Alberta Aversa

E-Mail Website
Guest Editor
Department of Applied Science and Technology, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
Interests: metallic materials; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Research related to additive manufacturing (AM) is rapidly evolving, both in terms of processes and materials. In particular, many papers have been published about processing existing materials, as well as introducing completely new materials specifically designed for additive technologies. These studies have demonstrated that AM processes introduce many possibilities to develop new materials with specific properties.

This Special Issue aims to publish results in the field of materials processed by AM, with special attention on material consolidation, microstructure, and properties.

Dr. Alberta Aversa
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
  • materials
  • metals
  • polymer
  • ceramic
  • composites

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Published Papers (6 papers)

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Research

26 pages, 13683 KiB  
Article
Application of Voronoi Tessellation to the Additive Manufacturing of Thermal Barriers of Irregular Porous Materials—Experimental Determination of Thermal Properties
by Beata Anwajler
Materials 2025, 18(8), 1873; https://doi.org/10.3390/ma18081873 - 19 Apr 2025
Viewed by 135
Abstract
The issue of energy transfer is extremely important. In order to achieve the lowest possible energy consumption and the required thermal efficiency in energy-efficient buildings, it is necessary, among other things, to minimize the heat-transfer coefficient, which depends on the properties of the [...] Read more.
The issue of energy transfer is extremely important. In order to achieve the lowest possible energy consumption and the required thermal efficiency in energy-efficient buildings, it is necessary, among other things, to minimize the heat-transfer coefficient, which depends on the properties of the insulating material. Analyses of the relationship between the structure of a material and its thermal conductivity coefficient have shown that lower values of this coefficient can be achieved with a more complex structure that mimics natural forms. This paper presents a design method based on the Voronoi diagram to obtain a three-dimensional structure of a porous composite material. The method was found to be effective in producing structures with predefined and functionally graded porosity. The porous specimens were fabricated from a biodegradable soybean oil-based resin using mSLA additive technology. Analyses were performed to determine the thermal parameters of the anisotropic composites. Experimental results showed that both porosity and irregularity affect the thermal properties. The lowest thermal conductivity coefficients were obtained for a 100 mm-thick prototype composite with the following parameters: wall thickness D = 0.2 mm, cell size S = 4 mm, number of structural layers n = 2, and degree of irregularity R = 4. The lowest possible thermal conductivity of the insulation was 0.026 W/(m·K), and the highest possible thermal resistance was 3.92 (m2·K)/W. The method presented in this study provides an effective solution for nature-inspired design and topological optimization of porous structures. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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12 pages, 5940 KiB  
Article
A Comparison Between the Residual Stresses of Ti6Al4V and Ti-6Al-2Sn-4Zr-6Mo Processed by Laser Powder Bed Fusion
by Alberta Aversa, Alessandro Carrozza, Vincenza Mercurio, Flaviana Calignano, Olha Sereda, Vaclav Pejchal and Mariangela Lombardi
Materials 2025, 18(3), 689; https://doi.org/10.3390/ma18030689 - 5 Feb 2025
Viewed by 595
Abstract
Metal additive manufacturing processes induce residual stress in as-built components. These residual stresses are detrimental to part quality as they can induce defects such as warping and delamination. In some cases, when complex components are built, residual stress can even cause a build [...] Read more.
