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Metals
Special Issues
Progress in Laser Advanced Manufacturing
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Progress in Laser Advanced Manufacturing

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

Deadline for manuscript submissions: closed (31 May 2024) | Viewed by 7791

Special Issue Editors

Prof. Dr. Gang Yu

E-Mail Website
Guest Editor
Institute of Mechanics, Chinese Academy of Sciences, Beijing 100190, China
Interests: laser advanced manufacturing; interaction of laser materials processing; experimental characterization; numerical simulation; data-driven modeling; artificial intelligence
Dr. Zhiyong Li

E-Mail Website
Guest Editor
Institute of Mechanics, Chinese Academy of Sciences, Beijing 100190, China
Interests: additive manufacturing; laser welding; multi-scale, multi-physics simulation; data-driven modeling; artificial intelligence

Special Issue Information

Dear Colleagues,

In modern industry communities, laser advanced manufacturing has been increasingly widely applied in the automotive, aerospace, energy, and chemical industries—to name a few—since its invention in 1960; this increase is a result of its advantages in manufacturing, including flexible transmission, easier automatic control and spatial-temporal transformation, and high accuracy. Amidst their rapid development, manufacturing technologies in which laser beams are used as the main tool could be classified into three groups, according to the mass variation of substrate materials, as follows: material-addition technology, such as laser additive manufacturing and laser welding; material-removal technology, including laser drilling and laser cutting; and mass conservation technology, e.g., laser surface modification and laser-assisted bending.

Typically, laser advanced manufacturing of metals is a process characterized with multi-temporal, multi-spatial, multi-physics strong coupling. Taking metal laser welding as an example, the energy distribution from the high-power density laser beam, the temperature field, the velocity field, the concentration field of the melt pool, the thermal stress, and the deformation are directly coupled, resulting in different joint performances. The interaction between laser photons and atoms of materials occurs on a microscale, the formation of the melt pool together with heat and mass transfer occurs on a mesoscale, and thermal deformation occurs on a macroscale. The multi-scale coupling and cross-scale effect are key features for metal manufacturing using laser beams.

As a result of the extreme manufacturing conditions—e.g., high temperature, high cooling rate, and rapid solidification—the further promotion of laser manufacturing remains restricted by major challenges. For example, defects including hot cracking, pores, and micro-segregation occur in laser additive manufacturing; spattering and cracking occur in high-efficiency, high-quality, defect-free laser welding of aluminum and copper in the electric and automotive industries; and the control of hole morphology is difficult in high-precision laser micro-drilling of metals. Scientific studies must work to solve these challenges and promote the development of laser advanced manufacturing.

This Special Issue is thus organized to publish state-of-the-art works which aim to explore new ideas, new points, and new conclusions surrounding these challenges in laser advanced manufacturing. Manuscripts focused on insightful experimental devices or strategies, novel numerical modeling methods, and promising data-driven models assisted by artificial intelligence are especially welcomed for submission to this Special Issue.

Prof. Dr. Gang Yu
Dr. Zhiyong Li
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

  • additive manufacturing
  • laser welding
  • laser drilling
  • laser cutting
  • laser-assisted bending
  • laser surface modification
  • numerical simulation
  • data-driven modeling
  • experimental characterization
  • artificial intelligence

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Published Papers (4 papers)

