Recent progress on in-situ characterization of laser additive manufacturing process by synchrotron radiation

doi:10.1016/j.jmst.2024.07.047

Abstract

Abstract: Laser additive manufacturing (LAM) has been widely used in high-end manufacturing fields such as aerospace, nuclear power, and shipbuilding. However, it is a grand challenge for direct and continuous observation of complex laser-matter interaction, melt flow, and defect formation during LAM due to extremely large temperature gradient, fast cooling rate, and small time (millisecond) and space (micron) scales. The emergence of synchrotron radiation provides a feasible approach for in situ observation of the LAM process. This paper outlines the current development in real-time characterization of LAM by synchrotron radiation, including laser-matter interaction, molten pool evolution, solidification structure evolution, and defects formation and elimination. Furthermore, the future development direction and application-oriented research are also discussed.

Key words: Laser additive manufacturing, Synchrotron radiation, Melt pool, Defect

Wenquan Lu, Liang Zhao, Zhun Su, Jianguo Li, Qiaodan Hu. Recent progress on in-situ characterization of laser additive manufacturing process by synchrotron radiation[J]. J. Mater. Sci. Technol., 2025, 217: 29-46.

References

[1] D.D. Gu, X.Y. Shi, R. Poprawe, D.L. Bourell, R. Setchi, J.H. Zhu, Science 372 (2021) eabg1487.
[2] Y.H. Chen, S.J. Clark, D.M. Collins, S. Marussi, S.A. Hunt, D.M. Fenech, T. Con-nolley, R.C. Atwood, O.V. Magdysyuk, G.J. Baxter, M.A. Jones, C.L.A. Leung, P.D. Lee, Acta Mater. 209(2021) 116777.
[3] J.W. Pegues, M.A. Melia, M.A. Rodriguez, T.F. Babuska, B. Gould, N. Argibay, A. Greco, A.B. Kustas, J. Alloy. Compd. 876(2021) 159505.
[4] M. Khorasani, I. Gibson, A.H. Ghasemi, E. Hadavi, B. Rolfe, Rapid Prototyp. J. 29(2023) 935-958.
[5] L. Sinclair, S.J. Clark, Y.H. Chen, S. Marussi, S.R. Shah, O.V. Magdysyuk, R.C.At-wood, G.J. Baxter, M. Jones, D.G. McCartney, C.L.A. Leung, P.D. Lee, Int. J. Mach. Tools Manuf. 176(2022) 103887.
[6] M. Khorasani, A.H. Ghasemi, B. Rolfe, I. Gibson, Rapid Prototyp. J. 28(2022) 87-100.
[7] C.L.A.Leung, S. Marussi, M.Towrie, R.C. Atwood, P.J. Withers, P.D. Lee, Acta Mater. 166(2019) 294-305.
[8] Y.H. Chen, S.J. Clark, C.L.A. Leung, L. Sinclair, S. Marussi, M.P. Olbinado, E. Boller, A. Rack, I. Todd, P.D. Lee, Appl. Mater. Today 20 (2020) 100650.
[9] L. Wang, Q.L. Guo, L.Y. Chen, W.T. Yan, Int. J. Mach. Tools Manuf. 193(2023) 104077.
[10] Y.H. Chen, S.J. Clark, L. Sinclair, C.L.A.Leung, S. Marussi, T.Connolley, R.C. At-wood, G.J. Baxter, M.A. Jones, I. Todd, P.D. Lee, Addit. Manuf. 41(2021) 101969.
[11] J.V. Gordon, S.P. Narra, R.W. Cunningham, H. Liu, H.M. Chen, R.M. Suter, J.L. Beuth, A.D. Rollett, Addit. Manuf. 36(2020) 101552.
[12] Q.L. Guo, C. Zhao, M.L. Qu, L.H. Xiong, L.I. Escano, S.M.H.Hojjatzadeh, N.D. Parab, K. Fezzaa, W.Everhart, T. Sun, L.Y. Chen, Addit. Manuf. 28(2019) 600-609.
[13] C.L.A.Leung, S. Marussi, M.Towrie, J.D. Garcia, R.C. Atwood, A.J. Bodey, J.R. Jones, P.J. Withers, P.D. Lee, Addit. Manuf. 24(2018) 647-657.
[14] R. Cunningham, S.P. Narra, C. Montgomery, J. Beuth, A.D. Rollett, JOM 69 (2017) 479-484.
