Additive manufacturing (AM) constitutes the new paradigm in materials processing and its use on metals and alloys opens new unforeseen possibilities, but is facing several challenges regarding the design of the microstructure, which is particularly awkward in the case of functional materials, like shape memory alloys (SMA), as they require a robust microstructure to withstand the constraints appearing during their shape change. In the present work, the attention is focused on the AM of the important Fe-Mn-Si-based SMA family, which is attracting a great technological interest in many industrial sectors. Initially, an overview on the design concepts of this SMA family is offered, with special emphasis to the problems arising during AM. Then, such concepts are considered in order to experimentally develop the AM production of the Fe-20Mn-6Si-9Cr-5Ni (wt%) SMA through laser powder bed fusion (LPBF). The complete methodology is approached, from the gas atomization of powders to the LPBF production and the final thermal treatments to functionalize the SMA. The microstructure is characterized by scanning and transmission electron microscopy after each step of the processing route. The reversibility of the ε martensitic transformation and its evolution on cycling are studied by internal friction and electron microscopy. An outstanding 14% of fully reversible thermal transformation of ε martensite is obtained. The present results show that, in spite of the still remaining challenges, AM by LPBF offers a good approach to produce this family of Fe-Mn-Si-based SMA, opening new opportunities for its applications.

This work has focused on the study of hot working behavior of Ti-Nb microalloyed steels with high Ti contents (> 0.05%). The role of Nb during the hot deformation of low carbon steels is well known: it mainly retards austenite recrystallization, leading to pancaked austenite microstructures before phase transformation and to refined room temperature microstructures. However, to design rolling schedules that result in properly conditioned austenite microstructures, it is necessary to develop models that take into account the effect of high Ti concentrations on the microstructural evolution of austenite. To that end, in this work torsion tests were performed to investigate the microstructural evolution during hot deformation of steels microalloyed with 0.03% Nb and different high Ti concentrations (0.05%, 0.1%, 0.15%). It was observed that the 0.1% and 0.15% Ti additions resulted in retarded softening kinetics at all the temperatures. This retardation can be mainly attributed to the solute drag effect exerted by Ti in solid solution. The precipitation state of the steels after reheating and after deformation was characterized and the applicability of existing microstructural evolution models was also evaluated. Determined recrystallization kinetics and recrystallized grain sizes reasonably agree with those predicted by equations previously developed for Nb-Ti microalloyed steels with lower Ti concentrations (<0.05%).

Friction stir welding (FSW) has emerged as a solid-state joining technique offering notable advantages over traditional welding methods. Gas metal arc welding (GMAW), a fusion-based process, remains widely used due to its high efficiency, productivity, weld quality, and ease of automation. To combine the benefits of both techniques, a hybrid welding approach integrating GMAW and FSW has been developed. This study investigates the impact of this hybrid technique on the joint quality and properties of AA5083-H111 and AA6082-T6 aluminum alloys. Butt joints were produced on 6 mm thick plates, with variations in friction process parameters. Characterization included macro- and microstructural analyses, mechanical testing (hardness and tensile strength), and corrosion resistance evaluation through stress corrosion cracking tests. Results showed that FSW significantly refined and homogenized the microstructure in both alloys. AA5083-H111 welds achieved a joint efficiency of 99%, while AA6082-T6 reached 66.7%, differences attributed to their distinct strengthening mechanisms and the thermal–mechanical effects of FSW. To assess hydrogen-related behavior, slow strain rate tensile (SSRT) tests were conducted in both inert and hydrogen-rich environments. Hydrogen content was measured in arc, friction, and overlap zones, revealing variations depending on the alloy and microstructure. Despite these differences, both alloys exhibited negligible hydrogen embrittlement. In conclusion, the GMAW–FSW hybrid process successfully produced sound joints with good mechanical and corrosion resistance performance in both aluminum alloys. The findings demonstrate the potential of hybrid welding as a viable method for enhancing weld quality and performance in applications involving dissimilar aluminum alloys.

In this work, multipass torsion tests followed by coiling simulations under different conditions have been performed with a reference Nb (0.03 pct) and a high Ti (0.1 pct)–Nb-microalloyed (0.03 pct) steel. In the case of the high Ti steel, estimated yield strengths close to or over 700 MPa were obtained for some of the conditions researched. However, a very significant effect of previous austenite grain size and strain accumulation on precipitation strengthening has also been observed. As a result, depending on deformation sequence and final cooling conditions, the coiling simulation temperatures that lead to the highest mechanical strength varied from 600 °C to 500 °C. The effect of increasing strain accumulation was mainly related to higher phase transformation temperatures, which led to a lower driving force for precipitation and higher microalloying element diffusivity, resulting in the formation of less and coarser precipitates.

Reducing hot cracking is essential for ensuring seamless production of nickel superalloys, which are extensively used in welded structures for aircraft engines. The prevalence of hot cracking in precipitation-strengthened alloy 718 is primarily governed by two factors: firstly, the chemical composition and the coarse microstructure formed during solidification, and secondly, the activation of hot cracking mechanisms, which is particularly critical in mushroom-shaped welding morphologies. In this study, different nickel-based superalloys welded using laser beam welding (LBW), more specifically bead on plate welding (BoP), specimens are compared. The cracking susceptibility of both wrought and two investment casting 718 alloys with tailored chemical compositions is examined through the application of both continuous and pulsed LBW. Additionally, various pre-weld treatments, including with and without Pre-HIP (hot isostatic pressing), are analyzed. The influences of chemical composition, LBW parameters and pre- and post-welding treatments on both internal and external cracks determined by conventional and advanced non-destructive tests are studied. A clear reduction of hot cracking susceptibility and overall welding quality improvement was observed in a tailored 718 alloy with relatively high Ni (55.6% wt) and Co (1.11% wt) contents.