Periodic Reporting for period 1 - SuMAM (All-in-one surface methodology for corrosion protection in Metal Additive Manufacturing)
Periodo di rendicontazione: 2023-09-01 al 2026-03-31
Sintesi del contesto e degli obiettivi generali del progetto
The SUMAM project has been, in general terms, successful. The core objectives have been achieved, and a pioneering framework for Metal Additive Manufacturing (MAM) has been established in the transport industry. Beyond the initial scope, the research has branched into novel applications, including biomedical scaffolds and advanced structural repairs, which have significantly enhanced the project's overall impact.
The scientific excellence of the work is substantiated by a series of high-impact publications in top-tier journals.
Key achievements include:
• Functionally graded materials: A Stainless steel-Copper system printed by laser-based direct energy deposition, the core of the SUMAM approach.
• Novel Al-Alloys designed for MAM: A comprehensive microstructural and electrochemical characterization of a novel Al-Fe-Zr alloy (Aheadd® CP1), revealing how rapid solidification produces refined nanoscale intermetallics that enhance electrochemical homogeneity.
• Advanced surface treatments: The development of in-situ Zn-Al Layered Double Hydroxide (LDH) conversion coatings on AM Al-Si alloys, which provide superior dissolution resistance compared to as-printed and conventional cast counterparts.
• Biomedical field: Beyond the transport-related application stated in the SUMAM scope, the exploration of cost-effective and eco-friendly surface treatments for Ti-6Al-4V scaffolds revealed a smoother finishing and excellent biocompatibility for stem cell growth.
• Multimaterial Al system: The formation of a multimaterial system based on an Al-Cu alloy printed on top of an Al-Mg alloy has been successfully achieved, and the publication is still in progress.
A cornerstone of the project's success has been my transition into a leadership and mentoring role. I have participated in the co-supervision of 4 PhD students at Vrije Universiteit Brussel (VUB), leading to high-quality collaborative research.
Dissemination and international networking have been extensive. I have delivered oral presentations at major conferences, including EUROCORR 2024 (Paris) and EUROCORR 2025 (Stavanger), where I also served as Chair of the Task Force on Additive Manufactured Metals. Also, I am participating in divulgation activities in CEBE (Association of Spanish Scientists in Belgium) to promote scientific collaboration in Europe and, in particular, in Belgium.
These achievements, along with the detailed analysis of the SUMAM project and new applications, will be further elaborated in the following sections of this report.
1.1 Objectives
*Objective 1: Achieve the targeted surface design during printing and removing the need for post processing for corrosion-sensitive applications in the transport industry.
*Status: Partially achieved
Although a fully industrial-ready material was not achieved within the project timeframe, the scientific understanding of surface phenomena and practical improvement strategies were successfully established. Besides, notable improvements in surface finishing were obtained. Importantly, it was demonstrated that by applying simple, low-cost, and environmentally friendly post-treatments, very good corrosion performance could be achieved.
*Objective 2: To establish the relation between printing conditions and surface creation for the most widely used materials in transport: Stainless steel and Aluminium alloys.
Status: Fully achieved
Significant progress has been made in establishing the relationship between different additive manufacturing techniques, processing parameters, and surface finishing in different steels, steel-copper systems, aluminium alloys, and titanium alloys.
This objective was possible thanks to extensive collaborations with several international partners, including the University of Udine (Italy), Chemtall (Germany), Vrije Universiteit Brussel, UCL, and KU Leuven (Belgium). Different geometries, alloy compositions, and processing strategies optimized by the abovementioned partners were investigated, thus fulfilling the scientific objective.
*Objective 3: To tailor the surface during printing by modifying the raw materials and/or via in-situ laser processing to create high corrosion resistance components.
Status: Fully achieved
Surface tailoring strategies were successfully implemented through:
Raw material modification and in-situ laser parameter adjustment. In detail, the most successfully developed material was the stainless steel-copper system printed under different compositional and laser-processing conditions to optimize the sample composition, surface integrity, and, therefore, its microstructure and corrosion performance. This was achieved through collaborative work with the additive manufacturing lab from the VUB.
*Objective 4: To study the surface phenomena by DML on Al-Si, Al-Cu, Al-Zn, Al-Sc, and Stainless steel.
Status: Fully achieved
Extensive work was carried out on aluminium-based systems and stainless steel, in line with Objectives 1 and 2. Note that another MAM technique has been used due to the availability of these technologies from the collaborators. Surface phenomena related to solidification dynamics, microstructural evolution, and defect formation were systematically analyzed.
*Objective 5: To publish the results in high-impact journals of corrosion and materials science.
Status: Fully achieved
The project results have been successfully disseminated through publications in peer-reviewed journals in the fields of corrosion and materials science. In addition, findings were presented at international conferences, contributing to the visibility and scientific impact of the project. These dissemination activities ensured that the generated knowledge reached both the academic and industrial communities. Note that some results are going to be disseminated in two upcoming conferences this year (ASST 2026 and EURCORR 2026), and two publications are still in progress (one submitted and the other in preparation). Also, experimental research based on surface treatments is being carried out in Al-Si and Al-Fe-Zr systems with ongoing projects with students. Several publications are expected.
*Objective 6: To develop crucial skills for a professional scientist: (i) communication skills and efficiency through teaching and dissemination activities, (ii) cooperation capacity with industrial/academic partners, and (iii) leadership qualities applied in budgeting, coordination, planning, and supervision of technological projects.
Status: Fully achieved
Substantial progress has been made in developing professional and transferable skills. The fellow actively participated in teaching and dissemination activities, strengthening communication skills. Supervision of students was carried out, including guidance in experimental work and support in disseminating their results through presentations and publications. Close cooperation with industrial and academic partners (including international institutions) enhanced collaborative and coordination capacities. Furthermore, participation in an additional research project contributed to the development of leadership skills related to planning, coordination, and project execution.
