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Time-Resolved In Situ Measurements During Rapid Alloy Solidification: Experimental Insight for Additive Manufacturing

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An Erratum to this article was published on 11 February 2016

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Abstract

Additive manufacturing (AM) of metals and alloys is becoming a pervasive technology in both research and industrial environments, though significant challenges remain before widespread implementation of AM can be realized. In situ investigations of rapid alloy solidification with high spatial and temporal resolutions can provide unique experimental insight into microstructure evolution and kinetics that are relevant for AM processing. Hypoeutectic thin-film Al–Cu and Al–Si alloys were investigated using dynamic transmission electron microscopy to monitor pulsed-laser-induced rapid solidification across microsecond timescales. Solid–liquid interface velocities measured from time-resolved images revealed accelerating solidification fronts in both alloys. The observed microstructure evolution, solidification product, and presence of a morphological instability at the solid–liquid interface in the Al–4 at.%Cu alloy are related to the measured interface velocities and small differences in composition that affect the thermophysical properties of the alloys. These time-resolved in situ measurements can inform and validate predictive modeling efforts for AM.

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  • 11 February 2016

    An erratum to this article has been published.

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Acknowledgements

This work was performed under the auspices of the U.S. Department of Energy, by Lawrence Livermore National Laboratory (LLNL) under Contract No. DE-AC52-07NA27344. Activities and personnel at LLNL were supported by the U.S. Department of Energy, Office of Science, Office of Basic Energy Sciences, Division of Materials Science and Engineering under FWP SCW0974. Activities and personnel at the University of Pittsburgh received support from the National Science Foundation, Division of Materials Research, Metals & Metallic Nanostructures program through Grant No. DMR 1105757. Work at Los Alamos National Laboratory (LANL) was performed under the auspices of the U.S. Department of Energy by Los Alamos National Security, LLC, under Contract No. DE-AC52-06NA25396. Activities and personnel at LANL were supported by AJC’s Early Career Award from the U.S. Department of Energy, Office of Science, Office of Basic Energy Sciences, Division of Materials Science and Engineering. DTEM sample preparation at LANL was performed at the Center for Integrated Nanotechnologies, an Office of Science User Facility operated for the U.S. Department of Energy, Office of Science.

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Authors and Affiliations

  1. Materials Science Division, Lawrence Livermore National Laboratory, Livermore, CA, 94550, USA

    Joseph T. McKeown, John D. Roehling & Geoffrey H. Campbell

  2. Department of Mechanical Engineering and Materials Science, University of Pittsburgh, Pittsburgh, PA, 15261, USA

    Kai Zweiacker, Can Liu & Jörg M. K. Wiezorek

  3. Materials Science and Technology Division, Los Alamos National Laboratory, Los Alamos, NM, 87545, USA

    Daniel R. Coughlin, Amy J. Clarke, John W. Gibbs, Seth D. Imhoff, Paul J. Gibbs & Damien Tourret

  4. Center for Integrated Nanotechnologies, Los Alamos National Laboratory, Los Alamos, NM, 87545, USA

    J. Kevin Baldwin

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  1. Joseph T. McKeown
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McKeown, J.T., Zweiacker, K., Liu, C. et al. Time-Resolved In Situ Measurements During Rapid Alloy Solidification: Experimental Insight for Additive Manufacturing. JOM 68, 985–999 (2016). https://doi.org/10.1007/s11837-015-1793-x

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