[15] S.M.H.Hojjatzadeh, N.D. Parab, Q.L. Guo, M.L. Qu, L.H. Xiong, C. Zhao, L.I. Es-cano, K. Fezzaa, W. Everhart, T. Sun, L.Y. Chen, Int. J. Mach. Tools Manuf. 153(2020) 103555.
[16] B.J. Simonds, J. Tanner, A. Artusio-Glimpse, P.A. Williams, N. Parab, Z. Cang, S. Tao, Proc. CIRP 94 (2020) 775-779.
[17] H.E.Ghasemi-Tabasi, C.de Formanoir, S. Van Petegem, J. Jhabvala, S. Hocine, E. Boillat, N. Sohrabi, F. Marone, D. Grolimund, H. Van Swygenhoven, R.E. Loge, Addit. Manuf. 51(2022) 102619.
[18] C.L.A.Leung, S. Marussi, R.C. Atwood, M. Towrie, P.J. Withers, P.D. Lee, Nat. Commun. 9(2018) 1355.
[19] D.D. Gu, Y.F. Shen, J. Alloy. Compd. 432(2007) 163-166.
[20] A.S. Wu, D.W. Brown, M. Kumar, G.F. Gallegos, W.E. King, Metall. Mater. Trans. A 45A (2014) 6260-6270.
[21] Y.N. Hu, S.C. Wu, P.J. Withers, J. Zhang, H.Y.X.Bao, Y.N. Fu, G.Z. Kang, Mater. Des. 192(2020) 108708.
[22] E. Liverani, S. Toschi, L. Ceschini, A. Fortunato, J. Mater. Process.Technol. 249(2017) 255-263.
[23] M. Grasso, A.G. Demir, B. Previtali, B.M. Colosimo, Robot. Computer-Integrated Manuf. 49(2018) 229-239.
[24] G. Repossini, V. Laguzza, M. Grasso, B.M. Colosimo, Addit. Manuf. 16(2017) 35-48.
[25] M.L. Qu, Q.L. Guo, L.I. Escano, A. Nabaa, K. Fezzaa, L.Y. Chen, Addit. Manuf. 60(2022) 103242.
[26] C. Zhao, K. Fezzaa, R.W. Cunningham, H.D. Wen, F. De Carlo, L.Y. Chen, A.D. Rollett, T. Sun, Sci. Rep. 7(2017) 3602.
[27] Q.L. Guo, C. Zhao, L.I. Escano, Z. Young, L.H. Xiong, K. Fezzaa, W. Everhart, B. Brown, T. Sun, L.Y. Chen, Acta Mater. 151(2018) 169-180.
[28] S. Karagadde, C.L.A. Leung, P.D. Lee, Materials 14 (2021) 2374.
[29] N.D. Parab, C. Zhao, R. Cunningham, L.I. Escano, K. Fezzaa, W. Everhart, A.D. Rollett, L.Y. Chen, T. Sun, J. Synchrot. Radiat. 25(2018) 1467-1477.
[30] A. Momose, T. Takeda, Y. Itai, K. Hirano, Nat. Med. 2(1996) 473-475.
[31] T.J. Davis, D. Gao, T.E. Gureyev, A.W. Stevenson, S.W. Wilkins, Nature 373 (1995) 595-598.
[32] S.P. Jiang, Y. Chen, M.-f. Li, L.Chen, Z. Xiong, Y.Q. Yu, Chin. J. Med. Imag. Tech-nol. 23(2007) 1721-1723.
[33] X.J. Zhao, K. Zhang, Y.L. Hong, W.X. Huang, Q.X. Yuan, P.P. Zhu, Z.Y. Wu, Acta Phys. Sin. 62(2013) 124202.
[34] P.P. Zhu, Q.X. Yuan, W.X. Huang, J.Y. Wang, H. Shu, Z.Y. Wu, D.C. Xian, Acta Phys. Sin. 55(2006) 1089-1098.
[35] T. Wang, J. Xu, W. Huang, C. Liu, Z. Cao, T. Li, Nucl. Technol. 33(2010) 4 43-4 46.
[36] L. Liu, P. Zhu, H. Shu, K. Zhang, Acta Opt. Sin. 28(2008) 1492-1495.
[37] F.F. Ahmed, S.J. Clark, C.L.A.Leung, L. Stanger, J.Willmott, S. Marussi, V. Honkimaki, N. Haynes, H.S. Zurob, P.D. Lee, A.B. Phillion, Mater. Des. 210(2021) 110072.