1.2 Explanation of the work carried out per WP
1.2.1 WORK PACKAGE 1 – ALLOY PREPARATION BY MAM
Progress: Fully completed
Brief summary of the work performed
Although the original plan focused primarily on the in-house LMD technique at the Vrije Universiteit Brussel (VUB), the experimental strategy was broadened to include additional MAM techniques. This decision was taken to accelerate progress, increase reproducibility, and strengthen the scientific robustness of the results.
Beyond powders from commercial suppliers, collaborations were established with international partners who provided previously optimised alloy systems. These materials had already undergone preliminary parameter optimisation, including: (i) raw material characteristics (composition, powder size distribution, alloy modifications), (ii) energy input parameters (laser power, scanning speed, spot size), and (iii) design-related factors (build orientation, scanning strategy, layer thickness). This optimization allowed to advance more efficiently toward surface quality control and defect mitigation.
In addition to the originally planned Al-Si, Al-Sc, Al-Cu, Al-Zn, and AISI 316L systems, the material portfolio was expanded with Ti6Al4V, Steel-copper graded material, and Al-Mg. WP1 was performed in parallel with WP2 and WP3, as foreseen in the original work plan. Note that Al-Sc and Al-Zn were not evaluated.
Outcome and results
All the materials were successfully fabricated across the abovementioned systems and MAM techniques. The extended experimental approach enhanced the scientific depth of the project, enabling a more robust and transferable understanding of surface formation mechanisms in MAM-produced alloys.
Achievement of scientific deliverables and milestones
• D1.1 (Alloy preparation and optimisation), D1.2 D1.3 (Parameter optimisation and defect control strategy): Fully achieved
Alloy systems were successfully prepared and processed, and key parameters were already optimized to obtain high surface quality components with different geometries.
• Milestone M1 (Establish clear relations between printing conditions and surface finishing–corrosion resistance): Fully achieved
A rigorous data analysis established clear correlations between processing parameters and surface finishing quality. These correlations provide the scientific foundation for subsequent WP2 and WP3.
1.2.2 WORK PACKAGE 2 – SURFACE TAILORING OF MAM ALLOYS (M2)
Progress: Fully completed
Brief summary of the work performed
WP2 focused on the development of surface-modified MAM alloys through additive incorporation and laser-based process optimisation. Based on the optimised printing parameters established in WP1, different surface tailoring strategies were systematically evaluated according to their targeted industrial application and expected corrosion performance.
Two main approaches were successfully addressed:
1. Stainless steel-copper system: A compositional gradient strategy was implemented using laser-based Directed Energy Deposition (DED), where two powders were mixed in controlled proportions during the printing process (co-injection approach, T2.1). By dynamically adjusting the feed rate of each powder, different stainless steel-copper ratios were obtained within the same build. This allowed precise control of surface chemistry and microstructural evolution.
2. Dual aluminium alloy system: Two aluminium alloys with different compositions were printed sequentially (one on top of the other) to generate a compositional and functional surface modification. This strategy aimed to combine bulk mechanical integrity with improved surface-related properties.
In both cases, corrosion performance was evaluated (T2.2) to identify the most promising processing conditions. Based on these results, minor adjustments in printing parameters were introduced (T2.3) to further optimise surface integrity and performance as a function of additive composition and laser processing conditions.
Outcome and results
Both surface-tailoring approaches demonstrated promising results:
• The stainless steel–copper system: A scientific manuscript reporting these results has been prepared and submitted to a peer-reviewed journal. Also, the results were presented at the EUROCORR 2025 conference.
• The dual aluminium alloy configuration successfully demonstrated the feasibility of compositional surface engineering through multi-material deposition, achieving improved surface characteristics while maintaining structural integrity. The results are going to be presented at the ASST conference, and the scientific manuscript is under preparation.
The results confirm the technical feasibility of the proposed methodology, integrating additive incorporation and laser parameter optimisation during the printing process to tailor surface properties directly during manufacturing.
Achievement of scientific deliverables and milestones
• T2.1 (Additive incorporation during printing): Fully achieved
Co-injection and multi-material deposition strategies were successfully implemented and validated.
• T2.2 (Short-term corrosion evaluation): Fully achieved
Comparative corrosion assessments enabled the identification of optimal material-processing combinations.
• T2.3 (Parameter optimisation according to additives): Fully achieved
Targeted parameter refinements were performed based on corrosion and surface results.
• D2.1 (Control report analysing additives): Fully achieved
A comprehensive internal evaluation of additive-performance relationships was completed.
• D2.2 (Draft manuscripts for publication): Fully achieved
A manuscript on this system has been submitted, and additional publications are in preparation.
• D2.3 (Scientific dissemination): Fully achieved
Results have been disseminated at scientific conferences aligned with the project timeline.
• Milestone M2 (Ascertain best printing conditions–additive compositions to quantify the suitability of the All-in-one methodology): Fully achieved
The most suitable processing–composition combinations were identified, validating the feasibility and effectiveness of the integrated surface-tailoring strategy.
1.2.3 WORK PACKAGE 3 – CHARACTERIZATION AND CORROSION PERFORMANCE
Progress: Fully completed
Brief summary of the work performed
WP3 was carried out in parallel with WP1 and WP2, as originally planned. All materials developed and optimised during alloy preparation (WP1) and surface tailoring (WP2) were systematically characterised to understand their microstructural features, surface finishing quality, and corrosion behaviour.
The study of corrosion mechanisms and surface-related phenomena (T3.1) was performed using advanced characterization and electrochemical techniques, including:
• Microstructural and surface characterization: (FE)SEM-EDX, XPS, ToF-SIMS, EBSD, XRD, SKPFM, and complementary techniques.
• Electrochemical corrosion testing: Electrochemical Impedance Spectroscopy (EIS), open circuit potential monitoring, and polarization measurements.
• Local electrochemical techniques: applied when required to better understand localized degradation processes (SVET) and microcapillary.
