Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing
Additive manufacturing (AM) is a rapidly evolving technology that enables the fabrication of complex 3D components across a wide range of materials and applications. Among various AM techniques, direct energy deposition (DED) has gained significant attention for its ability to produce metal and allo...
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MDPI AG
2025-06-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/6/194 |
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| author | Nika Zakerin Khashayar Morshed-Behbahani Donald Paul Bishop Ali Nasiri |
| author_facet | Nika Zakerin Khashayar Morshed-Behbahani Donald Paul Bishop Ali Nasiri |
| author_sort | Nika Zakerin |
| collection | DOAJ |
| description | Additive manufacturing (AM) is a rapidly evolving technology that enables the fabrication of complex 3D components across a wide range of materials and applications. Among various AM techniques, direct energy deposition (DED) has gained significant attention for its ability to produce metal and alloy components with moderate geometric complexity while maintaining a high deposition rate. This makes DED particularly suitable for real-world applications, including in-situ repair and restoration of metallic parts. Due to the nature of the DED process, components undergo extreme heating and cooling cycles, leading to microstructural evolution, process-induced defects, and variations in properties. While extensive research has explored the microstructure and mechanical properties of DED-fabricated alloys, studies on their surface degradation remain incomplete. Corrosion behavior has been well documented, given its significance in AM alloys; however, their tribological performance remains largely unexplored. This paper provides a comprehensive review of the wear behavior of DED-manufactured alloys, emphasizing the potential of DED technology for producing durable components. Specifically, it examines the wear characteristics of four key material groups—Fe-based, Ni-based, Ti-based, and Cu-based alloys—by summarizing existing studies and analyzing the underlying mechanisms influencing their wear resistance. Finally, the paper identifies research gaps and outlines future directions to advance the understanding of wear performance in DED alloys, paving the way for further innovation in this field. |
| format | Article |
| id | doaj-art-6fd1b70bbd684239a09766c030dfff80 |
| institution | DOAJ |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-6fd1b70bbd684239a09766c030dfff802025-08-20T03:16:22ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-06-019619410.3390/jmmp9060194Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive ManufacturingNika Zakerin0Khashayar Morshed-Behbahani1Donald Paul Bishop2Ali Nasiri3Department of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, CanadaDepartment of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, CanadaDepartment of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, CanadaDepartment of Mechanical Engineering, Dalhousie University, 1360 Barrington St., Halifax, NS B3H 4R2, CanadaAdditive manufacturing (AM) is a rapidly evolving technology that enables the fabrication of complex 3D components across a wide range of materials and applications. Among various AM techniques, direct energy deposition (DED) has gained significant attention for its ability to produce metal and alloy components with moderate geometric complexity while maintaining a high deposition rate. This makes DED particularly suitable for real-world applications, including in-situ repair and restoration of metallic parts. Due to the nature of the DED process, components undergo extreme heating and cooling cycles, leading to microstructural evolution, process-induced defects, and variations in properties. While extensive research has explored the microstructure and mechanical properties of DED-fabricated alloys, studies on their surface degradation remain incomplete. Corrosion behavior has been well documented, given its significance in AM alloys; however, their tribological performance remains largely unexplored. This paper provides a comprehensive review of the wear behavior of DED-manufactured alloys, emphasizing the potential of DED technology for producing durable components. Specifically, it examines the wear characteristics of four key material groups—Fe-based, Ni-based, Ti-based, and Cu-based alloys—by summarizing existing studies and analyzing the underlying mechanisms influencing their wear resistance. Finally, the paper identifies research gaps and outlines future directions to advance the understanding of wear performance in DED alloys, paving the way for further innovation in this field.https://www.mdpi.com/2504-4494/9/6/194wearadditive manufacturingdirected energy depositionmetalsalloys |
| spellingShingle | Nika Zakerin Khashayar Morshed-Behbahani Donald Paul Bishop Ali Nasiri Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing Journal of Manufacturing and Materials Processing wear additive manufacturing directed energy deposition metals alloys |
| title | Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing |
| title_full | Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing |
| title_fullStr | Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing |
| title_full_unstemmed | Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing |
| title_short | Review of Tribological and Wear Behavior of Alloys Fabricated via Directed Energy Deposition Additive Manufacturing |
| title_sort | review of tribological and wear behavior of alloys fabricated via directed energy deposition additive manufacturing |
| topic | wear additive manufacturing directed energy deposition metals alloys |
| url | https://www.mdpi.com/2504-4494/9/6/194 |
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