@conference {1596, title = {3D Characterization of the Columnar-to-Equiaxed Transition in Additively Manufactured Inconel 718}, booktitle = {Superalloys 2020}, year = {2020}, publisher = {Springer International Publishing}, organization = {Springer International Publishing}, abstract = {

Additive manufacturing (AM) provides enormous process- ing flexibility, enabling novel part geometries and opti- mized designs. Access to a local heat source further per- mits the potential for local microstructure control on the scale of individual melt pools, which can enable local con- trol of part properties. In order to design tailored process- ing strategies for target microstructures, models predict- ing the columnar-to-equiaxed transition must be extended to the high solidification velocities and complex thermal histories present in AM. Here, we combine 3D charac- terization with advanced modeling techniques to develop a more complete understanding of the solidification pro- cess and evolution of microstructure during electron beam melting (EBM) of Inconel 718. Full calibration of existing microstructure prediction models demonstrates the differ- ences between AM processes and more conventional weld- ing techniques, underlying the need for accurate deter- mination of key parameters that can only be measured directly in 3D. The ability to combine multisensor data in a consistent 3D framework via data fusion algorithms is essential to fully leverage these advanced characteriza- tion approaches. Thermal modeling provides insight on microstructure development within isolated solidification events and demonstrates the role of Marangoni effects on controlling solidification behavior.

}, keywords = {Additive manufacturing, Microstructure, Solidification, Tomography}, isbn = {9783030518349}, doi = {10.1007/978-3-030-51834-9}, url = {http://dx.doi.org/10.1007/978-3-030-51834-9_65}, author = {Polonsky, Andrew T. and Raghavan, Narendran and Echlin, Mclean P. and Kirka, Michael M. and Dehoff, Ryan R. and Pollock, Tresa M.}, editor = {Tin, Sammy and Hardy, Mark and Clews, Justin and Cormier, Jonathan and Feng, Qiang and Marcin, John and O{\textquoteright}Brien, Chris and Suzuki, Akane} } @conference {1591, title = {Microstructure and Tensile Properties of a CoNi-Based Superalloy Fabricated by Selective Electron Beam Melting}, booktitle = {Superalloys 2020}, year = {2020}, publisher = {Springer International Publishing}, organization = {Springer International Publishing}, abstract = {

Successful application of selective electron beam melting to a novel CoNi-based superalloy named SB-CoNi-10 is demonstrated. Crack-free as-printed microstructures exhibit excellent ductilities above 30\% and ultimate tensile strengths above 1.1 GPa at room temperature in tension. Conventional post-processing consisting of a super-solvus hot isostatic pressing (HIP), a solution heat treatment (SHT), and a low-temperature aging has been applied to remove microstructural inhomogeneities present in the as-printed microstructure. The microstructures of the as-printed and HIP+SHT+Aged alloys have been investigated to determine the effect of post-processing heat treatments on the nanoscale \γ/\γ\&$\#$39; microstructure and the mesoscale grain structure. Tensile tests have been conducted at room temperature and elevated temperatures above 850 {\textopenbullet}C to investigate mechanical properties in both the as-printed and HIP+SHT+Aged conditions. The high- temperature ductility and strength are strongly affected by the microstructure, with a mostly columnar-grained microstructure in the as-printed condition exhibiting superior ductility to the fully recrystallized microstructure in the HIP+SHT+Aged condition.

}, keywords = {Additive manufacturing, CoNi-based superalloys, Mechanical properties}, isbn = {9783030518349}, doi = {10.1007/978-3-030-51834-9}, url = {http://dx.doi.org/10.1007/978-3-030-51834-9_65}, author = {Murray, Sean P. and Pusch, Kira M. and Polonsky, Andrew T. and Torbet, Chris J. and Seward, Gareth G. E. and Nandwana, Peeyush and Kirka, Michael M. and Dehoff, Ryan R. and Zhou, Ning and Forsik, St{\'e}phane A. J. and Slye, William and Pollock, Tresa M.}, editor = {Tin, Sammy and Hardy, Mark and Clews, Justin and Cormier, Jonathan and Feng, Qiang and Marcin, John and O{\textquoteright}Brien, Chris and Suzuki, Akane} } @article {1406, title = {Solidification-driven orientation gradients in additively manufactured stainless steel}, journal = {Acta Materialia}, volume = {183}, year = {2020}, pages = {249{\textendash}260}, abstract = {