In addition to the originally planned methods, further advanced analyses were conducted in collaboration with external institutions to strengthen the interpretation of corrosion mechanisms and surface chemistry evolution.
For the most promising alloy systems, prototype components were designed and manufactured (T3.2) followed by detailed microstructural evaluation to assess surface finishing and functional performance (T3.3).
In a specific case study involving titanium alloys, collaboration was established with the Université catholique de Louvain (UCLouvain, Belgium) to perform a preliminary biomedical evaluation, extending the potential application scope of the developed methodology beyond structural and transport applications.
Outcome and results
The combined microstructural and electrochemical analyses enabled:
• Identification of corrosion mechanisms associated with different printing conditions and compositional strategies.
• Quantification of the influence of surface finishing and defect density on electrochemical performance.
• Validation of the effectiveness of surface-tailoring approaches developed in WP2.
Prototype components of optimised aluminium and steel systems were successfully fabricated. The final testing results confirmed the technical feasibility and reproducibility of the proposed methodology. In the case of titanium, the additional biomedical-related evaluation broadened the scientific and application impact of the project.
Achievement of scientific deliverables and milestones
• T3.1 (Corrosion mechanism study using advanced tools): Fully achi
eved
Comprehensive microstructural and electrochemical characterization was performed on the optimised materials.
• T3.2 (Prototype development): Fully achieved
Prototype components of optimised MAM aluminium and steel alloys were successfully developed.
• T3.3 (Microstructural evaluation of best components): Fully achieved
Surface finishing and microstructure were systematically analysed using advanced characterization tools.
• D3.1 (Control report on corrosion mechanisms and prototyping): Fully achieved
A complete internal scientific assessment was conducted linking processing–structure–corrosion relationships.
• D3.2 (Draft manuscripts for publication): Fully achieved
Manuscripts have been prepared and submitted or are in preparation for high-impact open-access journals.
• D3.3 (Scientific dissemination): Fully achieved
Results were disseminated to both scientific and general audiences through conferences and outreach activities.
• D3.4 (Final test results of optimized prototypes for patent evaluation): In progress
• Milestone M3 (Completion of scientific data analysis and scientific part of the project): Fully achieved
The scientific data analysis has been completed, and the core scientific objectives of the project have been successfully finalised.
1.2.4 WORK PACKAGE 4 – PROJECT MANAGEMENT (M4)
1.2.5 WORK PACKAGE 5 – TRAINING AND TRANSFER OF KNOWLEDGE (M5)
1.2.6 WORK PACKAGE 6 – DISSEMINATION, EXPLOITATION, COMMUNICATION AND PUBLIC OUTREACH (M6)
Progress: Fully completed
Brief summary of the work performed.
WP4, WP5, and WP6 were implemented according to the original work plan throughout the entire duration of the fellowship (M1–M24), ensuring effective coordination, structured training progression, and maximisation of scientific and societal impact.
WP4 – Project Management
Regular monthly meetings were held with the supervisors to monitor scientific progress, optimise resource allocation, and address potential risks through continuous assessment and contingency planning (T4.1). Budget execution was periodically reviewed to ensure alignment with experimental needs and project objectives (T4.2).
The Data Management Plan (DMP) was continuously updated to guarantee reproducibility, appropriate data storage, protection of results, and compliance with open science principles. Internal presentations were prepared to document decision-making processes and ensure traceability of progress across WP1-WP3.
WP5 – Training and Transfer of Knowledge
Scientific and transferable skills development was actively monitored through structured progress meetings and biannual Career Development Plan (CDP) evaluations (T5.1 T5.2).
Training included:
• Advanced use of microstructural and electrochemical characterization tools.
• Independent operation of laboratory equipment following certified training and authorisation procedures in the host institution.
• Development of competencies in project planning, budgeting, and execution.
• Supervision and mentoring of students, contributing to two-way knowledge transfer within the research group.
The researcher progressively achieved full autonomy in advanced experimental techniques and strengthened leadership, coordination, and teaching capabilities.
WP6 – Dissemination, Exploitation and Communication
Dissemination and exploitation activities were carried out continuously throughout the fellowship. A structured publication and dissemination strategy was implemented (T6.1–T6.3) including:
• Preparation and submission of peer-reviewed manuscripts derived from WP1-WP3 results.
• Participation in scientific conferences and seminars.
• Internal evaluation meetings to assess which results were suitable for publication and which had potential for intellectual property protection.
The project’s exploitation potential was periodically assessed in alignment with prototype development and performance validation.
Outcome and results
• Efficient project execution: The project was managed according to the planned timeline and budget, ensuring optimal use of resources and smooth integration between scientific work packages.
• Strengthened researcher profile: The fellow significantly enhanced both scientific expertise and transferable skills, including leadership, supervision, communication, and strategic project planning.
• Knowledge transfer: Effective two-way knowledge exchange occurred within the host group and collaborating institutions, contributing to institutional capacity building.
• Scientific dissemination and impact: Publications, conference presentations, and outreach activities maximised the visibility of the project results at both scientific and societal levels.
• Exploitation pathway: Regular evaluation of results allowed identification of outcomes with potential for patenting and future technological transfer.
Achievement of scientific deliverables and milestones
WP4
• D4.1 (Periodic meeting reports and data management monitoring): Fully achieved
• D4.2 (Budget documentation and resource justification): Fully achieved
• Milestone M4 (Correct project management and budgeting): Fully achieved
WP5
• D5.1 (Reports on patents and publications from WP1–WP3): Fully achieved
• D5.2 (Training validation and independent lab authorisation): Fully achieved
• Milestone M5 (Completion of Career Development Plan): Fully achieved
WP6
• D6.1 (Periodic dissemination articles and outputs): Fully achieved
• Tasks T6.1–T6.3 (Exploitation strategy, publication/patent evaluation, compliance with deadlines): Fully achieved
• Milestone M6 (Effective dissemination and exploitation of results): Fully achieved
• OTHER ASPECTS OF THE WORK PLAN:
ANOTHER ASPECTS
a. Gender dimension in the research and innovation content
Due to the technical and materials-science-oriented nature of the project, no direct gender-related variables were scientifically relevant to the research content. In detail, the investigated phenomena (microstructure evolution, electrochemical behaviour, surface finishing, and additive incorporation) are material-dependent and not influenced by biological or socio-gender variables. Therefore, the integration of sex and/or gender analysis did not apply to the scientific objectives of the project.