[38] K. Prasad, Y. Horita, A. Ito, S. Torizuka, Scr. Mater. 200(2021) 113896.
[39] J.P. Oliveira, A.J. Cavaleiro, N. Schell, A. Stark, R.M. Miranda, J.L. Ocana, F.M.B.Fernandes, Scr. Mater. 152(2018) 122-126.
[40] Y.H. Chen, S.J. Clark, Y.Z. Huang, L. Sinclair, C.L.A.Leung, S. Marussi, T.Con-nolley, O.V. Magdysyuk, R.C. Atwood, G.J. Baxter, M.A. Jones, I. Todd, P.D. Lee, Mater. Lett. 286(2021) 129205.
[41] N. Derimow, E.J. Schwalbach, J.T. Benzing, J.P. Killgore, A.B.Artusio-Glimpse, N.Hrabe, B.J. Simonds, J. Alloy. Compd. 900(2022) 163494.
[42] Y.Z. Huang, T.G. Fleming, S.J. Clark, S. Marussi, K. Fezzaa, J. Thiyagalingam, C.L.A.Leung, P.D. Lee, Nat. Commun. 13(2022) 1170.
[43] T.R. Allen, W.K. Huang, J.R. Tanner, W.D. Tan, J.M. Fraser, B.J. Simonds, Phys. Rev. Appl. 13(2020) 064070.
[44] P. Bidare, I. Bitharas, R. Ward, M. Attallah, A.J. Moore, Acta Mater. 142(2018) 107-120.
[45] Y.F. Wang, L.L. Xing, K.L. Li, C.F. Yu, J. Ma, W. Liu, Z.J. Shen, Metall. Mater. Trans. B 50 (2019) 1035-1041.
[46] A. Keshavarzkermani, E. Marzbanrad, R. Esmaeilizadeh, Y. Mahmoodkhani, U. Ali, P.D. Enrique, N.Y. Zhou, A. Bonakdar, E. Toyserkani, Opt. Laser Technol. 116(2019) 83-91.
[47] I. Bitharas, N. Parab, C. Zhao, T. Sun, A.D. Rollett, A.J. Moore, Nat. Commun. 13(2022) 2959.
[48] V. Gunenthiram, P. Peyre, M. Schneider, M. Dal, F. Coste, I. Koutiri, R. Fabbro, J. Mater. Process.Technol. 251(2018) 376-386.
[49] R. Indhu, V. Vivek, L. Sarathkumar, A. Bharatish, S. Soundarapandian, Lasers Manuf. Mater. Process. 5(2018) 458-481.
[50] T. Thiede, T. Mishurova, S. Evsevleev, I. Serrano-Munoz, C. Gollwitzer, G. Bruno, Quantum Beam Sci. 3(2019) 3.
[51] B.J. Simonds, E.J. Garboczi, T.A. Palmer, P.A. Williams, Phys. Rev. Appl. 13(2020) 024057.
[52] G. Soundarapandiyan, C.L.A.Leung, C. Johnston, B.Chen, R.H.U. Khan, P. Mc- Nutt, A. Bhatt, R.C. Atwood, P.D. Lee, M.E. Fitzpatrick, Int. J. Mach. Tools Manuf. 190(2023) 104049.
[53] B.J. Simonds, J. Tanner, A. Artusio-Glimpse, P.A. Williams, N. Parab, C. Zhao, T. Sun, Appl. Mater. Today 23 (2021) 1011049.
[54] J. Trapp, A.M. Rubenchik, G. Guss, M.J. Matthews, Appl. Mater. Today 9 (2017) 341-349.
[55] S.A. Khairallah, A.A. Martin, J.R.I. Lee, G. Guss, N.P. Calta, J.A. Hammons, M.H. Nielsen, K. Chaput, E. Schwalbach, M.N. Shah, M.G. Chapman, T.M. Wil-ley, A.M. Rubenchik, A.T. Anderson, Y.M. Wang, M.J. Matthews, W.E. King, Sci-ence 368 (2020) 660.
[56] R.B. Jiang, J. Smith, Y.T. Yi, T. Sun, B.J. Simonds, A.D.Rollett, npj Comput.Mater. 10(2024) 6.
[57] C.L.A.Leung, D. Luczyniec, E.Y. Guo, S. Marussi, R.C. Atwood, M. Meisnar, B. Saunders, P.D. Lee, Adv. Sci. 9(2022) 2203546.