A sample of 304L stainless steel manufactured by Laser Engineered Net Shaping (LENS) was characterized in 3D using TriBeam tomography. The crystallographic, structural, and chemical properties of the as-deposited microstructure have been studied in detail. 3D characterization reveals complex grain morphologies and large orientation gradients, in excess of 10o, that are not easily interpreted from 2D cross-sections alone. Misorientations were calculated via a methodology that locates the initial location and orientation of grains that grow during the build process. For larger grains, misorientation increased along the direction of solidification. For grains with complex morphologies, K-means clustering in orientation space is demonstrated as a useful approach for determining the initial growth orientation. The gradients in misorientation directly tracked with gradients in chemistry predicted by a Scheil analysis. The accumulation of misorientation is linked to the solutal and thermal solidification path, offering potential design pathways for novel alloys more suited for additive manufacturing.

}, keywords = {Additive manufacturing, Microstructure, Solidification, Tomography, Tribeam}, issn = {13596454}, doi = {10.1016/j.actamat.2019.10.047}, author = {Polonsky, Andrew T. and Lenthe, William C. and Echlin, Mclean P. and Livescu, Veronica and Gray, George T. and Pollock, Tresa M.} } @article {1361, title = {Three-dimensional Analysis and Reconstruction of Additively Manufactured Materials in the Cloud-Based BisQue Infrastructure}, journal = {Integrating Materials and Manufacturing Innovation}, volume = {8}, year = {2019}, pages = {37{\textendash}51}, abstract = {

A microstructure analytics and 3D reconstruction software package, DREAM.3D, was integrated as a module into a cloud-based platform, BisQue. Parallelization of DREAM.3D module executions and the ability to parameterize pipeline variables over a range of values have led to insights about the grain segmentation misorientation tolerance in TriBeam-collected 3D EBSD datasets of additively manufactured materials with complex anisotropic microstructures. Furthermore, a comparison in grain size measurements was made between standard 2D metallographic slices and 3D measures using BisQue\&$\#$39;s parallelized DREAM.3D module executions. The direction of cloud-based data infrastructure and the prospects for impact in material science are also discussed.

}, keywords = {3D materials science, 3D metal printing, Additive manufacturing, Cloud infrastructure, Microstructure analytics, Tomography}, isbn = {4019201900}, issn = {21939772}, doi = {10.1007/s40192-019-00126-7}, author = {Polonsky, Andrew T. and Lang, Christian A. and Kvilekval, Kristian G. and Latypov, Marat I. and Echlin, McLean L.P. and Manjunath, B. S. and Pollock, Tresa M.} } @article {1326, title = {Defects and 3D structural inhomogeneity in electron beam additively manufactured Inconel 718}, journal = {Materials Characterization}, volume = {143}, year = {2018}, pages = {171{\textendash}181}, abstract = {

Material structure and defects created during additive manufacturing contribute to the variability in mechanical properties of these parts, limiting their use for critical applications. Three-dimensional crystallographic, structural, and chemical information in electron beam melted Inconel 718 was collected from the sub-micron to the millimeter scale using the TriBeam tomography system. The relationship of defects to the surrounding microstructure has been studied in detail. Lack of fusion defects created sharp discontinuities in the grain morphology that extended several build layers beyond the layer where the defect originated. Nitrides and carbides in the size range of 1.25 \μm to 10 \μm were observed throughout the volume, with pronounced nitride clustering. The similarities between solidification in additive manufacturing and traditional manufacturing processes are demonstrated by the comparable size and distribution of carbides measured for industrial-scale samples of 718. Defects created during additive manufacturing cannot be easily remedied via standard post-processing techniques, and will likely diminish the mechanical performance of additively manufactured parts.

}, keywords = {Additive manufacturing, Electron beam melting, Lack of fusion, Microstructure, Tomography}, issn = {10445803}, doi = {10.1016/j.matchar.2018.02.020}, author = {Polonsky, Andrew T. and Echlin, Mclean P. and Lenthe, William C. and Dehoff, Ryan R. and Kirka, Michael M. and Pollock, Tresa M.} }