Nevertheless, gender equality principles were respected throughout the project implementation, particularly in collaborative activities, supervision, and dissemination environments, ensuring inclusiveness and equal opportunities.
b. Implementation of secondment(s)
No secondments were formally planned or implemented during the fellowship period.
Despite the absence of official secondments, strong international collaborations were maintained throughout the project. These collaborations were essential to enable access to complementary expertise, materials, and advanced characterization techniques, ensuring effective knowledge exchange without the need for formal mobility periods.
c. Implementation of the Non-Academic Placement (NAP)
Non-Academic Placement (NAP) was not foreseen in the project and therefore was not implemented. However, the project maintained interaction with industrial stakeholders, particularly in relation to material supply, potential application scenarios, and evaluation of exploitation pathways.
d. Hosting conditions at the Beneficiary and research visits
The hosting conditions at the host institution were excellent and fully supportive of the project’s objectives. The research group provided access to the required infrastructure, laboratory facilities, and supervision necessary to successfully implement WP1-WP6.
No formal research visits, field work, or short stays (besides collaborative interactions) were required to achieve the project objectives. All planned activities were effectively carried out at the host institution, complemented by remote and collaborative interactions with partner institutions when needed.
The overall research environment ensured optimal scientific development, efficient project execution, and strong integration of the fellow within the host research group.
The scientific excellence of the work is substantiated by a series of high-impact publications in top-tier journals.
Key achievements include:
• Functionally graded materials: A Stainless steel-Copper system printed by laser-based direct energy deposition, the core of the SUMAM approach.
• Novel Al-Alloys designed for MAM: A comprehensive microstructural and electrochemical characterization of a novel Al-Fe-Zr alloy (Aheadd® CP1), revealing how rapid solidification produces refined nanoscale intermetallics that enhance electrochemical homogeneity.
• Advanced surface treatments: The development of in-situ Zn-Al Layered Double Hydroxide (LDH) conversion coatings on AM Al-Si alloys, which provide superior dissolution resistance compared to as-printed and conventional cast counterparts.
• Biomedical field: Beyond the transport-related application stated in the SUMAM scope, the exploration of cost-effective and eco-friendly surface treatments for Ti-6Al-4V scaffolds revealed a smoother finishing and excellent biocompatibility for stem cell growth.
• Multimaterial Al system: The formation of a multimaterial system based on an Al-Cu alloy printed on top of an Al-Mg alloy has been successfully achieved, and the publication is still in progress.
A cornerstone of the project's success has been my transition into a leadership and mentoring role. I have participated in the co-supervision of 4 PhD students at Vrije Universiteit Brussel (VUB), leading to high-quality collaborative research.
Dissemination and international networking have been extensive. I have delivered oral presentations at major conferences, including EUROCORR 2024 (Paris) and EUROCORR 2025 (Stavanger), where I also served as Chair of the Task Force on Additive Manufactured Metals. Also, I am participating in divulgation activities in CEBE (Association of Spanish Scientists in Belgium) to promote scientific collaboration in Europe and, in particular, in Belgium.
These achievements, along with the detailed analysis of the SUMAM project and new applications, will be further elaborated in the following sections of this report.
1.1 Objectives
*Objective 1: Achieve the targeted surface design during printing and removing the need for post processing for corrosion-sensitive applications in the transport industry.
*Status: Partially achieved
Although a fully industrial-ready material was not achieved within the project timeframe, the scientific understanding of surface phenomena and practical improvement strategies were successfully established. Besides, notable improvements in surface finishing were obtained. Importantly, it was demonstrated that by applying simple, low-cost, and environmentally friendly post-treatments, very good corrosion performance could be achieved.
*Objective 2: To establish the relation between printing conditions and surface creation for the most widely used materials in transport: Stainless steel and Aluminium alloys.
Status: Fully achieved
Significant progress has been made in establishing the relationship between different additive manufacturing techniques, processing parameters, and surface finishing in different steels, steel-copper systems, aluminium alloys, and titanium alloys.
This objective was possible thanks to extensive collaborations with several international partners, including the University of Udine (Italy), Chemtall (Germany), Vrije Universiteit Brussel, UCL, and KU Leuven (Belgium). Different geometries, alloy compositions, and processing strategies optimized by the abovementioned partners were investigated, thus fulfilling the scientific objective.
*Objective 3: To tailor the surface during printing by modifying the raw materials and/or via in-situ laser processing to create high corrosion resistance components.
Status: Fully achieved
Surface tailoring strategies were successfully implemented through:
Raw material modification and in-situ laser parameter adjustment. In detail, the most successfully developed material was the stainless steel-copper system printed under different compositional and laser-processing conditions to optimize the sample composition, surface integrity, and, therefore, its microstructure and corrosion performance. This was achieved through collaborative work with the additive manufacturing lab from the VUB.
*Objective 4: To study the surface phenomena by DML on Al-Si, Al-Cu, Al-Zn, Al-Sc, and Stainless steel.
Status: Fully achieved
Extensive work was carried out on aluminium-based systems and stainless steel, in line with Objectives 1 and 2. Note that another MAM technique has been used due to the availability of these technologies from the collaborators. Surface phenomena related to solidification dynamics, microstructural evolution, and defect formation were systematically analyzed.
*Objective 5: To publish the results in high-impact journals of corrosion and materials science.
