Welding and Additive Manufacturing Processes

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 15 September 2025 | Viewed by 2336

Special Issue Editors


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Guest Editor
Faculty of Technology, University of Sunderland, Sunderland SR1 3SD, UK
Interests: additive manufacturing; friction stir welding; welding; microstructure; metallurgy; joining; hybrid welding; 4D printing; materials science; cryogenic treatments

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Guest Editor
Department of Mechatronics Engineering, SRM Institute of Science and Technology, Kattankulathur Campus, Chennai 603203, Tamilnadu, India
Interests: mechatronics; unconventional machining; optimization; manufacturing automation; printed electronics
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Special Issue Information

Dear Colleagues,

Welding and additive manufacturing processes are integral to various industries, including automotive, aerospace, medical devices, and construction. The performance and reliability of welded joints and additively manufactured components are intrinsically linked to the processes employed, encompassing thermal cycles, material flow, and phase transformations. It is crucial to thoroughly understand and control these processes to ensure the production of high-quality, defect-free products. This Special Issue will explore the latest innovations, modeling techniques, and quality assurance methods that drive the efficiency and sustainability of welding and additive manufacturing, highlighting their role in modern manufacturing and future industry trends.

The Special Issue on "Welding and Additive Manufacturing Processes" aims to address recent advancements and applications in welding and additive manufacturing processes. Potential topics include but are not limited to the following:

  1. Innovative welding processes:
  • Developments in traditional welding methods (MIG, TIG, arc welding, etc.);
  • Advancements in hybrid welding techniques;
  • High-energy-density welding processes (laser, electron beam, etc.);
  • Friction stir welding and its applications.
  1. Additive manufacturing technologies:
  • State-of-the-art additive manufacturing processes (SLS, SLA, DMLS, FDM, etc.);
  • Integration of additive manufacturing with conventional processes;
  • Material innovations and their implications in additive manufacturing;
  • Process optimization and control in additive manufacturing.
  1. Process modeling and simulation:
  • Computational models for welding and additive manufacturing;
  • Simulation of thermal cycles and residual stresses;
  • Predictive modeling for defect prevention and quality assurance;
  • Multi-scale modeling approaches.
  1. Quality assurance and inspection:
  • Non-destructive testing methods for welded and additively manufactured components;
  • In situ monitoring and real-time quality control;
  • Post-process inspection techniques;
  • Standards and certification in welding and additive manufacturing.
  1. Sustainability and future trends:
  • Eco-friendly welding and additive manufacturing practices;
  • Energy-efficient process innovations;
  • Future trends and emerging technologies in welding and additive manufacturing;
  • Roadmaps for industry 4.0 and smart manufacturing.

Dr. Dhanesh G. Mohan
Dr. Muthuramalingam Thangaraj
Guest Editors

Manuscript Submission Information

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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. Processes 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 2400 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

  • welding techniques
  • additive manufacturing
  • metallurgical processes
  • joint formation
  • dissimilar metal joining
  • process simulation
  • in situ monitoring
  • fusion welding
  • solid-state welding

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Published Papers (2 papers)

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Research

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15 pages, 8643 KiB  
Article
Temperature Profile from Parts Produced by Fused Filament Fabrication (FFF) Measured by In Situ Infrared Thermography
by Marceli do N. da Conceição, Henrique M. da Fonseca and Rossana M. S. M. Thiré
Processes 2025, 13(1), 60; https://doi.org/10.3390/pr13010060 - 30 Dec 2024
Viewed by 725
Abstract
Fused Filament Fabrication (FFF) is the most used additive manufacturing (AM) technique. Understanding the behavior of the in situ temperature profile during the cooling stage is crucial to enhancing the mechanical properties of the parts manufactured by FFF since adhesion between printed layers [...] Read more.
Fused Filament Fabrication (FFF) is the most used additive manufacturing (AM) technique. Understanding the behavior of the in situ temperature profile during the cooling stage is crucial to enhancing the mechanical properties of the parts manufactured by FFF since adhesion between printed layers is strongly related to the polymer cooling rate. However, only some studies analyze each layer in detail. For such analysis, infrared thermographic cameras can be used as a tool for non-contact temperature measurement. Numerous variables in constructing the part offer potential for such investigation. This study may lead to the enhancement of the part manufactured and improvements in the 3D printer itself. In addition, the polymer matrix and the manufacturing software can also be optimized. This work aims to systematically evaluate the temperature profile along the deposited layers during the fabrication of three-dimensional parts using poly(lactic acid) (PLA) filament. An infrared camera was used for real-time temperature measurements, and the data were processed with MATLAB® as a function of time and part length. A difference of up to 30 °C was observed between the edges, and non-uniform temperature profiles were also observed at the beginning, middle, and end of the part manufacturing. The highest temperatures were observed at the side where the print nozzle positions itself for the base to descend to the next layer. Several strategies are proposed to enhance the temperature distribution during the cooling process. Full article
(This article belongs to the Special Issue Welding and Additive Manufacturing Processes)
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Review

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21 pages, 3056 KiB  
Review
Influence of Additional Devices and Polymeric Matrix on In Situ Welding in Material Extrusion: A Review
by Marceli do N. da Conceição, Javier Anaya-Mancipe, Daniele C. Bastos, Patrícia S. C. Pereira and Elaine V. D. G. Libano
Processes 2025, 13(1), 171; https://doi.org/10.3390/pr13010171 - 9 Jan 2025
Viewed by 634
Abstract
The rise of Industry 4.0 has introduced challenges and new production models like additive manufacturing (AM), enabling the creation of complex objects previously unattainable. However, many polymers remain underutilized due to the need for improved mechanical properties and reduced process-induced anisotropy. ME-based part [...] Read more.
The rise of Industry 4.0 has introduced challenges and new production models like additive manufacturing (AM), enabling the creation of complex objects previously unattainable. However, many polymers remain underutilized due to the need for improved mechanical properties and reduced process-induced anisotropy. ME-based part construction involves successive filament deposition, akin to welding. Upon exiting the nozzle, the polymer solidifies within seconds, limiting the time and temperature available for diffusion and efficient bonding with the adjacent filament. Therefore, optimizing this welding process is essential. The primary objective of this review was to report on the equipment utilized to enhance the bonding between filaments deposited during manufacturing. While higher temperatures improve welding, most equipment cannot endure prolonged high-heat operations, limiting the use of engineering-grade polymers. Modifying polymer matrices by incorporating low-molar-mass molecules can boost welding and mechanical strength. Significant gains in mechanical properties have come from matrix modifications and new in situ welding devices. Reported devices use light (laser, UV IR), electric current, radio frequency and heat collection from the nozzle. The simplest device is a heat collector, while a double laser beam system has achieved the highest mechanical properties without matrix modification. There was an improvement in properties ranging from 20% to 200%. Full article
(This article belongs to the Special Issue Welding and Additive Manufacturing Processes)
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