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Micromachines
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Laser Additive Manufacturing of Metallic Materials, 2nd Edition
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Laser Additive Manufacturing of Metallic Materials, 2nd Edition

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D3: 3D Printing and Additive Manufacturing".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 6915

Special Issue Editors

Prof. Dr. Chunlei Qiu

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Beihang University, Beijing 100191, China
Interests: metallic additive manufacturing; near-net-shape hot isostatic pressing; nickel-based superalloys; titanium-based alloys
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Chang-Hwan Choi

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Stevens Institute of Technology, Hoboken, NJ 07030, USA
Interests: surface modification; additive manufacturing of metals; nanofabrication; nanostructured materials; interfacial phenomena (wetting; adhesion; friction; icing; corrosion, etc.)
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metallic additive manufacturing has garnered significant interest in both industry and academia in the past decade. The small-melt-pool-based layered additive manufacturing process not only demonstrates exceptional near-net-shape manufacturing capability but can also generate numerous novel metallurgical phenomena in a great number of metallic materials due to its unique processing characteristics, such as complex laser-material interaction, a steep thermal gradient within melt pools, rapid solidification, and cooling. Non-equilibrium or novel microstructures are often produced in this process, leading to an improved mechanical performance. This opens up the possibility for further improvement in the properties of existing metallic materials and for the development and synthesis of new metallic materials with enhanced properties through alloy design and process optimization. Meanwhile, defects, stress, and microstructural control pose significant challenges to the widespread industrial application of this process.

This Special Issue seeks research papers and review articles focused on the novel development of metallic additive manufacturing. The scope covers all relevant topics, including (but not limited to) laser-material interaction; melt flow behavior; process modeling; porosity formation mechanism; cracking mechanism; novel metallurgical phenomena; new microstructural and mechanical property development; defect and microstructural control; stress development and control; novel metallic material development; new structural design and fabrication; and new applications.

Prof. Dr. Chunlei Qiu
Prof. Dr. Chang-Hwan Choi
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. Micromachines 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

  • metallic additive manufacturing
  • 3D printing
  • microstructural control
  • new material development

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Related Special Issue

Published Papers (6 papers)