Status: Fully achieved
The project results have been successfully disseminated through publications in peer-reviewed journals in the fields of corrosion and materials science. In addition, findings were presented at international conferences, contributing to the visibility and scientific impact of the project. These dissemination activities ensured that the generated knowledge reached both the academic and industrial communities. Note that some results are going to be disseminated in two upcoming conferences this year (ASST 2026 and EURCORR 2026), and two publications are still in progress (one submitted and the other in preparation). Also, experimental research based on surface treatments is being carried out in Al-Si and Al-Fe-Zr systems with ongoing projects with students. Several publications are expected.
*Objective 6: To develop crucial skills for a professional scientist: (i) communication skills and efficiency through teaching and dissemination activities, (ii) cooperation capacity with industrial/academic partners, and (iii) leadership qualities applied in budgeting, coordination, planning, and supervision of technological projects.
Status: Fully achieved
Substantial progress has been made in developing professional and transferable skills. The fellow actively participated in teaching and dissemination activities, strengthening communication skills. Supervision of students was carried out, including guidance in experimental work and support in disseminating their results through presentations and publications. Close cooperation with industrial and academic partners (including international institutions) enhanced collaborative and coordination capacities. Furthermore, participation in an additional research project contributed to the development of leadership skills related to planning, coordination, and project execution.
1.2 Explanation of the work carried out per WP
1.2.1 WORK PACKAGE 1 – ALLOY PREPARATION BY MAM
Progress: Fully completed
Brief summary of the work performed
Although the original plan focused primarily on the in-house LMD technique at the Vrije Universiteit Brussel (VUB), the experimental strategy was broadened to include additional MAM techniques. This decision was taken to accelerate progress, increase reproducibility, and strengthen the scientific robustness of the results.
Beyond powders from commercial suppliers, collaborations were established with international partners who provided previously optimised alloy systems. These materials had already undergone preliminary parameter optimisation, including: (i) raw material characteristics (composition, powder size distribution, alloy modifications), (ii) energy input parameters (laser power, scanning speed, spot size), and (iii) design-related factors (build orientation, scanning strategy, layer thickness). This optimization allowed to advance more efficiently toward surface quality control and defect mitigation.
In addition to the originally planned Al-Si, Al-Sc, Al-Cu, Al-Zn, and AISI 316L systems, the material portfolio was expanded with Ti6Al4V, Steel-copper graded material, and Al-Mg. WP1 was performed in parallel with WP2 and WP3, as foreseen in the original work plan. Note that Al-Sc and Al-Zn were not evaluated.
Outcome and results
All the materials were successfully fabricated across the abovementioned systems and MAM techniques. The extended experimental approach enhanced the scientific depth of the project, enabling a more robust and transferable understanding of surface formation mechanisms in MAM-produced alloys.
Achievement of scientific deliverables and milestones
• D1.1 (Alloy preparation and optimisation), D1.2 D1.3 (Parameter optimisation and defect control strategy): Fully achieved
Alloy systems were successfully prepared and processed, and key parameters were already optimized to obtain high surface quality components with different geometries.
• Milestone M1 (Establish clear relations between printing conditions and surface finishing–corrosion resistance): Fully achieved
A rigorous data analysis established clear correlations between processing parameters and surface finishing quality. These correlations provide the scientific foundation for subsequent WP2 and WP3.
1.2.2 WORK PACKAGE 2 – SURFACE TAILORING OF MAM ALLOYS (M2)
Progress: Fully completed
Brief summary of the work performed
WP2 focused on the development of surface-modified MAM alloys through additive incorporation and laser-based process optimisation. Based on the optimised printing parameters established in WP1, different surface tailoring strategies were systematically evaluated according to their targeted industrial application and expected corrosion performance.
Two main approaches were successfully addressed:
1. Stainless steel-copper system: A compositional gradient strategy was implemented using laser-based Directed Energy Deposition (DED), where two powders were mixed in controlled proportions during the printing process (co-injection approach, T2.1). By dynamically adjusting the feed rate of each powder, different stainless steel-copper ratios were obtained within the same build. This allowed precise control of surface chemistry and microstructural evolution.
2. Dual aluminium alloy system: Two aluminium alloys with different compositions were printed sequentially (one on top of the other) to generate a compositional and functional surface modification. This strategy aimed to combine bulk mechanical integrity with improved surface-related properties.
In both cases, corrosion performance was evaluated (T2.2) to identify the most promising processing conditions. Based on these results, minor adjustments in printing parameters were introduced (T2.3) to further optimise surface integrity and performance as a function of additive composition and laser processing conditions.
Outcome and results
Both surface-tailoring approaches demonstrated promising results:
• The stainless steel–copper system: A scientific manuscript reporting these results has been prepared and submitted to a peer-reviewed journal. Also, the results were presented at the EUROCORR 2025 conference.
• The dual aluminium alloy configuration successfully demonstrated the feasibility of compositional surface engineering through multi-material deposition, achieving improved surface characteristics while maintaining structural integrity. The results are going to be presented at the ASST conference, and the scientific manuscript is under preparation.
The results confirm the technical feasibility of the proposed methodology, integrating additive incorporation and laser parameter optimisation during the printing process to tailor surface properties directly during manufacturing.
Achievement of scientific deliverables and milestones
• T2.1 (Additive incorporation during printing): Fully achieved
Co-injection and multi-material deposition strategies were successfully implemented and validated.
• T2.2 (Short-term corrosion evaluation): Fully achieved
Comparative corrosion assessments enabled the identification of optimal material-processing combinations.
• T2.3 (Parameter optimisation according to additives): Fully achieved
Targeted parameter refinements were performed based on corrosion and surface results.
• D2.1 (Control report analysing additives): Fully achieved
A comprehensive internal evaluation of additive-performance relationships was completed.
• D2.2 (Draft manuscripts for publication): Fully achieved
A manuscript on this system has been submitted, and additional publications are in preparation.
• D2.3 (Scientific dissemination): Fully achieved
Results have been disseminated at scientific conferences aligned with the project timeline.