Metal additive manufacturing processes induce residual stress in as-built components. These residual stresses are detrimental to part quality as they can induce defects such as warping and delamination. In some cases, when complex components are built, residual stress can even cause a build job to fail due to the recoater crashing into the distorted part. In this paper, the residual stress values of Ti6Al4V and Ti-6Al-2Sn-4Zr-6Mo alloys were evaluated by the cantilever approach and by the X-ray diffraction sin2(Ψ) method. The results showed that, as expected, Ti6Al4V as-built cantilevers displayed high distortion and von Mises equivalent stress values up to 494 MPa. On the contrary, as-built Ti-6Al-2Sn-4Zr-6Mo cantilevers were characterized by almost null warping and a residual stress value in the as-built state of 191 MPa. This different behavior is mainly due to the different properties of the hexagonal α’ martensite in Ti6Al4V and the soft orthorhombic α’’ martensite in Ti6246. The post-processing heat treatment significantly reduced the residual stress in Ti6Al4V, lowering it to 44 MPa, while, in the case of Ti-6Al-2Sn-4Zr-6Mo, the post-processing heat treatment did not affect the residual stress conditions. These findings suggest that Ti-6Al-2Sn-4Zr-6Mo could be a suitable candidate for the additive manufacturing production of extremely complex parts, as it could reduce the risks associated with recoater crashes and job failures. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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12 pages, 4261 KiB  
Article
Cell Structure in LPBF 316L—Microstructural Heterogeneity, Thermal Stability, and Mechanical Properties
by Jayant Barode, Marco Brander, Tianbo Yu, Venkata Karthik Nadimpalli, Dorte Juul Jensen and Xiaobo Wang
Materials 2025, 18(3), 475; https://doi.org/10.3390/ma18030475 - 21 Jan 2025
Viewed by 807
Abstract
The microstructure of additively manufactured 316L stainless steel is hierarchical, and on a fine scale, it contains cell structures and dislocations. These microstructures define the mechanical properties, and it is thus of importance to quantify them and understand their thermal stability. This study [...] Read more.
The microstructure of additively manufactured 316L stainless steel is hierarchical, and on a fine scale, it contains cell structures and dislocations. These microstructures define the mechanical properties, and it is thus of importance to quantify them and understand their thermal stability. This study investigates the heterogeneity of the microstructure in laser powder bed-fused 316L with a focus on variations in the cell and dislocation structures through the sample thickness along the build direction. While at the coarse scale the microstructure is rather homogeneous throughout its thickness, there are significant variations in the dislocation network, highlighting a higher dislocation density near the bottom layers than near the top. Furthermore, post-processing heat treatment at 500 °C and 800 °C reveals different stabilities of the cell structures, with significant cell dissolution at 800 °C, particularly at the top of the build. Microhardness measurements corroborate these findings, showing higher hardness in the bottom layers across all conditions, e.g., an increase in hardness from 225 HV to 236 HV is observed in the as-built condition. These results underpin the suggestion that significant microstructural heterogeneity may exist through the thickness in as-built parts, which affects the mechanical properties and subsequent heat treatments. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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18 pages, 5341 KiB  
Article
Functional Silsesquioxanes—Tailoring Hydrophobicity and Anti-Ice Properties of Polylactide in 3D Printing Applications
by Roksana Konieczna, Robert E. Przekop, Daria Pakuła, Julia Głowacka, Katarzyna Ziętkowska, Rafał Kozera and Bogna Sztorch
Materials 2024, 17(19), 4850; https://doi.org/10.3390/ma17194850 - 1 Oct 2024
Cited by 1 | Viewed by 1179
Abstract
To explore the tailoring of hydrophobicity in 3D-printed polylactide (PLA) composites for advanced applications using additive manufacturing (AM), this study focuses on the use of Fused Deposition Modeling (FDM) 3D printing. PLA, a material derived from renewable sources, is favored for its eco-friendliness [...] Read more.
To explore the tailoring of hydrophobicity in 3D-printed polylactide (PLA) composites for advanced applications using additive manufacturing (AM), this study focuses on the use of Fused Deposition Modeling (FDM) 3D printing. PLA, a material derived from renewable sources, is favored for its eco-friendliness and user accessibility. Nonetheless, PLA’s inherent hydrophilic properties result in moisture absorption, negatively affecting its performance. This research aims to modify PLA with organosilicon compounds to enhance its hydrophobic and anti-icing properties. Incorporating fluorinated siloxane derivatives led to significant increases in water contact angles by up to 39%, signifying successful hydrophobic modification. Mechanical testing demonstrated that the addition of organosilicon additives did not compromise the tensile strength of PLA and, in some instances, improved impact resistance, especially with the use of OSS-4OFP:2HEX:2TMOS, which resulted in an increase in the tensile strength value of 25% and increased impact strength by 20% compared to neat PLA. Differential scanning calorimetry (DSC) analysis indicated that the modified PLA exhibited reduced cold crystallization temperatures without altering the glass transition or melting temperatures. These results suggest that organosilicon-modified PLA has the potential to expand the material’s application in producing moisture and ice-resistant 3D-printed prototypes for various industrial uses, thereby facilitating the creation of more durable and versatile 3D-printed components. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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15 pages, 11778 KiB  
