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Additive manufacturing (AM) can be seen as a disruptive process that builds complex components layer upon layer. Two of its distinct technologies are Selective Laser Melting (SLM) and Electron Beam Melting (EBM), which are powder bed fusion processes that create metallic parts with the aid of a beam source. One of the most studied and manufactured superalloys in metal AM is the Ti–6Al–4V, which can be applied in the aerospace field due to its low density and high melting point, and in the biomedical area owing to its high corrosion resistance and excellent biocompatibility when in contact with tissues or bones of the human body. The research novelty of this work is the aggregation of all kinds of data from the last 20 years of investigation about Ti–6Al–4V parts manufactured via SLM and EBM, namely information related to residual stresses (RS), as well as the influence played by different heat treatments in reducing porosity and increasing mechanical properties. Throughout the report, it can be seen that the expected microstructure of the Ti–6Al–4V alloy is different in both manufacturing processes, mainly due to the distinct cooling rates. However, heat treatments can modify the microstructure, reduce RS, and increase the ductility, fatigue life, and hardness of the components. Furthermore, distinct post-treatments can induce compressive RS on the part’s surface, consequently enhancing the fatigue life.

Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.

To investigate the first melts of the mantle wedge in subduction zones and their relationship to primitive magmas erupted at arcs, the compositions of low degree melts of hydrous garnet lherzolite have been experimentally determined at 3.2 GPa over the temperature range of 925–1150 °C. Two starting compositions with variable H2O contents were studied; a subduction-enriched peridotite containing 0.61% Na2O, 0.16 K2O% (wt%) with 4.2 wt% H2O added (Mitchell and Grove in Contrib Mineral Petrol 170:13, 2015) and an undepleted mantle peridotite (Hart and Zindler in Chem Geol 57:247–267, 1986) with 14.5% H2O added (Till et al. in Contrib Mineral Petrol 163:669–688, 2012). Saturating phases include olivine, orthopyroxene, clinopyroxene, garnet and rutile. Melting extent is tracked from near solidus (~ 5 wt%) to 25 wt%, which is close to or beyond the point where clinopyroxene and garnet are exhausted. The beginning of melting is a peritectic reaction where 0.54 orthopyroxene + 0.17 clinopyroxene + 0.13 garnet react to produce 1.0 liquid + 0.88 olivine. The melt production rate near the solidus is 0.1 wt% °C−1 and increases to 0.3 wt% °C−1 over the experimentally studied interval. These values are significantly lower than that observed for anhydrous lherzolite (~ 1 wt% °C−1). When melting through this reaction is calculated for a metasomatized lherzolite source, the rare earth element characteristics of the melt are similar to melts of an eclogite, as well as those observed in many subduction zone magmas. Moreover, since rutile is stable up to ~ 8 wt% melting, the first melts of a hydrous lherzolite source could also show strong high field strength element depletions as is observed in many subduction zone lavas. The silicate melts measured at the lowest temperatures and melting extents (< 10 wt%) are high silica andesites (56–60 wt% SiO2) and contain very low Ca/Al and high alkalis. These deep low degree andesitic melts, if added to experimentally produced hydrous liquids from melting (20–25 wt%) of harzburgite residues at shallow pressures (1.0–1.2 GPa, Mitchell and Grove in Contrib Mineral Petrol 170:13, 2015), can match the compositional characteristics of primitive natural basaltic andesite and magnesian andesite lavas found globally in arcs. In addition to a silicate melt phase, there is a small amount of silicate dissolved in the H2O supercritical fluid that coexists with the silicate liquid and solids in our experiments. The composition of this fluid is in equilibrium with the Mg-rich minerals and it is granitic. The results presented here are used to develop a model for producing hydrous arc magmas. We hypothesize that mantle wedge melting produced by the flux of hydrous fluid from the slab occurs over a range of depths that begins at the base of the mantle wedge and ends at shallow mantle depths. These melts ascend and remain isolated until they mix in the shallow, hottest part of the mantle wedge. In this melting scenario, the metasomatic “slab melt” contributions to arc magmas is small (~ 5 wt%), but its effect on the alkali, REE and incompatible trace element budget of the derivative magmas is large and able to reproduce the trace elemental characteristics of the primitive andesites. Higher proportions of slab or sediment melt do not resemble primitive high magnesian arc andesites and basaltic andesites.