• Milestone M2 (Ascertain best printing conditions–additive compositions to quantify the suitability of the All-in-one methodology): Fully achieved
The most suitable processing–composition combinations were identified, validating the feasibility and effectiveness of the integrated surface-tailoring strategy.
1.2.3 WORK PACKAGE 3 – CHARACTERIZATION AND CORROSION PERFORMANCE
Progress: Fully completed
Brief summary of the work performed
WP3 was carried out in parallel with WP1 and WP2, as originally planned. All materials developed and optimised during alloy preparation (WP1) and surface tailoring (WP2) were systematically characterised to understand their microstructural features, surface finishing quality, and corrosion behaviour.
The study of corrosion mechanisms and surface-related phenomena (T3.1) was performed using advanced characterization and electrochemical techniques, including:
• Microstructural and surface characterization: (FE)SEM-EDX, XPS, ToF-SIMS, EBSD, XRD, SKPFM, and complementary techniques.
• Electrochemical corrosion testing: Electrochemical Impedance Spectroscopy (EIS), open circuit potential monitoring, and polarization measurements.
• Local electrochemical techniques: applied when required to better understand localized degradation processes (SVET) and microcapillary.
In addition to the originally planned methods, further advanced analyses were conducted in collaboration with external institutions to strengthen the interpretation of corrosion mechanisms and surface chemistry evolution.
For the most promising alloy systems, prototype components were designed and manufactured (T3.2) followed by detailed microstructural evaluation to assess surface finishing and functional performance (T3.3).
In a specific case study involving titanium alloys, collaboration was established with the Université catholique de Louvain (UCLouvain, Belgium) to perform a preliminary biomedical evaluation, extending the potential application scope of the developed methodology beyond structural and transport applications.
Outcome and results
The combined microstructural and electrochemical analyses enabled:
• Identification of corrosion mechanisms associated with different printing conditions and compositional strategies.
• Quantification of the influence of surface finishing and defect density on electrochemical performance.
• Validation of the effectiveness of surface-tailoring approaches developed in WP2.
Prototype components of optimised aluminium and steel systems were successfully fabricated. The final testing results confirmed the technical feasibility and reproducibility of the proposed methodology. In the case of titanium, the additional biomedical-related evaluation broadened the scientific and application impact of the project.
Achievement of scientific deliverables and milestones
• T3.1 (Corrosion mechanism study using advanced tools): Fully achi
eved
Comprehensive microstructural and electrochemical characterization was performed on the optimised materials.
• T3.2 (Prototype development): Fully achieved
Prototype components of optimised MAM aluminium and steel alloys were successfully developed.
• T3.3 (Microstructural evaluation of best components): Fully achieved
Surface finishing and microstructure were systematically analysed using advanced characterization tools.
• D3.1 (Control report on corrosion mechanisms and prototyping): Fully achieved
A complete internal scientific assessment was conducted linking processing–structure–corrosion relationships.
• D3.2 (Draft manuscripts for publication): Fully achieved
Manuscripts have been prepared and submitted or are in preparation for high-impact open-access journals.
• D3.3 (Scientific dissemination): Fully achieved
Results were disseminated to both scientific and general audiences through conferences and outreach activities.
• D3.4 (Final test results of optimized prototypes for patent evaluation): In progress
• Milestone M3 (Completion of scientific data analysis and scientific part of the project): Fully achieved
The scientific data analysis has been completed, and the core scientific objectives of the project have been successfully finalised.
1.2.4 WORK PACKAGE 4 – PROJECT MANAGEMENT (M4)
1.2.5 WORK PACKAGE 5 – TRAINING AND TRANSFER OF KNOWLEDGE (M5)
1.2.6 WORK PACKAGE 6 – DISSEMINATION, EXPLOITATION, COMMUNICATION AND PUBLIC OUTREACH (M6)
Progress: Fully completed
Brief summary of the work performed.
WP4, WP5, and WP6 were implemented according to the original work plan throughout the entire duration of the fellowship (M1–M24), ensuring effective coordination, structured training progression, and maximisation of scientific and societal impact.
WP4 – Project Management
Regular monthly meetings were held with the supervisors to monitor scientific progress, optimise resource allocation, and address potential risks through continuous assessment and contingency planning (T4.1). Budget execution was periodically reviewed to ensure alignment with experimental needs and project objectives (T4.2).
The Data Management Plan (DMP) was continuously updated to guarantee reproducibility, appropriate data storage, protection of results, and compliance with open science principles. Internal presentations were prepared to document decision-making processes and ensure traceability of progress across WP1-WP3.
WP5 – Training and Transfer of Knowledge
Scientific and transferable skills development was actively monitored through structured progress meetings and biannual Career Development Plan (CDP) evaluations (T5.1 T5.2).
Training included:
• Advanced use of microstructural and electrochemical characterization tools.
• Independent operation of laboratory equipment following certified training and authorisation procedures in the host institution.
• Development of competencies in project planning, budgeting, and execution.
• Supervision and mentoring of students, contributing to two-way knowledge transfer within the research group.
The researcher progressively achieved full autonomy in advanced experimental techniques and strengthened leadership, coordination, and teaching capabilities.
WP6 – Dissemination, Exploitation and Communication
Dissemination and exploitation activities were carried out continuously throughout the fellowship. A structured publication and dissemination strategy was implemented (T6.1–T6.3) including:
• Preparation and submission of peer-reviewed manuscripts derived from WP1-WP3 results.
• Participation in scientific conferences and seminars.
• Internal evaluation meetings to assess which results were suitable for publication and which had potential for intellectual property protection.
The project’s exploitation potential was periodically assessed in alignment with prototype development and performance validation.
Outcome and results
• Efficient project execution: The project was managed according to the planned timeline and budget, ensuring optimal use of resources and smooth integration between scientific work packages.
• Strengthened researcher profile: The fellow significantly enhanced both scientific expertise and transferable skills, including leadership, supervision, communication, and strategic project planning.