Article
A Comparative Evaluation of Powder Characteristics of Recycled Material from Bronze Grinding Chips for Additive Manufacturing
by Eckart Uhlmann, Julian Polte, Janek Maria Fasselt, Vinzenz Müller, Christian Klötzer-Freese, Rafael Kleba-Ehrhardt, Max Biegler and Michael Rethmeier
Materials 2024, 17(14), 3396; https://doi.org/10.3390/ma17143396 - 9 Jul 2024
Cited by 1 | Viewed by 1093
Abstract
In the manufacturing process of ship propellers, large quantities of grinding chips are generated. These grinding chips result from the finishing of the blade surfaces after the primary casting process of the propeller. The aim of this study was to investigate and compare [...] Read more.
In the manufacturing process of ship propellers, large quantities of grinding chips are generated. These grinding chips result from the finishing of the blade surfaces after the primary casting process of the propeller. The aim of this study was to investigate and compare different preparation processes used to produce chip powders with sufficient powder quality for the additive manufacturing process of directed energy deposition. The preparation of the samples was performed through different sieving, milling and re-melting processes. For the characterization of the prepared samples, powder analysis according to relevant industry standards was carried out. It was found that the re-melting processes result in superior powder quality for additive manufacturing in terms of particle size, morphology, and flowability. For some characteristics, the powder exhibits even better properties than those of commercial powders. Furthermore, the powder properties of the milled samples demonstrate a promising potential for use in additive manufacturing. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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22 pages, 6871 KiB  
Article
Mechanical Properties of 3D-Printed Liquid Crystalline Polymers with Low and High Melting Temperatures
by Kai S. Johann, Andreas Wolf and Christian Bonten
Materials 2024, 17(1), 152; https://doi.org/10.3390/ma17010152 - 27 Dec 2023
Cited by 5 | Viewed by 2214
Abstract
Additive manufacturing allows for the production of complex components using various types of materials such as plastics, metals and ceramics without the need for molding tools. In the field of high-performance polymers, semi-crystalline polymers such as polyetheretherketone (PEEK) or amorphous polymers such as [...] Read more.
Additive manufacturing allows for the production of complex components using various types of materials such as plastics, metals and ceramics without the need for molding tools. In the field of high-performance polymers, semi-crystalline polymers such as polyetheretherketone (PEEK) or amorphous polymers such as polyetherimide (PEI) are already successfully applied. Contrary to semi-crystalline and amorphous polymers, thermotropic liquid crystalline polymers (LCPs) do not change into an isotropic liquid during melting. Instead, they possess anisotropic properties in their liquid phase. Within the scope of this work, this special group of polymers was investigated with regard to its suitability for processing by means of fused filament fabrication. Using an LCP with a low melting temperature of around 280 °C is compared to processing an LCP that exhibits a high melting temperature around 330 °C. In doing so, it was revealed that the achievable mechanical properties strongly depend on the process parameters such as the direction of deposition, printing temperature, printing speed and layer height. At a layer height of 0.10 mm, a Young’s modulus of 27.3 GPa was achieved. Moreover, by employing an annealing step after the printing process, the tensile strength could be increased up to 406 MPa at a layer height of 0.15 mm. Regarding the general suitability for FFF as well as the achieved uniaxial mechanical properties, the LCP with a low melting temperature was advantageous compared to the LCP with a high melting temperature. Full article
(This article belongs to the Special Issue Materials for Additive Manufacturing Processes)
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