Correlative Synchrotron X-ray Imaging and Diffraction of Directed Energy Deposition Additive Manufacturing

Yunhui Chen; Samuel J. Clark; David M. Collins; Sebastian Marussi; Simon A. Hunt; Danielle M. Fenech; Thomas Connolley; Robert C. Atwood; Oxana V. Magdysyuk; Gavin J. Baxter; Martyn A. Jones; Chu Lun Alex Leung; Peter D. Lee

doi:10.1016/j.actamat.2021.116777

Correlative Synchrotron X-ray Imaging and Diffraction of Directed Energy Deposition Additive Manufacturing

Yunhui Chen^*, Samuel J. Clark, David M. Collins^*, Sebastian Marussi, Simon A. Hunt, Danielle M. Fenech, Thomas Connolley, Robert C. Atwood, Oxana V. Magdysyuk, Gavin J. Baxter, Martyn A. Jones, Chu Lun Alex Leung, Peter D. Lee^*

^*Corresponding author for this work

Metallurgy and Materials

Research output: Contribution to journal › Article › peer-review

31 Citations (Scopus)

Abstract

The governing mechanistic behaviour of Directed Energy Deposition Additive Manufacturing (DED-AM) is revealed by a combined in situ and operando synchrotron X-ray imaging and diffraction study of a nickel-base superalloy, IN718. Using a unique DED-AM process replicator, real-space imaging enables quantification of the melt-pool boundary and flow dynamics during solidification. This imaging knowledge was also used to inform precise diffraction measurements of temporally resolved microstructural phases during transformation and stress development with a spatial resolution of 100 µm. The diffraction quantified thermal gradient enabled a dendritic solidification microstructure to be predicted and coupled to the stress state. The fast cooling rate entirely suppressed the formation of secondary phases or recrystallisation in the solid-state. Upon solidification, the stresses rapidly increase to the yield strength during cooling. This insight, combined with the large solidification range of IN718 suggests that the accumulated plasticity exhausts the ductility of the alloy, causing liquation cracking. This study has revealed the mechanisms that govern the formation of highly non-equilibrium microstructures during DED-AM.

Original language	English
Article number	116777
Number of pages	13
Journal	Acta Materialia
Volume	209
Early online date	1 Mar 2021
DOIs	https://doi.org/10.1016/j.actamat.2021.116777
Publication status	Published - 1 May 2021

Bibliographical note

Acknowledgements:
This research was supported under MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes (EP/P006566/1), a Royal Academy of Engineering Chair in Emerging Technology (CiET1819/10), and Rolls-Royce plc. via the Horizon 2020 Clean Sky 2 WP5.8.1 programme. This work has been supported by the Office of Naval Research (ONR) Grant N62909-19-1-2109. The provision of materials and technical support from Rolls-Royce plc is gratefully acknowledged. Laboratory space and facilities were provided by the Research Complex at Harwell. The authors thank Diamond Light Source for providing beamtime (MT20096) and the staff at I12 beamline for technical assistance.

Publisher Copyright:
© 2021

Keywords

Directed Energy Deposition Additive Manufacturing
IN718
Laser Additive Manufacturing
Synchrotron X-ray diffraction
Synchrotron X-ray imaging

ASJC Scopus subject areas

Electronic, Optical and Magnetic Materials
Ceramics and Composites
Polymers and Plastics
Metals and Alloys

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https://discovery.ucl.ac.uk/id/eprint/10113563/

Cite this

Chen, Y., Clark, S. J., Collins, D. M., Marussi, S., Hunt, S. A., Fenech, D. M., Connolley, T., Atwood, R. C., Magdysyuk, O. V., Baxter, G. J., Jones, M. A., Leung, C. L. A., & Lee, P. D. (2021). Correlative Synchrotron X-ray Imaging and Diffraction of Directed Energy Deposition Additive Manufacturing. Acta Materialia, 209, Article 116777. https://doi.org/10.1016/j.actamat.2021.116777

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abstract = "The governing mechanistic behaviour of Directed Energy Deposition Additive Manufacturing (DED-AM) is revealed by a combined in situ and operando synchrotron X-ray imaging and diffraction study of a nickel-base superalloy, IN718. Using a unique DED-AM process replicator, real-space imaging enables quantification of the melt-pool boundary and flow dynamics during solidification. This imaging knowledge was also used to inform precise diffraction measurements of temporally resolved microstructural phases during transformation and stress development with a spatial resolution of 100 µm. The diffraction quantified thermal gradient enabled a dendritic solidification microstructure to be predicted and coupled to the stress state. The fast cooling rate entirely suppressed the formation of secondary phases or recrystallisation in the solid-state. Upon solidification, the stresses rapidly increase to the yield strength during cooling. This insight, combined with the large solidification range of IN718 suggests that the accumulated plasticity exhausts the ductility of the alloy, causing liquation cracking. This study has revealed the mechanisms that govern the formation of highly non-equilibrium microstructures during DED-AM.",