• Knowledge transfer: Effective two-way knowledge exchange occurred within the host group and collaborating institutions, contributing to institutional capacity building.
• Scientific dissemination and impact: Publications, conference presentations, and outreach activities maximised the visibility of the project results at both scientific and societal levels.
• Exploitation pathway: Regular evaluation of results allowed identification of outcomes with potential for patenting and future technological transfer.
Achievement of scientific deliverables and milestones
WP4
• D4.1 (Periodic meeting reports and data management monitoring): Fully achieved
• D4.2 (Budget documentation and resource justification): Fully achieved
• Milestone M4 (Correct project management and budgeting): Fully achieved
WP5
• D5.1 (Reports on patents and publications from WP1–WP3): Fully achieved
• D5.2 (Training validation and independent lab authorisation): Fully achieved
• Milestone M5 (Completion of Career Development Plan): Fully achieved
WP6
• D6.1 (Periodic dissemination articles and outputs): Fully achieved
• Tasks T6.1–T6.3 (Exploitation strategy, publication/patent evaluation, compliance with deadlines): Fully achieved
• Milestone M6 (Effective dissemination and exploitation of results): Fully achieved
• OTHER ASPECTS OF THE WORK PLAN:
ANOTHER ASPECTS
a. Gender dimension in the research and innovation content
Due to the technical and materials-science-oriented nature of the project, no direct gender-related variables were scientifically relevant to the research content. In detail, the investigated phenomena (microstructure evolution, electrochemical behaviour, surface finishing, and additive incorporation) are material-dependent and not influenced by biological or socio-gender variables. Therefore, the integration of sex and/or gender analysis did not apply to the scientific objectives of the project.
Nevertheless, gender equality principles were respected throughout the project implementation, particularly in collaborative activities, supervision, and dissemination environments, ensuring inclusiveness and equal opportunities.
b. Implementation of secondment(s)
No secondments were formally planned or implemented during the fellowship period.
Despite the absence of official secondments, strong international collaborations were maintained throughout the project. These collaborations were essential to enable access to complementary expertise, materials, and advanced characterization techniques, ensuring effective knowledge exchange without the need for formal mobility periods.
c. Implementation of the Non-Academic Placement (NAP)
Non-Academic Placement (NAP) was not foreseen in the project and therefore was not implemented. However, the project maintained interaction with industrial stakeholders, particularly in relation to material supply, potential application scenarios, and evaluation of exploitation pathways.
d. Hosting conditions at the Beneficiary and research visits
The hosting conditions at the host institution were excellent and fully supportive of the project’s objectives. The research group provided access to the required infrastructure, laboratory facilities, and supervision necessary to successfully implement WP1-WP6.
No formal research visits, field work, or short stays (besides collaborative interactions) were required to achieve the project objectives. All planned activities were effectively carried out at the host institution, complemented by remote and collaborative interactions with partner institutions when needed.
The overall research environment ensured optimal scientific development, efficient project execution, and strong integration of the fellow within the host research group.
Lavoro eseguito dall’inizio del progetto fino alla fine del periodo coperto dalla relazione e principali risultati finora ottenuti
SCIENTIFIC AND TECHNOLOGICAL IMPACT
The project is practically completed in terms of the planned Work Packages and originally defined objectives.
Main scientific and technological achievements
The project has delivered the following key contributions to the state of the art:
• Demonstration of integrated surface-tailoring strategies during metal additive manufacturing (MAM), including in-situ compositional modulation.
• Validation of multi-material approaches (e.g. stainless steel–copper and hybrid aluminium systems) to control surface-related properties directly during fabrication.
• Establishment of clear processing-microstructure-corrosion relationships through advanced electrochemical and surface characterization techniques.
• Development and testing of optimised prototypes to assess technological feasibility.
As stated before, although certain publications are still in progress, the scientific foundation and experimental validation have been completed. The continuation of dissemination and related research activities after the formal end of the project demonstrates the sustainability and long-term relevance of the results.
No major deviations from the expected impacts described in Annex 1 occurred. The use of additional materials and techniques strengthened rather than reduced the project’s scientific impact.
a. Researcher's training and career development
The fellowship has had a substantial and measurable impact on the researcher’s scientific maturity, technical expertise, and career progression. From a scientific perspective, the researcher acquired advanced knowledge and hands-on experience in:
• Metal Additive Manufacturing (MAM), including laser-based Directed Energy Deposition and multi-material processing strategies.
• Advanced microstructural and surface characterization techniques (electron microscopy, surface-sensitive spectroscopy, electrochemical methods, and local corrosion techniques).
• Integrated processing-structure-property correlation methodologies.
The researcher achieved full autonomy in the operation of advanced experimental equipment and in the design of complex experimental campaigns.
From a professional development perspective, the fellowship significantly strengthened the international experience and networking, proposal writing skills, supervision and mentoring experience, project management and budgeting skills, and scientific communication skills.
Overall, as expected, the fellowship has positioned the researcher at a higher level of independence and competitiveness for securing a stable academic or research-oriented position in Europe.
b. Transfer of knowledge from the host(s) to the researcher and from the researcher to the host(s)
The knowledge exchange within the project was strongly bidirectional.
Transfer from the host to the researcher
The researcher gained specialized knowledge in the previously mentioned aspects, which significantly broadened the researcher’s scientific profile beyond previous specialization areas.
Transfer from the researcher to the host
The researcher contributed prior expertise in surface treatments and corrosion mitigation strategies, which proved essential for the successful implementation of the project. Namely: Knowledge on environmentally friendly and cost-effective post-treatment strategies, Experience in surface modification approaches and corrosion-resistant design concepts, and methodological approaches for linking surface chemistry with electrochemical behaviour.
This expertise enriched the host group’s capabilities in surface engineering and corrosion science and contributed directly to achieving the scientific objectives of WP1-WP3. Additionally, through student supervision and daily research interaction, the researcher contributed to strengthening the group’s know-how in corrosion-oriented surface assessment methodologies.