[58] Q.L. Guo, M.L. Qu, L.I. Escano, S.M.H.Hojjatzadeh, Z. Young, K.Fezzaa, L.Y. Chen, Int. J. Mach. Tools Manuf. 175(2022) 103861.
[59] C.P. Wang, X.J. Liu, I. Ohnuma, R. Kainuma, K. Ishida, Science 297 (2002) 990-993.
[60] S.A. Khairallah, A.T. Anderson, A. Rubenchik, Y.E. King, Acta Mater. 196(2020) 30.
[61] X.Q. Fan, T.G. Fleming, D.T. Rees, Y.Z. Huang, S. Marussi, C.L.A.Leung, R.C. At-wood, A.D. Kao, P.D. Lee, Addit. Manuf. 71(2023) 103587.
[62] W.E. King, H.D. Barth, V.M. Castillo, G.F. Gallegos, J.W. Gibbs, D.E. Hahn, C. Ka-math, A.M. Rubenchik, J. Mater. Process. Technol. 214(2014) 2915-2925.
[63] M.H. Farshidianfar, A. Khajepour, A.P. Gerlich, J. Mater. Process.Technol. 231(2016) 468-478.
[64] H. Wang, B. Gould, M. Moorehead, M. Haddad, A. Couet, S.J. Wolff, J. Mater. Process.Technol. 299(2022) 117363.
[65] B. Gould, S. Wolff, N. Parab, C. Zhao, M.C. Lorenzo-Martin, K. Fezzaa, A. Greco, T. Sun, JOM 73 (2021) 201-211.
[66] J. Lamb, R. Ochoa, A. Eres-Castellanos, J. Klemm-Toole, M.P. Echlin, T. Sun, K. Fezzaa, A. Clarke, T.M. Pollock, Scr. Mater. 245(2024) 116036.
[67] Y.J. Gu, J.D. Yuan, L.Y. Chen, Phys. Rev. Mater. 7(2023) 103401.
[68] G. Graf, J. Rosigkeit, E. Krohmer, P. Staron, R. Krenn, H. Clemens, P. Spo-erk-Erdely, Adv.Eng. Mater. 23(2021) 2100557.
[69] H.H. Konig, N.H. Pettersson, A. Durga, S. Van Petegem, D. Grolimund, A.C. Chuang, Q.L. Guo, L.Y. Chen, C. Oikonomou, F. Zhang, G. Lindwall, Acta Mater. 246(2023) 118713.
[70] T. Mishurova, S. Cabeza, K. Artzt, J. Haubrich, M. Klaus, C. Genzel, G. Requena, G. Bruno, Materials 10 (2017) 348.
[71] D.S. Zhang, W. Liu, Y.X. Li, D.R. Sun, Y. Wu, S.N. Luo, S. Chen, Y. Tao, B.B. Zhang, Nat. Commun. 14(2023) 2961.
[72] M.L. Qu, J.D. Yuan, A. Nabaa, J. Anne, J.Y. Huang, C.A. Chuang, L.Y. Chen, Acta Mater. 271(2024) 119875.
[73] Z.H. Wu, M. Asherloo, R.B. Jiang, M.H. Delpazir, N. Sivakumar, M. Pali-wal, J.Capone, B. Gould, A. Rollett, A. Mostafaei, Addit. Manuf. 47(2021) 102323.
[74] C. Zhao, Y.Q. Yang, B. Shi, W.J. Shao, S.L. Chen, Chin. Sci. Bull. 67(2022) 3036-3053.
[75] C. Zhao, N.D. Parab, X.X. Li, K. Fezzaa, W.D. Tan, A.D. Rollett, T. Sun, Science 370 (2020) 1080-1086.
[76] C. Weingarten, D. Buchbinder, N. Pirch, W. Meiners, K. Wissenbach, R. Poprawe, J. Mater. Process.Technol. 221(2015) 112-120.
[77] H. Wang, B. Gould, M. Haddad, Z.H. Wu, S.J. Wolff, J. Manuf. Process. 79(2022) 11-18.
[78] S.Y. Zhang, C.X. Yao, D.S. Zhang, W. Liu, L. He, D.F. Du, B.D. Sun, A.P. Dong, B.B. Zhang, L.H. Xiong, Int. J. Mach. Tools Manuf. 200(2024) 104181.
[79] K. Zhang, Y.H. Chen, S. Marussi, X.Q. Fan, M. Fitzpatrick, S. Bhagavath, M. Ma-jkut, B.Lukic, K. Jakata, A. Rack, M.A. Jones, J. Shinjo, C. Panwisawas, C.L.A. Le-ung, P.D. Lee, Nat. Commun. 15(2024) 1715.
