3D Printed Alloy Microstructures Analyzed via X-rays

Cornell University researchers have employed X-rays to inspect the developing microstructure of a 3D printed metal alloy during its printing process. This approach visualized thermomechanical deformation on the microscale, such as bending, fragmentation, and oscillation.

This live observation can aid in producing materials tailored to desired mechanical characteristics. Their study, titled “Dendritic Deformation Modes in Additive Manufacturing Revealed by Operando X-Ray Diffraction,” revolves around the nickel-based superalloy IN625, applied via nozzle and melted using a laser.

Instead of analyzing condensed diffraction data, the team delved into raw detector images, presenting a comprehensive view of IN625’s formation. Recognized microstructural features resulting from the process encompassed torsion, bending, fragmentation, assimilation, oscillation, and interdendritic growth. This technique’s potential extends to other 3D printed metals with crystalline structures, enhancing material properties by understanding in-process dynamics.

“We always look at these microstructures after processing, but there’s a lot of information that you’re missing by conducting only postmortem characterizations. Now we have tools to be able to watch these microstructural evolutions as they are happening,” said Atieh Moridi, assistant professor at Cornell.

“We want to be able to understand how these tiny patterns or microstructures are formed because they dictate everything about performance of printed parts.”

The research’s implications suggest enhanced material development in 3D printing. As real-time observation becomes commonplace, material selection and processing methods will become increasingly precise, guiding the industry toward optimized outcomes.

If you would like to read more about the research, you can access the original paper at this link.

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