The project is practically completed in terms of the planned Work Packages and originally defined objectives.
Main scientific and technological achievements
The project has delivered the following key contributions to the state of the art:
• Demonstration of integrated surface-tailoring strategies during metal additive manufacturing (MAM), including in-situ compositional modulation.
• Validation of multi-material approaches (e.g. stainless steel–copper and hybrid aluminium systems) to control surface-related properties directly during fabrication.
• Establishment of clear processing-microstructure-corrosion relationships through advanced electrochemical and surface characterization techniques.
• Development and testing of optimised prototypes to assess technological feasibility.
As stated before, although certain publications are still in progress, the scientific foundation and experimental validation have been completed. The continuation of dissemination and related research activities after the formal end of the project demonstrates the sustainability and long-term relevance of the results.
No major deviations from the expected impacts described in Annex 1 occurred. The use of additional materials and techniques strengthened rather than reduced the project’s scientific impact.
a. Researcher's training and career development
The fellowship has had a substantial and measurable impact on the researcher’s scientific maturity, technical expertise, and career progression. From a scientific perspective, the researcher acquired advanced knowledge and hands-on experience in:
• Metal Additive Manufacturing (MAM), including laser-based Directed Energy Deposition and multi-material processing strategies.
• Advanced microstructural and surface characterization techniques (electron microscopy, surface-sensitive spectroscopy, electrochemical methods, and local corrosion techniques).
• Integrated processing-structure-property correlation methodologies.
The researcher achieved full autonomy in the operation of advanced experimental equipment and in the design of complex experimental campaigns.
From a professional development perspective, the fellowship significantly strengthened the international experience and networking, proposal writing skills, supervision and mentoring experience, project management and budgeting skills, and scientific communication skills.
Overall, as expected, the fellowship has positioned the researcher at a higher level of independence and competitiveness for securing a stable academic or research-oriented position in Europe.
b. Transfer of knowledge from the host(s) to the researcher and from the researcher to the host(s)
The knowledge exchange within the project was strongly bidirectional.
Transfer from the host to the researcher
The researcher gained specialized knowledge in the previously mentioned aspects, which significantly broadened the researcher’s scientific profile beyond previous specialization areas.
Transfer from the researcher to the host
The researcher contributed prior expertise in surface treatments and corrosion mitigation strategies, which proved essential for the successful implementation of the project. Namely: Knowledge on environmentally friendly and cost-effective post-treatment strategies, Experience in surface modification approaches and corrosion-resistant design concepts, and methodological approaches for linking surface chemistry with electrochemical behaviour.
This expertise enriched the host group’s capabilities in surface engineering and corrosion science and contributed directly to achieving the scientific objectives of WP1-WP3. Additionally, through student supervision and daily research interaction, the researcher contributed to strengthening the group’s know-how in corrosion-oriented surface assessment methodologies.
Progressi oltre lo stato dell’arte e potenziale impatto previsto (incluso l’impatto socioeconomico e le implicazioni sociali più ampie del progetto fino ad ora)
ECONOMIC, INDUSTRIAL AND SOCIETAL IMPACT
The project contributes to improving the durability and corrosion resistance of additively manufactured metallic components, which directly impacts:
• Industrial production efficiency: Reducing post-processing needs and increasing component lifetime.
• Cost reduction: Integrating surface engineering strategies during manufacturing.
• Sustainability: Reducing material waste, improving resource efficiency, and developing environmentally friendly post-treatment strategies.
Contribution to EU Headline Priorities
The project contributes, directly or indirectly, to several EU priorities:
• European Green Deal:
By enhancing the durability and corrosion resistance of lightweight alloys and reducing the need for aggressive post-treatments, the project supports sustainable manufacturing, resource efficiency, and extended component lifetime.
• Economy that works for people:
The development of advanced manufacturing methodologies strengthens European industrial competitiveness and innovation capacity in high-value sectors such as transport and biomedicine.
• Promoting the European way of life:
The research supports safer, more durable materials for infrastructure and transport applications, contributing to long-term societal resilience and quality standards.
• A stronger Europe in the world:
By advancing European expertise in metal additive manufacturing and corrosion science, the project reinforces Europe’s global leadership in advanced manufacturing technologies.
While not directly policy-oriented, the project aligns with EU strategies on sustainable industry.
POTENTIAL USERS AND COMMUNICATION WITH STAKEHOLDERS
Potential users of the project results include: industrial partners, companies and research institutions in the additive manufacturing and surface engineering sectors, such as transport and biomedicine.
The project contributes to improving the durability and corrosion resistance of additively manufactured metallic components, which directly impacts:
• Industrial production efficiency: Reducing post-processing needs and increasing component lifetime.
• Cost reduction: Integrating surface engineering strategies during manufacturing.
• Sustainability: Reducing material waste, improving resource efficiency, and developing environmentally friendly post-treatment strategies.
Contribution to EU Headline Priorities
The project contributes, directly or indirectly, to several EU priorities:
• European Green Deal:
By enhancing the durability and corrosion resistance of lightweight alloys and reducing the need for aggressive post-treatments, the project supports sustainable manufacturing, resource efficiency, and extended component lifetime.
• Economy that works for people:
The development of advanced manufacturing methodologies strengthens European industrial competitiveness and innovation capacity in high-value sectors such as transport and biomedicine.
• Promoting the European way of life:
The research supports safer, more durable materials for infrastructure and transport applications, contributing to long-term societal resilience and quality standards.
• A stronger Europe in the world:
By advancing European expertise in metal additive manufacturing and corrosion science, the project reinforces Europe’s global leadership in advanced manufacturing technologies.
While not directly policy-oriented, the project aligns with EU strategies on sustainable industry.
POTENTIAL USERS AND COMMUNICATION WITH STAKEHOLDERS
Potential users of the project results include: industrial partners, companies and research institutions in the additive manufacturing and surface engineering sectors, such as transport and biomedicine.