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Research

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9 pages, 3248 KiB  
Article
Crack Control in Additive Manufacturing by Leveraging Process Parameters and Lattice Design
by Jun Hak Lee, Seong Je Park, Jeongho Yang, Seung Ki Moon and Jiyong Park
Micromachines 2024, 15(11), 1361; https://doi.org/10.3390/mi15111361 - 10 Nov 2024
Viewed by 776
Abstract
This study investigates the design of additive manufacturing for controlled crack propagation using process parameters and lattice structures. We examine two lattice types—octet-truss (OT) and diamond (DM)—fabricated via powder bed fusion with Ti-6Al-4V. Lattice structures are designed with varying densities (10%, 30%, and [...] Read more.
This study investigates the design of additive manufacturing for controlled crack propagation using process parameters and lattice structures. We examine two lattice types—octet-truss (OT) and diamond (DM)—fabricated via powder bed fusion with Ti-6Al-4V. Lattice structures are designed with varying densities (10%, 30%, and 50%) and process using two different laser energies. Using additive-manufactured specimens, Charpy impact tests are conducted to evaluate the fracture behavior and impact energy levels of the specimens. Results show that the type of the lattice structures, the density of the lattice structures, and laser energy significantly influence crack propagation patterns and impact energy. OT exhibits straighter crack paths, while DM demonstrates more random fracture patterns. Higher-density lattices and increased laser energy generally improve the impact energy. DM consistently outperformed OT in the impact energy for angle specimens, while OT showed superior performance in stair specimens. Finally, a case study demonstrates the potential for combining OT and DM structures to guide crack propagation along predetermined paths, offering a novel approach to protect critical components during product failure. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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16 pages, 5590 KiB  
Article
Corrosion Behavior and Biological Properties of ZK60/HA Composites Prepared by Laser Powder Bed Fusion
by Cijun Shuai, Cheng Chen, Zhenyu Zhao and Youwen Yang
Micromachines 2024, 15(9), 1156; https://doi.org/10.3390/mi15091156 - 15 Sep 2024
Viewed by 955
Abstract
Magnesium alloy ZK60 shows great promise as a medical metal material, but its corrosion resistance in the body is inadequate. Hydroxyapatite (HA), the primary inorganic component of human and animal bones, can form chemical bonds with body tissues at the interface, promoting the [...] Read more.
Magnesium alloy ZK60 shows great promise as a medical metal material, but its corrosion resistance in the body is inadequate. Hydroxyapatite (HA), the primary inorganic component of human and animal bones, can form chemical bonds with body tissues at the interface, promoting the deposition of phosphorus products and creating a dense calcium and phosphorus layer. To enhance the properties of ZK60, HA was added to create HA/ZK60 composite materials. These composites, fabricated using the advanced technique of LPBF, demonstrated superior corrosion resistance and enhanced bone inductive capabilities compared to pristine ZK60. Notably, the incorporation of 3 wt% led to a significant reduction in bulk porosity, achieving a value of 0.8%. The Ecorr value increased from −1.38 V to −1.32 V, while the minimum Icorr value recorded at 33.9 μA·cm−2. Nano-HA achieved the lowest volumetric porosity and optimal corrosion resistance. Additionally, these composites significantly promoted osteogenic differentiation in bone marrow stromal cells (BMSCs), as evidenced by increased alkaline phosphatase (ALP) activity and robust calcium nodule formation, highlighting their excellent biocompatibility and osteo-inductive potential. However, when increasing the HA content to 6 wt%, the bulk porosity rose significantly to 3.3%. The Ecorr value was −1.3 V, with the Icorr value being approximately 50 μA·cm−2. This increase in porosity and weaker interfacial bonding, ultimately accelerated electrochemical corrosion. Therefore, a carefully balanced amount of HA significantly enhances the performance of the ZK60 magnesium alloy, while excessive amounts can be detrimental. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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13 pages, 18959 KiB  
Article
The Microstructure and Properties of Ni60/60% WC Wear-Resistant Coatings Prepared by Laser-Directed Energy Deposition
by Husen Yang, Wen Li, Yichun Liu, Fengxian Li, Jianhong Yi and Jürgen Eckert
Micromachines 2024, 15(9), 1071; https://doi.org/10.3390/mi15091071 - 25 Aug 2024
Viewed by 1047
Abstract
Ni60/60% WC composite coatings with a good surface roughness and high mechanical properties were successfully prepared on 316L stainless steel substrate by laser-directed energy deposition (LDED) technology. The effects of laser power on the microstructural evolution and mechanical properties of the Ni60/60% WC [...] Read more.
Ni60/60% WC composite coatings with a good surface roughness and high mechanical properties were successfully prepared on 316L stainless steel substrate by laser-directed energy deposition (LDED) technology. The effects of laser power on the microstructural evolution and mechanical properties of the Ni60/60% WC composite coating were investigated. The relationships between the chemical composition, the microstructure, the hardness, and the friction wear resistance of the composite coatings were characterized and investigated. The results show that the laser power had a significant effect on the energy input, which determined the melting extent of the Ni60 phases around the WC particles and the bonding strength between the reinforcements and the matrix, as well as the bonding strength between the substrate and the coatings. With an increase in the laser power from 800 W to 1400 W, the average hardness of the coating surface increased due to the increased densification of the deposited coatings and then decreased due to grain coarsening under a high energy input. The average coefficient of friction of the coatings decreased gradually to 0.383 at 1000 W, showing a minimum wear of 0.00013 mm2 at 1200 W. The main wear mechanisms on the coated surfaces were adhesive wear and abrasive wear. Moreover, the coatings deposited at 1200 W exhibited better forming quality and wear resistance. This work suggests that the processing parameters during LDED can be optimized to prepare Ni60/60% WC wear-resistant coatings with excellent mechanical properties. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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13 pages, 8361 KiB  
Article
Microstructure and Mechanical Properties of Laser Direct Energy Deposited Martensitic Stainless Steel 410
by Hyun-Ki Kang, Hyungsoo Lee, Chang-Seok Oh and Jongcheon Yoon
Micromachines 2024, 15(7), 837; https://doi.org/10.3390/mi15070837 - 28 Jun 2024
Viewed by 925
Abstract
The aim of this work is to study the phase transformations, microstructures, and mechanical properties of martensitic stainless steel (MSS) 410 deposits produced by laser powder-directed energy deposition (LP-DED) additive manufacturing. The LP-DED MSS 410 deposits underwent post-heat treatment, which included austenitizing at [...] Read more.
The aim of this work is to study the phase transformations, microstructures, and mechanical properties of martensitic stainless steel (MSS) 410 deposits produced by laser powder-directed energy deposition (LP-DED) additive manufacturing. The LP-DED MSS 410 deposits underwent post-heat treatment, which included austenitizing at 980 °C for 3 h, followed by different tempering treatments at the temperatures of 250, 600, and 750 °C for 5 h, respectively. The analyses of phase transformations and microstructural evolutions of LP-DED MSS 410 were carried out using X-ray diffraction, SEM-EDS, and EBSD. Vickers hardness and tensile strength properties were also measured to analyze the effects of the different tempering heat treatments. It revealed that the as-built MSS 410 has very fine lath martensite, high hardness of about 480 HV1.0, and tensile strength of about 1280 MPa, but elongation was much lower than the post-heat-treated ones. Precipitations of chromium carbide (Cr23C6) were most commonly observed at the grain boundaries and the entire matrix at the tempering temperatures of 600 °C and 750 °C. In general, the tensile strength decreased from 1381 MPa to 688 MPa as tempering temperatures increased to 750 °C from 250 °C. Additionally, as the tempering temperature increased, the chromium carbide and tempered martensite structures became coarser. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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21 pages, 5142 KiB  
Article
On the Role of ZrN Particles in the Microstructural Development in a Beta Titanium Alloy Processed by Laser Powder Bed Fusion
by Xu Chen and Chunlei Qiu
Micromachines 2024, 15(1), 104; https://doi.org/10.3390/mi15010104 - 5 Jan 2024
Viewed by 1223
Abstract
Additive manufacturing of titanium alloys usually ends up with large columnar grains due to the steep thermal gradients within melt pools during solidification. In this study, ZrN particles were added into a beta titanium alloy, Ti-10V-2Fe-3Al, with the aim of promoting columnar-to-equiaxed grain [...] Read more.
Additive manufacturing of titanium alloys usually ends up with large columnar grains due to the steep thermal gradients within melt pools during solidification. In this study, ZrN particles were added into a beta titanium alloy, Ti-10V-2Fe-3Al, with the aim of promoting columnar-to-equiaxed grain transition during laser bed powder fusion (L-PBF). It was found that the addition of ZrN leads to the development of alternate layers of equiaxed grains and refined columnar grains, which is in sharp contrast to the dominant large columnar grains formed in the pure L-PBF-processed titanium alloy. An investigation on single laser melted tracks revealed that the sample with added ZrN showed fine equiaxed grains in the upper regions of solidified melt pools and columnar grains in the lower regions, whereas the solidified melt pools of the pure titanium alloy were dominated by large columnar grains due to epitaxial growth from the previous layer. The formation of equiaxed grains in the former sample is attributed to multiple factors including an increased gradient of liquidus temperature due to the solution of N and a reduced actual melt temperature gradient due to the melting of high-melting-point ZrN particles, which would have expanded constitutional undercooling, a grain growth restriction effect induced by the segregation of N along grain boundaries and the accumulation of unmelted ZrN particles in the upper regions of melt pools. The addition of ZrN also resulted in significant α precipitation, which showed strong variant selection and was found to be driven by laser reheating and the N solution in the matrix. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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Review