Solid-state Li–S batteries (SSLSBs) are made of low-cost and abundant materials free of supply chain concerns. Owing to their high theoretical energy densities, they are highly desirable for electric vehicles 1 – 3 . However, the development of SSLSBs has been historically plagued by the insulating nature of sulfur 4 , 5 and the poor interfacial contacts induced by its large volume change during cycling 6 , 7 , impeding charge transfer among different solid components. Here we report an S 9.3 I molecular crystal with I 2 inserted in the crystalline sulfur structure, which shows a semiconductor-level electrical conductivity (approximately 5.9 × 10 −7  S cm −1 ) at 25 °C; an 11-order-of-magnitude increase over sulfur itself. Iodine introduces new states into the band gap of sulfur and promotes the formation of reactive polysulfides during electrochemical cycling. Further, the material features a low melting point of around 65 °C, which enables repairing of damaged interfaces due to cycling by periodical remelting of the cathode material. As a result, an Li–S 9.3 I battery demonstrates 400 stable cycles with a specific capacity retention of 87%. The design of this conductive, low-melting-point sulfur iodide material represents a substantial advancement in the chemistry of sulfur materials, and opens the door to the practical realization of SSLSBs. A conductive, low-melting-point and healable sulfur iodide material aids the practical realization of solid-state Li–S batteries, which have high theoretical energy densities and show potential in next-generation battery chemistry.

WC-Co hardmetals are widely used in wear-resistant parts, cutting tools, molds, and mining parts, owing to the combination of high hardness and high toughness. WC-Co hardmetal parts are usually produced by casting and powder metallurgy, which cannot manufacture parts with complex geometries and often require post-processing such as machining. Additive manufacturing (AM) technologies are able to fabricate parts with high geometric complexity and reduce post-processing. Therefore, additive manufacturing of WC-Co hardmetals has been widely studied in recent years. In this article, the current status of additive manufacturing of WC-Co hardmetals is reviewed. The advantages and disadvantages of different AM processes used for producing WC-Co parts, including selective laser melting (SLM), selective electron beam melting (SEBM), binder jet additive manufacturing (BJAM), 3D gel-printing (3DGP), and fused filament fabrication (FFF) are discussed. The studies on microstructures, defects, and mechanical properties of WC-Co parts manufactured by different AM processes are reviewed. Finally, the remaining challenges in additive manufacturing of WC-Co hardmetals are pointed out and suggestions on future research are discussed.

With the development of the aerospace and automotive industries, high heat exchange efficiency is a challenge facing the development of various industries. Pure copper has excellent mechanical and physical properties, especially high thermal conductivity and electrical conductivity. These excellent properties make pure copper the material of choice for the manufacture of heat exchangers and other electrical components. However, the traditional processing method is difficult to achieve the production of pure copper complex parts, so the production of pure copper parts through additive manufacturing has become a problem that must be overcome in industrial development. In this article, we not only reviewed the current status of research on the structural design and preparation of complex pure copper parts by researchers using selective laser melting (SLM), selective electron beam melting (SEBM) and binder jetting (BJ) in recent years, but also reviewed the forming, physical properties and mechanical aspects of pure copper parts prepared by different additive manufacturing methods. Finally, the development trend of additive manufacturing of pure copper parts is also prospected.

Additive manufacturing promises a major transformation of the production of high economic value metallic materials, enabling innovative, geometrically complex designs with minimal material waste. The overarching challenge is to design alloys that are compatible with the unique additive processing conditions while maintaining material properties sufficient for the challenging environments encountered in energy, space, and nuclear applications. Here we describe a class of high strength, defect-resistant 3D printable superalloys containing approximately equal parts of Co and Ni along with Al, Cr, Ta and W that possess strengths in excess of 1.1 GPa in as-printed and post-processed forms and tensile ductilities of greater than 13% at room temperature. These alloys are amenable to crack-free 3D printing via electron beam melting (EBM) with preheat as well as selective laser melting (SLM) with limited preheat. Alloy design principles are described along with the structure and properties of EBM and SLM CoNi-base materials. Additive manufacturing promises a major transformation of the production of high economic value metallic materials. Here, the authors describe a new class of 3D printable superalloys that are amenable to crack-free 3D printing via electron beam melting as well as selective laser melting.