keywords = "Directed Energy Deposition Additive Manufacturing, IN718, Laser Additive Manufacturing, Synchrotron X-ray diffraction, Synchrotron X-ray imaging",

author = "Yunhui Chen and Clark, {Samuel J.} and Collins, {David M.} and Sebastian Marussi and Hunt, {Simon A.} and Fenech, {Danielle M.} and Thomas Connolley and Atwood, {Robert C.} and Magdysyuk, {Oxana V.} and Baxter, {Gavin J.} and Jones, {Martyn A.} and Leung, {Chu Lun Alex} and Lee, {Peter D.}",

note = "Acknowledgements: This research was supported under MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes (EP/P006566/1), a Royal Academy of Engineering Chair in Emerging Technology (CiET1819/10), and Rolls-Royce plc. via the Horizon 2020 Clean Sky 2 WP5.8.1 programme. This work has been supported by the Office of Naval Research (ONR) Grant N62909-19-1-2109. The provision of materials and technical support from Rolls-Royce plc is gratefully acknowledged. Laboratory space and facilities were provided by the Research Complex at Harwell. The authors thank Diamond Light Source for providing beamtime (MT20096) and the staff at I12 beamline for technical assistance. Publisher Copyright: {\textcopyright} 2021",

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AU - Chen, Yunhui

AU - Clark, Samuel J.

AU - Collins, David M.

AU - Marussi, Sebastian

AU - Hunt, Simon A.

AU - Fenech, Danielle M.

AU - Connolley, Thomas

AU - Atwood, Robert C.

AU - Magdysyuk, Oxana V.

AU - Baxter, Gavin J.

AU - Jones, Martyn A.

AU - Leung, Chu Lun Alex

AU - Lee, Peter D.

N1 - Acknowledgements: This research was supported under MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes (EP/P006566/1), a Royal Academy of Engineering Chair in Emerging Technology (CiET1819/10), and Rolls-Royce plc. via the Horizon 2020 Clean Sky 2 WP5.8.1 programme. This work has been supported by the Office of Naval Research (ONR) Grant N62909-19-1-2109. The provision of materials and technical support from Rolls-Royce plc is gratefully acknowledged. Laboratory space and facilities were provided by the Research Complex at Harwell. The authors thank Diamond Light Source for providing beamtime (MT20096) and the staff at I12 beamline for technical assistance. Publisher Copyright: © 2021

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N2 - The governing mechanistic behaviour of Directed Energy Deposition Additive Manufacturing (DED-AM) is revealed by a combined in situ and operando synchrotron X-ray imaging and diffraction study of a nickel-base superalloy, IN718. Using a unique DED-AM process replicator, real-space imaging enables quantification of the melt-pool boundary and flow dynamics during solidification. This imaging knowledge was also used to inform precise diffraction measurements of temporally resolved microstructural phases during transformation and stress development with a spatial resolution of 100 µm. The diffraction quantified thermal gradient enabled a dendritic solidification microstructure to be predicted and coupled to the stress state. The fast cooling rate entirely suppressed the formation of secondary phases or recrystallisation in the solid-state. Upon solidification, the stresses rapidly increase to the yield strength during cooling. This insight, combined with the large solidification range of IN718 suggests that the accumulated plasticity exhausts the ductility of the alloy, causing liquation cracking. This study has revealed the mechanisms that govern the formation of highly non-equilibrium microstructures during DED-AM.

AB - The governing mechanistic behaviour of Directed Energy Deposition Additive Manufacturing (DED-AM) is revealed by a combined in situ and operando synchrotron X-ray imaging and diffraction study of a nickel-base superalloy, IN718. Using a unique DED-AM process replicator, real-space imaging enables quantification of the melt-pool boundary and flow dynamics during solidification. This imaging knowledge was also used to inform precise diffraction measurements of temporally resolved microstructural phases during transformation and stress development with a spatial resolution of 100 µm. The diffraction quantified thermal gradient enabled a dendritic solidification microstructure to be predicted and coupled to the stress state. The fast cooling rate entirely suppressed the formation of secondary phases or recrystallisation in the solid-state. Upon solidification, the stresses rapidly increase to the yield strength during cooling. This insight, combined with the large solidification range of IN718 suggests that the accumulated plasticity exhausts the ductility of the alloy, causing liquation cracking. This study has revealed the mechanisms that govern the formation of highly non-equilibrium microstructures during DED-AM.

KW - Directed Energy Deposition Additive Manufacturing

KW - IN718

KW - Laser Additive Manufacturing

KW - Synchrotron X-ray diffraction

KW - Synchrotron X-ray imaging

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DO - 10.1016/j.actamat.2021.116777

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SN - 1359-6454

VL - 209

JO - Acta Materialia

JF - Acta Materialia

M1 - 116777

ER -

Correlative Synchrotron X-ray Imaging and Diffraction of Directed Energy Deposition Additive Manufacturing

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

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