[80] S. Webster, N. Moser, K. Fezzaa, T. Sun, K. Ehmann, E. Garboczi, J. Cao, PNAS Nexus 2 (2023) pgad178.
[81] D. Riabov, E. Hryha, M. Rashidi, S. Bengtsson, L. Nyborg, Surf. Interface Anal. 52(2020) 694-706.
[82] S.M.H.Hojjatzadeh, N.D. Parab, W.T. Yan, Q.L. Guo, L.H. Xiong, C. Zhao, M.L. Qu, L.I. Escano, X.H. Xiao, K. Fezzaa, W. Everhart, T. Sun, L.Y. Chen, Nat. Commun. 10(2019) 3088.
[83] A. Ladewig, G. Schlick, M. Fisser, V. Schulze, U. Glatzel, Addit. Manuf. 10(2016) 1-9.
[84] A. Bin Anwar, Q.C. Pham, Addit. Manuf. 22(2018) 86-97.
[85] J. Yin, D.Z. Wang, L.L. Yang, H.L. Wei, P. Dong, L.D. Ke, G.Q. Wang, H.H. Zhu, X.Y. Zeng, Addit. Manuf. 31(2020) 100958.
[86] M.T. Andani, R. Dehghani, M.R.Karamooz-Ravari, R.Mirzaeifar, J. Ni, Mater. Des. 131(2017) 460-469.
[87] M.J. Matthews, G. Guss, S.A. Khairallah, A.M. Rubenchik, P.J. Depond, W.E. King, Acta Mater. 114(2016) 33-42.
[88] C. Zhao, Q.L. Guo, X.X. Li, N. Parab, K. Fezzaa, W.D. Tan, L.Y. Chen, T. Sun, Phys. Rev. X 9 (2019) 021052.
[89] Z.A. Young, Q.L. Guo, N.D. Parab, C. Zhao, M.L. Qu, L. Escano, K. Fezzaa, W. Ev-erhart, T.Sun, L.Y. Chen, Addit. Manuf. 36(2020) 101438.
[90] S.C. Wu, Y.N. Hu, H. Duan, C. Yu, H.S. Jiao, Int. J. Fatigue 91 (2016) 1-10.
[91] K.J. Pang, H. Yuan, Int. J. Fatigue 136 (2020) 105575.
[92] Y. Chastel, N. Caillet, P.O. Bouchard, J. Mater. Process.Technol. 177(2006) 202-205.
[93] Y.K. Gao, X.B. Li, Q.X. Yang, M. Yao, Mater. Lett. 61(2007) 466-469.
[94] H.R. Sandgren, Y. Zhai, D.A. Lados, P.A. Shade, J.C. Schuren, M.A. Groeber, P. Kenesei, A.G. Gayras, Addit. Manuf. 12(2016) 132-141.
[95] T.G. Fleming, D.T. Rees, S. Marussi, T. Connolley, R.C. Atwood, M.A. Jones, J.M. Fraser, C.L.A.Leung, P.D. Lee, Addit. Manuf. 71(2023) 103579.
[96] H. Choo, L.P. White, X.H. Xiao, C.C. Sluss, D. Morin, E. Garlea, Addit. Manuf. 40(2021) 101914.
[97] N. Kouraytem, P. Chiang, R.B. Jiang, C. Kantzos, J. Pauza, R. Cunningham, Z.H. Wu, G.N. Tang, N. Parab, C. Zhao, K. Fezzaa, T. Sun, A.D. Rollett, Addit. Manuf. 42(2021) 101959.
[98] M.L. Qu, Q.L. Guo, L.I. Escano, J.D. Yuan, S.M.H.Hojjatzadeh, S.J. Clark, K. Fez-zaa, T.Sun, L.Y. Chen, Addit. Manuf. 59(2022) 103081.
[99] H. Wang, B. Gould, M. Haddad, M. Moorehead, A. Couet, S.J.J.Wolff, J. Manuf. Process. 75(2022) 1003-1011.
[100] C.L.A. Leung, I. Elizarova, M. Isaacs, S. Marathe, E. Saiz, P.D. Lee, Appl. Mater. Today 23 (2021) 101009.
[101] Z.S. Ren, L. Gao, S.J. Clark, K. Fezzaa, P. Shevchenko, A. Choi, W. Everhart, A.D. Rollett, L.Y. Chen, T. Sun, Science 379 (2023) 89-93.