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Metals
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Additive Manufacturing of Light Metal Alloys
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Additive Manufacturing of Light Metal Alloys

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

Deadline for manuscript submissions: closed (30 June 2024) | Viewed by 6612

Special Issue Editors

Dr. Antonello Astarita

E-Mail Website
Guest Editor
Department of Chemical, Materials and Production Engineering, University of Naples “Federico II”, Naples, Italy
Interests: manufacturing; additive manufacturing; solid state processes; microstructure; cold spray
Special Issues, Collections and Topics in MDPI journals
Dr. Andrea El Hassanin

E-Mail Website
Co-Guest Editor
Department of Chemical, Materials and Production Engineering, University of Naples “Federico II”, Naples, Italy
Interests: additive manufacturing; metallurgy; surface analysis; design of experiments; surface finishing treatments
Dr. Alessia Teresa Silvestri

E-Mail Website
Co-Guest Editor
Department of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, Naples, Italy
Interests: additive manufacturing; friction stir welding; characterization; metallurgy; mechanical properties; surface analysis
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Interest in metal additive manufacturing (AM) has increased steeply over the last twenty years. This is due to the great advantages offered by metal AM technologies such as laser–powder bed fusion (L-PBF), electron beam–powder bed fusion (E-PBF) and laser-engineered net shaping (LENS): these include high design freedom, waste reduction, parts performance optimization and strong tuning of material properties.

In this context, light alloys such as aluminum-, titanium- and magnesium-based alloys represent one of the most investigated class of metal alloys due to their intriguing properties such as high strength-to-weight ratios, high corrosion resistance and wide possibilities of properties enhancing through alloying. When these advantages are combined with the ones provided by AM, it is clear that the interest in this field is huge from both academia and industry.

As witnessed over the last years by a large number of published papers, the field of the AM of light alloys represent a very hot topic, with direct industrial implications for several fields and especially for the ones with strict requirements of performance with a contained parts weight (i.e., aerospace, automotive, etc.).

With this premise, this Special Issue of Metals represents a will to contribute to the growth of the know-how in the field of processing light alloys by means of AM technologies, mostly intended as powder-based ones. The contribution may involve any aspect concerning the subject matter, including process–properties relationships, more sustainable and effective processing approaches, improvements in the pre and post-process handling steps and so on. Your contribution to this 2022 account is highly valuable and appreciated. We therefore invite you to contribute with original research work concerning the AM of light alloys.

The topics covered by this Special Issue include, but are not limited to:

  • The study of powder spreading in additive layer manufacturing;
  • The modeling of additive manufacturing processes;
  • New technologies;
  • The development of processes for new alloys and new mixtures;
  • Surface finishing;
  • The sustainability of additive processes;
  • Characterization techniques;
  • Microstructure and mechanical properties.

Dr. Antonello Astarita
Dr. Andrea El Hassanin
Dr. Alessia Teresa Silvestri
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. 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

  • metal additive manufacturing
  • light alloys
  • aluminum
  • titanium
  • magnesium
  • lightweight structures
  • characterization
  • sustainability
  • modeling

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Published Papers (5 papers)