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28 pages, 10556 KiB  
Review
A Review of the Vaporization Behavior of Some Metal Elements in the LPBF Process
by Guanglei Shi, Runze Zhang, Yachao Cao and Guang Yang
Micromachines 2024, 15(7), 846; https://doi.org/10.3390/mi15070846 - 29 Jun 2024
Cited by 2 | Viewed by 1329
Abstract
Metal additive manufacturing technology has developed by leaps and bounds in recent years; selective laser melting technology is a major form in metal additive manufacturing, and its application scenarios are numerous. For example, it is involved in many fields including aerospace field, automotive, [...] Read more.
Metal additive manufacturing technology has developed by leaps and bounds in recent years; selective laser melting technology is a major form in metal additive manufacturing, and its application scenarios are numerous. For example, it is involved in many fields including aerospace field, automotive, mechanical processing, and the nuclear industry. At the same time, it also indirectly provides more raw materials for all walks of life in our country. However, during the selective laser melting process, due to the action of high-energy-density lasers, the temperature of most metal powders can reach above the vaporization temperature. Light metals with relatively low vaporization temperatures such as magnesium and zinc have more significant vaporization and other behaviors. At the same time, during the metal vaporization process, a variety of by-products are generated, which seriously affect the forming quality and mechanical properties of the workpiece, resulting in the workpiece quality possibly not reaching the expected target. This paper mainly interprets the metal vaporization behavior in the LPBF process and summarizes the international research progress and suppression methods for vaporization. Full article
(This article belongs to the Special Issue Laser Additive Manufacturing of Metallic Materials, 2nd Edition)
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