High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy

Y. Chen; Y.T. Tang; D.M. Collins; S.J. Clark; W. Ludwig; R. Rodriguez-Lamas; C. Detlefs; R.C. Reed; P.D. Lee; P.J. Withers; C. Yildirim

doi:10.1016/j.scriptamat.2023.115579

High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy

Y. Chen, Y.T. Tang, D.M. Collins, S.J. Clark, W. Ludwig, R. Rodriguez-Lamas, C. Detlefs, R.C. Reed, P.D. Lee, P.J. Withers, C. Yildirim^*

^*Corresponding author for this work

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

Abstract

The industrialization of Laser Additive Manufacturing (LAM) is challenged by the undesirable microstructures and high residual stresses originating from the fast and complex solidification process. Non-destructive assessment of the mechanical performance controlling deformation patterning is therefore critical. Here, we use Dark Field X-ray Microscopy (DFXM) to map the 3D subsurface intragranular orientation and strain variations throughout a surface-breaking grain within a directed energy deposition nickel superalloy. DFXM results reveal a highly heterogenous 3D microstructure in terms of the local orientation and lattice strain. The grain comprises ≈ 5 μm-sized cells with alternating strain states, as high as 5 × 10^-3, and orientation differences <0.5°. The DFXM results are compared to Electron Backscatter Diffraction measurements of the same grain from its cut-off surface. We discuss the microstructure developments during LAM, rationalising the development of the deformation patterning from the extreme thermal gradients during processing and the susceptibility for solute segregation.

Original language	English
Article number	115579
Number of pages	6
Journal	Scripta Materialia
Volume	234
Early online date	31 May 2023
DOIs	https://doi.org/10.1016/j.scriptamat.2023.115579
Publication status	Published - Sept 2023

Bibliographical note

Acknowledgments:
We thank the ESRF for the provision of beamtime at ID06-HXM and ID11. YC acknowledges the support from the RMIT Vice Chancellor's Senior Research Fellowship. YC acknowledges travel funding (AS/IA223/19250) provided by the International Synchrotron Access Program (ISAP) managed by the Australian Synchrotron, part of ANSTO, and funded by the Australian Government. PJW and YT acknowledge support from the European Research Council Grant No 695638. The authors are grateful to Alloyed Ltd for the provision of material. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science user facility at Argonne National Laboratory, and is based on research supported by the US DOE Office of Science-Basic Energy Sciences, under Contract No. DE-AC02-06CH11357.

Keywords

Directed energy deposition
Laser additive manufacturing
Dark field x-ray microscopy
Electron backscatter diffraction
Microstructure

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https://discovery.ucl.ac.uk/id/eprint/10171766/

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Chen, Y., Tang, Y. T., Collins, D. M., Clark, S. J., Ludwig, W., Rodriguez-Lamas, R., Detlefs, C., Reed, R. C., Lee, P. D., Withers, P. J., & Yildirim, C. (2023). High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy. Scripta Materialia, 234, Article 115579. https://doi.org/10.1016/j.scriptamat.2023.115579

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title = "High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy",

abstract = "The industrialization of Laser Additive Manufacturing (LAM) is challenged by the undesirable microstructures and high residual stresses originating from the fast and complex solidification process. Non-destructive assessment of the mechanical performance controlling deformation patterning is therefore critical. Here, we use Dark Field X-ray Microscopy (DFXM) to map the 3D subsurface intragranular orientation and strain variations throughout a surface-breaking grain within a directed energy deposition nickel superalloy. DFXM results reveal a highly heterogenous 3D microstructure in terms of the local orientation and lattice strain. The grain comprises ≈ 5 μm-sized cells with alternating strain states, as high as 5 × 10-3, and orientation differences <0.5°. The DFXM results are compared to Electron Backscatter Diffraction measurements of the same grain from its cut-off surface. We discuss the microstructure developments during LAM, rationalising the development of the deformation patterning from the extreme thermal gradients during processing and the susceptibility for solute segregation.",

keywords = "Directed energy deposition, Laser additive manufacturing, Dark field x-ray microscopy, Electron backscatter diffraction, Microstructure",

author = "Y. Chen and Y.T. Tang and D.M. Collins and S.J. Clark and W. Ludwig and R. Rodriguez-Lamas and C. Detlefs and R.C. Reed and P.D. Lee and P.J. Withers and C. Yildirim",

