Scientific Highlights

The thermal conditions during laser-based additive manufacturing are inferred from high-speed X-ray diffraction data and can be linked to a model for rapid solidification.

High-speed in situ X-ray diffraction is used to measure temperature profiles and cooling rates during 3D printing of a a Ti-6Al-4V single-track wall.

In situ alloying is an effective method to engineer microstructures of additively manufactured Ti6Al4V3Fe alloys. 

We present a novel monitoring strategy for 3D print processes that consists of developing and training a hybrid machine learning model that can classify regimes across different time scales based on heterogeneous sensing data. 

The reaction of elemental scandium and zirconium powders with liquid aluminum is observed directly via operando X-ray diffraction during laser 3D printing. This work demonstrates that elemental blends can be used to create fine-grained crack-free Al-alloys and highlights the importance of feature size.

Operando high-speed X-ray radiography experiments reveal the cracking mechanism during 3D laser printing of a Ni superalloy.

Synchrotron X-ray diffraction experiments reveal the presence of a non- negligible amount of tetragonal phase in 3D printed red-gold samples.