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Research

24 pages, 23178 KiB  
Article
The Optimization of the Synthesis of Antibacterial Coatings on Ti6Al4V Coupons Obtained by Electron Beam Melting
by Javier Molina, Ana Valero-Gómez, Patricia Bernabé-Quispe, María Ángeles Tormo-Mas and Francisco Bosch
Metals 2024, 14(8), 855; https://doi.org/10.3390/met14080855 - 25 Jul 2024
Viewed by 556
Abstract
Prosthetic joint infection represents a problem that worsens the patient’s quality of life and produces an economic impact on health systems. We report the anodization of Ti6Al4V coupons obtained by electron beam melting to produce a nanostructured surface. Anodization at 10 V produced [...] Read more.
Prosthetic joint infection represents a problem that worsens the patient’s quality of life and produces an economic impact on health systems. We report the anodization of Ti6Al4V coupons obtained by electron beam melting to produce a nanostructured surface. Anodization at 10 V produced TiO2 nanopores with a diameter in the range of 15–20 nm. Thereafter, Ag nanoparticles (AgNPs) were deposited in three different ways to provide antibacterial functionality to the coatings: electrochemically, thermally, and chemically. The electrochemical method did not provide good coverage of AgNPs. At 0.1 V of synthesis potential, cubic, octahedral, and truncated octahedral Ag crystals were obtained. The thermal method provided a good distribution of AgNPs but it damaged the TiO2 nanostructure. The chemical method showed the best distribution of AgNPs over the anodized surface and preserved the anodized nanostructure. For this reason, the chemical method was selected to perform further studies. Ag+ release was monitored in simulated body fluid at 37 °C, reaching 1.86 mg Ag+/L after 42 days. The antibacterial coating showed excellent antibacterial activity and inhibited biofilm formation for Staphylococcus epidermidis RP62A and Staphylococcus aureus V329 strains (lethality > 99.9% for both bacteria and assays). Full article
(This article belongs to the Special Issue Additive Manufacturing of Light Metal Alloys)
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13 pages, 10598 KiB  
Article
Solidification Mechanism of Microstructure of Al-Si-Cu-Ni Alloy Manufactured by Laser Powder Bed Fusion and Mechanical Properties Effect
by Zhichao Shi, Pengfei Yan and Biao Yan
Metals 2024, 14(5), 586; https://doi.org/10.3390/met14050586 - 17 May 2024
Viewed by 783
Abstract
Based on previous work, where Al-Si-Cu-Ni alloy was successfully manufactured by laser powder bed fusion (PBF-LB/M) technology, in this study, we further observe the microstructure of the alloy, analyze the formation mechanism of the microstructure during solidification, and discuss their implications for the [...] Read more.
Based on previous work, where Al-Si-Cu-Ni alloy was successfully manufactured by laser powder bed fusion (PBF-LB/M) technology, in this study, we further observe the microstructure of the alloy, analyze the formation mechanism of the microstructure during solidification, and discuss their implications for the mechanical properties. The results indicate that the microstructure comprises multi-level cellular heterogeneous structures, with an α-Al matrix in the interior of the cellular structure and Cu- and Ni-rich phases clustered at the boundaries, intertwined with the silicon network. During solidification, α-Al solidifies first and occupies the core of the cells, while Si phases and Cu- and Ni-rich phases deposit along the cellular boundaries under the influence of surface tension. During the solidification process of cellular boundaries, influenced by spinodal decomposition and lattice spacing, Si phases and Cu- and Ni-rich phases interconnect and distribute crosswise, collectively forming multi-level cellular structures. The refined cellular microstructure of the PBF-LB/M Al-Si-Cu-Ni alloy enhances the mechanical properties of the alloy. The alloy exhibits a bending strength of 766 ± 30 MPa, a tensile strength and yield strength of 437 ± 6 MPa and 344 ± 4 MPa, respectively, with a relatively low fracture elongation of approximately 1.51 ± 0.07%. Subsequent improvement can be achieved through appropriate heat treatment processes. Full article
(This article belongs to the Special Issue Additive Manufacturing of Light Metal Alloys)
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13 pages, 6001 KiB  
Article
Comparison of STP and TP Modes of Wire and Arc Additive Manufacturing of Aluminum–Magnesium Alloys: Forming, Microstructures and Mechanical Properties
by Qiang Zhu, Ping Yao and Huan Li
Metals 2024, 14(5), 549; https://doi.org/10.3390/met14050549 - 7 May 2024
Viewed by 845
Abstract
Aluminum–magnesium (Al–Mg) alloys, known for their lightweight properties, are extensively utilized and crucial in the advancement of wire and arc additive manufacturing (WAAM) for direct high-quality printing—a focal point in additive manufacturing research. This study employed 1.2 mm ER5356 welding wire as the [...] Read more.