The mechanical properties and biocompatibility of titanium alloy medical devices and implants produced by additive manufacturing (AM) technologies – in particular, selective laser melting (SLM), electron beam melting (EBM) and laser metal deposition (LMD) – have been investigated by several researchers demonstrating how these innovative processes are able to fulfil medical requirements for clinical applications. This work reviews the advantages given by these technologies, which include the possibility to create porous complex structures to improve osseointegration and mechanical properties (best match with the modulus of elasticity of local bone), to lower processing costs, to produce custom-made implants according to the data for the patient acquired via computed tomography and to reduce waste.

Magnesium alloys, renowned for their lightweight yet high-strength characteristics, with exceptional mechanical properties, are highly coveted for numerous applications. The emergence of magnesium alloy additive manufacturing (Mg AM) has further propelled their popularity, offering advantages such as unparalleled precision, swift production rates, enhanced design freedom, and optimized material utilization. This technology holds immense potential in fabricating intricate geometries, complex internal structures, and performance-tailored microstructures, enabling groundbreaking applications. In this paper, we delve into the core processes and pivotal influencing factors of the current techniques employed in Mg AM, including selective laser melting (SLM), electron beam melting (EBM), wire arc additive manufacturing (WAAM), binder jetting (BJ), friction stir additive manufacturing (FSAM), and indirect additive manufacturing (I-AM). Laser powder bed fusion (LPBF) excels in precision but is limited by a low deposition rate and chamber size; WAAM offers cost-effectiveness, high efficiency, and scalability for large components; BJ enables precise material deposition for customized parts with environmental benefits; FSAM achieves fine grain sizes, low defect rates, and potential for precision products; and I-AM boasts a high build rate and industrial adaptability but is less studied recently. This paper attempts to explore the possibilities and challenges for future research in AM. Among them, two issues are how to mix different AM applications and how to use the integration of Internet technologies, machine learning, and process modeling with AM, which are innovative breakthroughs in AM.

Melting of the Greenland Ice Sheet (GrIS) is the largest single contributor to eustatic sea level and is amplified by the growth of pigmented algae on the ice surface, which increases solar radiation absorption. This biological albedo-reducing effect and its impact upon sea level rise has not previously been quantified. Here, we combine field spectroscopy with a radiative-transfer model, supervised classification of unmanned aerial vehicle (UAV) and satellite remote-sensing data, and runoff modelling to calculate biologically driven ice surface ablation. We demonstrate that algal growth led to an additional 4.4–6.0 Gt of runoff from bare ice in the south-western sector of the GrIS in summer 2017, representing 10 %–13 % of the total. In localized patches with high biomass accumulation, algae accelerated melting by up to 26.15±3.77 % (standard error, SE). The year 2017 was a high-albedo year, so we also extended our analysis to the particularly low-albedo 2016 melt season. The runoff from the south-western bare-ice zone attributed to algae was much higher in 2016 at 8.8–12.2 Gt, although the proportion of the total runoff contributed by algae was similar at 9 %–13 %. Across a 10 000 km2 area around our field site, algae covered similar proportions of the exposed bare ice zone in both years (57.99 % in 2016 and 58.89 % in 2017), but more of the algal ice was classed as “high biomass” in 2016 (8.35 %) than 2017 (2.54 %). This interannual comparison demonstrates a positive feedback where more widespread, higher-biomass algal blooms are expected to form in high-melt years where the winter snowpack retreats further and earlier, providing a larger area for bloom development and also enhancing the provision of nutrients and liquid water liberated from melting ice. Our analysis confirms the importance of this biological albedo feedback and that its omission from predictive models leads to the systematic underestimation of Greenland's future sea level contribution, especially because both the bare-ice zones available for algal colonization and the length of the biological growth season are set to expand in the future.