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Research

17 pages, 9717 KiB  
Article
Metallurgical Defects and Roughness Investigation in the Laser Powder Bed Fusion Multi-Scanning Strategy of AlSi10Mg Parts
by Alberto Boschetto, Luana Bottini and Daniela Pilone
Metals 2024, 14(6), 711; https://doi.org/10.3390/met14060711 - 16 Jun 2024
Viewed by 1513
Abstract
Laser Powder Bed Fusion is the most attractive additive manufacturing technology for its capability to produce metal components with complex geometry. One of the main drawbacks is the poor surface roughness. In this work, different scan strategies and process parameters were studied and [...] Read more.
Laser Powder Bed Fusion is the most attractive additive manufacturing technology for its capability to produce metal components with complex geometry. One of the main drawbacks is the poor surface roughness. In this work, different scan strategies and process parameters were studied and their effect on surface roughness, alloy microstructure, and metallurgical defects were discussed. The results highlighted that only tailored process conditions could combine acceptable roughness and absence of metallurgical defects. For the upskin, it has been seen that, although by increasing the Volumetric Energy Density value the Ra decreases, Volumetric Energy Density values higher than 69 J/mm3 determine meltpool instability with consequent formation of gas defects in the subsurface area. Similarly, by increasing the Linear Energy Density value, the Ra of the lateral surfaces decreases, but above 0.37 J/mm, metallurgical defects form in the subsurface area. This study also highlighted that the proposed process involves only a contained increase of the production times. In fact, the evaluation of the increased production times, related to the adoption of this multi-scanning strategy, is of fundamental importance to consider if the proposed process can be advantageously applied on an industrial scale. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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14 pages, 4620 KiB  
Article
Rheological Behavior of TRIP600 Steel during Deformation
by Yanjun Yin, Hengyan Zhai and Xinfeng Kan
Metals 2024, 14(6), 633; https://doi.org/10.3390/met14060633 - 26 May 2024
Viewed by 1120
Abstract
Due to the phenomenon of deformation-induced phase transformation, the mechanical properties of TRIP steel, including the elastic modulus, undergo changes during the deformation process. This deviation from plastic theory in describing the deformation process is addressed in this study. Through tensile and cupping [...] Read more.
Due to the phenomenon of deformation-induced phase transformation, the mechanical properties of TRIP steel, including the elastic modulus, undergo changes during the deformation process. This deviation from plastic theory in describing the deformation process is addressed in this study. Through tensile and cupping tests conducted at different rates, the relationship between inelastic deformation and forming time in TRIP steel is established. These tests demonstrate the presence of viscosity and the rheological behavior of solid metal materials during inelastic deformation. The experimental findings also highlight the significance of selecting an appropriate deformation rate for successful TRIP steel forming. Excessive deformation rates can result in the rapid transformation of residual austenite into martensite and increase the likelihood of material cracking. Building upon rheological theory, a constitutive equation is developed to describe the relationship between stress, strain, and strain rate for TRIP600 under creep test conditions. This constitutive model is then applied to simulate the cupping test, and by comparing the simulation results with actual test data, it is confirmed that the rheological constitutive model provides a more accurate representation of TRIP steel deformation. Furthermore, it can guide the improvement of the forming process to enhance the success rate of forming operations. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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10 pages, 3154 KiB  
Article
Study of Tensile Strength of Aluminum Alloy Caused by Pulsed Laser Drilling
by Heyan Gao, Ying Wang, Jifei Ye, Lan Li, Bangdeng Du, Sai Li and Mingyu Li
Metals 2022, 12(12), 2049; https://doi.org/10.3390/met12122049 - 29 Nov 2022
Cited by 5 | Viewed by 1555
Abstract
In the process of pulsed laser drilling, the material properties in the heat-affected zone will change due to the thermal effect of the laser. To study the effect of this change on the material tensile strength, two lasers were used to punch the [...] Read more.
In the process of pulsed laser drilling, the material properties in the heat-affected zone will change due to the thermal effect of the laser. To study the effect of this change on the material tensile strength, two lasers were used to punch the standard 6061 aluminum alloy specimens with millisecond and nanosecond pulse widths, and then the tensile test was carried out on the standard specimens with a tensile tester to measure the ultimate tensile strength of the aluminum alloy. Finally, the micro-morphology of the fracture was photographed by scanning electron microscopy (SEM), and the fracture mechanism of the aluminum alloy was analyzed. The experimental results show that the relationship between the rate of intensity change induced by the millisecond laser and the ablation area ratio is more linear than that of the nanosecond laser; with the increase of ablation area ratio, the rate of intensity changes induced by the nanosecond and millisecond lasers becomes increasingly closer; three types of fractures are produced with two types of laser ablation; the plasticity of the material rapidly decreases with laser drilling, and the main reason for decrease in plasticity was stress concentration. This study provides an important point of reference for how to ensure the strength and plasticity of the components after laser drilling. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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18 pages, 5279 KiB  
Article
Surface Tension-Driven Flow and Its Correlation with Mass Transfer during L-DED of Co-Based Powders
by Zhiyong Li, Gang Yu, Xiuli He, Shaoxia Li and Zhuang Shu
Metals 2022, 12(5), 842; https://doi.org/10.3390/met12050842 - 14 May 2022
Cited by 6 | Viewed by 2457
Abstract
Laser direct energy deposition (L-DED) is one of the most promising additive manufacturing methods, which has been paid more and more attention in recent years. An improved heat and mass transfer model was developed here to analyze thermal behavior, driving force, surface tension-driven [...] Read more.
Laser direct energy deposition (L-DED) is one of the most promising additive manufacturing methods, which has been paid more and more attention in recent years. An improved heat and mass transfer model was developed here to analyze thermal behavior, driving force, surface tension-driven flow and its correlation with dilution during L-DED of Co-based powders to a 38MnVS substrate. Thermal behavior was firstly studied for its fundamental influence on fluid flow and mass transfer. Next, the roles of capillary force and thermal capillary force were characterized using both the dimensional analysis and simulation methods, and the mechanism of surface tension-driven flow was also qualitatively investigated. Finally, flow characteristics inside the melt pool were studied in detail and their correlation with the dilution phenomenon was analyzed based on the multi-component mass transfer model. The temperature gradient was found to be much larger at the front of the melt pool, and it took about 200 ms for the melt pool to reach a quasi-steady condition. Moreover, sharp changes in the curvature of the solid/liquid boundary were observed. Surface tension was demonstrated as the main driver for fluid flow and resulted in centrally outward Marangoni flow. Capillary force contributes to the reduction of the curvature of the free surface, and thermal capillary force (Marangoni force) dominated the Marangoni convection. Alloy elements from the powders, such as Co and Ni, were added to the front part of the melt pool and mainly diluted at the upper side of the rear region near the symmetric plane of the melt pool. Fundamental results in this work provide a valuable understanding of the surface tension-driven flow and its correlation with concentration dilution during the additive manufacturing process. Full article
(This article belongs to the Special Issue Progress in Laser Advanced Manufacturing)
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