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In situ/operando synchrotron x-ray studies of metal additive manufacturing

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Abstract

Additive manufacturing (AM) comprises a group of transformative technologies that are likely to revolutionize manufacturing. In particular, laser-based metal AM techniques can not only fabricate parts with extreme complexity, but also provide innovative means for designing and processing new metallic systems. However, there are still several technical barriers that constrain metal AM. Overcoming these barriers requires a better understanding of the physics underlying the complex and dynamic laser–metal interaction at the heart of many AM processes. This article briefly describes the state of the art of in situ/operando synchrotron x-ray imaging and diffraction for studying metal AM, mostly the laser powder-bed fusion process. It highlights the immediate impact of operando synchrotron studies on the advancement of AM technologies, and presents future research challenges and opportunities.

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Acknowledgments

We are pleased to acknowledge our many colleagues for their contributions to the in situ/operando synchrotron studies described herein, including C. Zhao, N. Parab, S. Wolff, B. Gould, N. Kouraytem, X. Li, Q. Guo, L. Escano, S.M. Hojjatzadeh, M. Qu, L. Xiong, R. Cunningham, C. Kantzos, and J. Pauza. We also thank K. Fezzaa and C.-P. Chuang for their support on the beamline experiments. W.T. acknowledges support from the National Science Foundation (NSF) (Award Nos. 1752218 and 1933368). L.C. acknowledges support from the NSF (Award Nos. 2002840 and 2011354). A.D.R. acknowledges support from the National Nuclear Security Administration under Grant No. DE-NA0003915. Synchrotron experiments described in this contribution used resources of the Advanced Photon Source, a US Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02–06CH11357.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, University of Virginia, USA

    Tao Sun

  2. Department of Mechanical Engineering, The University of Utah, USA

    Wenda Tan

  3. Department of Mechanical Engineering, University of Wisconsin–Madison, USA

    Lianyi Chen

  4. Department of Materials Science and Engineering, Carnegie Mellon University, USA

    Anthony Rollett

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  1. Tao Sun
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  2. Wenda Tan
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Corresponding author

Correspondence to Tao Sun.

Appendix

Appendix

Tao Sun has been an associate professor in the Department of Materials Science and Engineering at University of Virginia since 2019. Previously, he served as a beamline scientist at the Advanced Photon Source of Argonne National Laboratory. He received his BS and MS degrees in materials science and engineering from Tsinghua University, China, and his PhD degree from Northwestern University. His research focuses on studying additive manufacturing processes and materials using synchrotron x-ray and other in situ/ex situ characterization tools. Sun can be reached by email at ts7qw@virginia.edu.

Wenda Tan is an assistant professor in the Department of Mechanical Engineering at the University of Utah. He received his BS and MS degrees in mechanical engineering from Tsinghua University, China, and his PhD degree in mechanical engineering from Purdue University. His research focuses on computational heat transfer, computational fluid mechanics, computational materials and their applications in various advanced manufacturing techniques, such as additive manufacturing, welding and joining, and casting. His awards include the National Science Foundation CAREER Award in 2018. Tan can be reached by email at wenda.tan@mech.utah.edu.

Lianyi Chen is an assistant professor in the Department of Mechanical Engineering at the University of Wisconsin-Madison. He received PhD degree in materials science and engineering from Zhejiang University, China. His research includes four highly interrelated research areas: metal additive manufacturing, metals design based on nanoelements, smart metal manufacturing, and in situ/in operando characterization. He has published more than 70 journal papers, and is an inventor with seven patents (two licensed). Chen can be reached by email at lianyi.chen@wisc.edu.

Anthony Rollett has been the U. S. Steel Professor in Materials Science and Engineering at Carnegie Mellon University (CMU). He received PhD degree in materials engineering from Drexel University. He previously worked at the Los Alamos National Laboratory (LANL) for sixteen years. He was the Deputy Division Director of Materials Science and Technology in LANL before taking the department head position in CMU in 1995. His awards include a Fellow of The Minerals, Metals & Materials Society in 2011, and an International Francqui Professor for 2020–2021, Belgium. He is a co-Director of the Next Manufacturing Center at CMU and is a leader in research and education in additive manufacturing. Rollet can be reached by email at rollett@andrew.cmu.edu.

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Sun, T., Tan, W., Chen, L. et al. In situ/operando synchrotron x-ray studies of metal additive manufacturing. MRS Bulletin 45, 927–933 (2020). https://doi.org/10.1557/mrs.2020.275

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