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Researchers developed a custom metal additive manufacturing (AM) system for in-situ synchrotron studies. This enables detailed analysis of the physical phenomena in metal AM processes, advancing material science and process optimization.

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Physics

Background:

  • Metal additive manufacturing (AM) adoption is rising, but understanding its complex physical phenomena remains a challenge.
  • Stochastic processes in metal AM hinder fundamental comprehension and optimization.

Purpose of the Study:

  • To construct a custom metal AM system for simulating powder-fed directed energy deposition.
  • To conduct operando studies of the metal AM process using synchrotron radiation.

Main Methods:

  • Integration of a custom metal AM system with the Cornell High Energy Synchrotron Source.
  • Utilizing state-of-the-art direct-detection x-ray area detectors for high-fidelity data acquisition.
  • Employing operando experiments to observe solidification pathways and lattice plane spacing changes.

Main Results:

  • Acquisition of high-fidelity data on metal AM processes.
  • Enabling studies on material response to non-equilibrium solidification and intrinsic heat treatment.
  • Characterization of lattice plane spacing changes to calculate thermo-mechanical history and microstructural features.

Conclusions:

  • The developed system and operando approach provide unprecedented insights into metal AM.
  • The generated data facilitates a deeper understanding of solidification and microstructural evolution.
  • Synchrotron datasets offer diverse analysis possibilities for advancing metal AM technology.