Aluminum–magnesium (Al–Mg) alloys, known for their lightweight properties, are extensively utilized and crucial in the advancement of wire and arc additive manufacturing (WAAM) for direct high-quality printing—a focal point in additive manufacturing research. This study employed 1.2 mm ER5356 welding wire as the raw material to fabricate two sets of 30-layer thin-walled structures. These sets were manufactured using two distinct welding modes, speed-twin pulse (STP) and twin pulse (TP). Comparative evaluations of the surface quality, microstructures, and mechanical properties of the two sets of samples indicated that both the STP and TP modes were suitable for the WAAM of Al–Mg alloys. Analyses of grain growth in the melt pools of both sample sets revealed a non-preferential grain orientation, with a mixed arrangement of equiaxed and columnar grains. The STP mode notably achieved a refined surface finish, a reduced grain size, and a slight increase in tensile strength compared to the TP mode. From the comparison of the tensile data at the bottom, middle, and top of the two groups of samples, the additive manufacturing process in the STP mode was more stable. Full article
(This article belongs to the Special Issue Additive Manufacturing of Light Metal Alloys)
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11 pages, 4707 KiB  
Article
Microstructure and Corrosion Resistance of Ti6Al4V Manufactured by Laser Powder Bed Fusion
by Yiwa Luo, Mingyong Wang, Jun Zhu, Jiguo Tu and Shuqiang Jiao
Metals 2023, 13(3), 496; https://doi.org/10.3390/met13030496 - 1 Mar 2023
Cited by 6 | Viewed by 1820
Abstract
Laser powder bed fusion (LPBF) technology has a dominant position in the preparation of titanium implants with a complex structure and precise size. However, the processing characteristics of rapid melting and solidification lead to the low density and poor corrosion resistance of the [...] Read more.
Laser powder bed fusion (LPBF) technology has a dominant position in the preparation of titanium implants with a complex structure and precise size. However, the processing characteristics of rapid melting and solidification lead to the low density and poor corrosion resistance of the alloy. Hereby, the effects of the laser power and scanning rate on the density, hardness, compressive strength, and corrosion resistance of the Ti6Al4V alloy prepared by LPBF technology have been investigated by metallographic microscopy, a mechanical analysis, and electrochemical tests. The results show that increasing the scanning rate and decreasing the laser power decreases the transformation power from the β phase to α′ phase and changes the morphology of the α′ phase from lath shaped to acicular. The hardness of the Ti6Al4V alloy reaches the maximum (480.53 HV) for a scanning rate of 1000 mm/s and laser power of 280 W, owing to the sufficient precipitation of the α′ phase. Unfused holes occur in the titanium alloy when the laser energy density is too low to melt the power. Pores occur when the laser energy density is too high to vaporize the powder. Both defects reduce the compressive strength of the alloy. The maximum relative density of the Ti6Al4V alloy is 99.96% for a scanning rate of 1200 mm/s and laser power of 240 W, and the compressive strength (1964 MPa) and corrosion resistance (3.16 MΩ·cm2) both reached the maximum. Full article
(This article belongs to the Special Issue Additive Manufacturing of Light Metal Alloys)
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13 pages, 6985 KiB  
Article
Self-Supporting Structures Produced through Laser Powder Bed Fusion of AlSi10Mg Alloy: Surface Quality and Hole Circularity Tolerance Assessment
by Andrea El Hassanin and Antonino Squillace
Metals 2022, 12(12), 2083; https://doi.org/10.3390/met12122083 - 4 Dec 2022
Viewed by 1765
Abstract
In the context of the Design for Additive Manufacturing (DfAM), the elimination and/or reduction of support structures for the parts is a key issue for process optimization in terms of sustainability and surface quality. In this work, the assessment of the surface quality [...] Read more.
In the context of the Design for Additive Manufacturing (DfAM), the elimination and/or reduction of support structures for the parts is a key issue for process optimization in terms of sustainability and surface quality. In this work, the assessment of the surface quality of overhanging thin walls and unsupported holes with different diameters (4, 6, 8 mm) was carried out through confocal microscopy, SEM-EDS analysis and CMM measurements. To this aim, two different types of AlSi10Mg alloy parts were produced with the L-PBF technology, having self-supporting features such as thin walls and holes with different overhang angles. The results showed that (i) unsupported, down-facing surfaces can be printed consecutively without supports up to a 30° overhang angle and with a surface roughness (Sa) ranging from 3 to 40 µm; (ii) unsupported holes can be produced as well, having a mean circularity tolerance ranging from 0.03 to 0.55 mm, regardless of the diameter value; (iii) density and microstructure analysis both revealed that the parts’ integrity was not affected by the design choices. Full article
(This article belongs to the Special Issue Additive Manufacturing of Light Metal Alloys)
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