note = "Acknowledgments: We thank the ESRF for the provision of beamtime at ID06-HXM and ID11. YC acknowledges the support from the RMIT Vice Chancellor's Senior Research Fellowship. YC acknowledges travel funding (AS/IA223/19250) provided by the International Synchrotron Access Program (ISAP) managed by the Australian Synchrotron, part of ANSTO, and funded by the Australian Government. PJW and YT acknowledge support from the European Research Council Grant No 695638. The authors are grateful to Alloyed Ltd for the provision of material. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science user facility at Argonne National Laboratory, and is based on research supported by the US DOE Office of Science-Basic Energy Sciences, under Contract No. DE-AC02-06CH11357.",

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AU - Chen, Y.

AU - Tang, Y.T.

AU - Collins, D.M.

AU - Clark, S.J.

AU - Ludwig, W.

AU - Rodriguez-Lamas, R.

AU - Detlefs, C.

AU - Reed, R.C.

AU - Lee, P.D.

AU - Withers, P.J.

AU - Yildirim, C.

N1 - Acknowledgments: We thank the ESRF for the provision of beamtime at ID06-HXM and ID11. YC acknowledges the support from the RMIT Vice Chancellor's Senior Research Fellowship. YC acknowledges travel funding (AS/IA223/19250) provided by the International Synchrotron Access Program (ISAP) managed by the Australian Synchrotron, part of ANSTO, and funded by the Australian Government. PJW and YT acknowledge support from the European Research Council Grant No 695638. The authors are grateful to Alloyed Ltd for the provision of material. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science user facility at Argonne National Laboratory, and is based on research supported by the US DOE Office of Science-Basic Energy Sciences, under Contract No. DE-AC02-06CH11357.

PY - 2023/9

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N2 - The industrialization of Laser Additive Manufacturing (LAM) is challenged by the undesirable microstructures and high residual stresses originating from the fast and complex solidification process. Non-destructive assessment of the mechanical performance controlling deformation patterning is therefore critical. Here, we use Dark Field X-ray Microscopy (DFXM) to map the 3D subsurface intragranular orientation and strain variations throughout a surface-breaking grain within a directed energy deposition nickel superalloy. DFXM results reveal a highly heterogenous 3D microstructure in terms of the local orientation and lattice strain. The grain comprises ≈ 5 μm-sized cells with alternating strain states, as high as 5 × 10-3, and orientation differences <0.5°. The DFXM results are compared to Electron Backscatter Diffraction measurements of the same grain from its cut-off surface. We discuss the microstructure developments during LAM, rationalising the development of the deformation patterning from the extreme thermal gradients during processing and the susceptibility for solute segregation.

AB - The industrialization of Laser Additive Manufacturing (LAM) is challenged by the undesirable microstructures and high residual stresses originating from the fast and complex solidification process. Non-destructive assessment of the mechanical performance controlling deformation patterning is therefore critical. Here, we use Dark Field X-ray Microscopy (DFXM) to map the 3D subsurface intragranular orientation and strain variations throughout a surface-breaking grain within a directed energy deposition nickel superalloy. DFXM results reveal a highly heterogenous 3D microstructure in terms of the local orientation and lattice strain. The grain comprises ≈ 5 μm-sized cells with alternating strain states, as high as 5 × 10-3, and orientation differences <0.5°. The DFXM results are compared to Electron Backscatter Diffraction measurements of the same grain from its cut-off surface. We discuss the microstructure developments during LAM, rationalising the development of the deformation patterning from the extreme thermal gradients during processing and the susceptibility for solute segregation.

KW - Directed energy deposition

KW - Laser additive manufacturing

KW - Dark field x-ray microscopy

KW - Electron backscatter diffraction

KW - Microstructure

U2 - 10.1016/j.scriptamat.2023.115579

DO - 10.1016/j.scriptamat.2023.115579

M3 - Article

SN - 1359-6462

VL - 234

JO - Scripta Materialia

JF - Scripta Materialia

M1 - 115579

ER -

High-resolution 3D strain and orientation mapping within a grain of a directed energy deposition laser additively manufactured superalloy

Abstract

Bibliographical note

Keywords

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