In situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysis.

Laser powder bed fusion is a promising technology for local deposition and microstructure control, but it suffers from defects such as delamination and porosity due to the lack of understanding of melt pool dynamics. To study the fundamental behavior of the melt pool, both geometric and thermal sensing with high spatial and temporal resolutions are necessary. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the evolution of the melt pool shape, keyhole, vapor plume, and thermal evolution in Ti-6Al-4V and 410 stainless steel spot melt cases. Aside from presenting the sensing capability, this paper develops an effective algorithm for high-speed X-ray imaging data to identify melt pool geometries accurately. Preprocessing methods are also implemented for the IR data to estimate the emissivity value and extrapolate the saturated pixels. Quantifications on boundary velocities, melt pool dimensions, thermal gradients, and cooling rates are performed, enabling future comprehensive melt pool dynamics and microstructure analysis. The study discovers a strong correlation between the thermal and X-ray data, demonstrating the feasibility of using relatively cheap IR cameras to predict features that currently can only be captured using costly synchrotron X-ray imaging. Such correlation can be used for future thermal-based melt pool control and model validation.

High Plasticity and Substantial Deformation in Nanocrystalline NiFe Alloys Under Dynamic Loading.

A nanocrystalline (NC) NiFe alloy is presented, in which both highly improved plasticity and strength are achieved by the dynamic-loading-induced deformation mechanisms of de-twinning (that is, reduction of twin density) and significant grain coarsening. This work highlights potential ingenious avenues to exploit the superior behavior of NC materials under extreme conditions.

Strain-dependent deformation behavior in nanocrystalline metals.

The deformation behavior as a function of applied strain was studied in a nanostructured Ni-Fe alloy using the in situ synchrotron diffraction technique. It was found that the plastic deformation process consists of two stages, undergoing a transition with applied strain. At low strains, the deformation is mainly accommodated at grain boundaries, while at large strains, the dislocation motion becomes probable and eventually dominates. In addition, current results revealed that, at small grain sizes, the 0.2% offset criterion cannot be used to define the macroscopic yield strength any more. The present study also explained the controversial observations in the literature.

Mechanical behavior of bulk amorphous alloys reinforced by ductile particles at cryogenic temperatures.

The mechanical behavior of Zr-based bulk amorphous alloy composites (BAACs) was investigated at 77 K. The 5 vol. % Ta-BAAC maintained large plastic strains of approximately 13% with a 16% strength increase, when compared with that at 298 K. The interaction between shear bands and particles shows that shear extension in particles has limited penetration, and shear bands build up around particles. In addition to on the failure surface of the amorphous matrix, molten characteristics were also found on the surface of sheared particles. Pair distribution function studies were performed to understand the mechanical behavior.