Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation
This study investigates various cracking mechanisms and their prevalence in fusion processing of steel-copper multi-materials using operando X-ray diffraction and imaging during laser powder-bed fusion (LPBF) of 316L-CuCrZr multi-material. During this investigation, three main types of cracking were...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2526798 |
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| author | Andaç Özsoy William A. Hearn Steve Gaudez Rijuta Jeswani Yunhui Chen Alexander Rack Zoltan Hegedüs Nicola Casati Roland E. Logé Steven Van Petegem |
| author_facet | Andaç Özsoy William A. Hearn Steve Gaudez Rijuta Jeswani Yunhui Chen Alexander Rack Zoltan Hegedüs Nicola Casati Roland E. Logé Steven Van Petegem |
| author_sort | Andaç Özsoy |
| collection | DOAJ |
| description | This study investigates various cracking mechanisms and their prevalence in fusion processing of steel-copper multi-materials using operando X-ray diffraction and imaging during laser powder-bed fusion (LPBF) of 316L-CuCrZr multi-material. During this investigation, three main types of cracking were identified: (i) solidification cracking, (ii) metal-induced embrittlement (MIE), and (iii) liquation cracking. All cracking types are closely related to phase formation during processing and stem from two underlying mechanisms. First, liquid–liquid phase separation (LLPS) and the monotectic reaction in the 316L-CuCrZr system cause two liquids with vastly different solidification ranges to form, leading to solidification cracking. Second, LLPS and the monotectic reaction uniformly distribute Cu-rich liquid between the Fe-rich dendrites, leading to MIE and/or liquation cracking. Conducted based on the insights gained from the operando characterisation, further experiments showed that cracking can be drastically reduced by avoiding phase separation. However, the complete elimination of cracking necessitates chemical alterations in the material feedstock, indicating that while process adjustments can mitigate cracking, they may fail to fully prevent it. These findings serve as a guideline for understanding the underlying causes of cracking in steel-copper multi-materials, how process optimisation can effectively mitigate cracking, and to what extent such adjustments in processing can achieve this outcome. |
| format | Article |
| id | doaj-art-a02851b9e8334690b7f856bc3bb62d1e |
| institution | OA Journals |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-a02851b9e8334690b7f856bc3bb62d1e2025-08-20T02:36:08ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2526798Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisationAndaç Özsoy0William A. Hearn1Steve Gaudez2Rijuta Jeswani3Yunhui Chen4Alexander Rack5Zoltan Hegedüs6Nicola Casati7Roland E. Logé8Steven Van Petegem9Laboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandLaboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandLaboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandLaboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandRMIT Centre for Additive Manufacturing, RMIT University, Melbourne, AustraliaESRF – The European Synchrotron, Grenoble, FranceDeutsches Elektronen-Synchrotron (DESY), Hamburg, GermanyLaboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandLaboratory of Thermomechanical Metallurgy (LMTM), École Polytechnique Fédérale de Lausanne (EPFL), Neuchatel, SwitzerlandLaboratory for Condensed Matter, PSI Center for Photon Science, Villigen, SwitzerlandThis study investigates various cracking mechanisms and their prevalence in fusion processing of steel-copper multi-materials using operando X-ray diffraction and imaging during laser powder-bed fusion (LPBF) of 316L-CuCrZr multi-material. During this investigation, three main types of cracking were identified: (i) solidification cracking, (ii) metal-induced embrittlement (MIE), and (iii) liquation cracking. All cracking types are closely related to phase formation during processing and stem from two underlying mechanisms. First, liquid–liquid phase separation (LLPS) and the monotectic reaction in the 316L-CuCrZr system cause two liquids with vastly different solidification ranges to form, leading to solidification cracking. Second, LLPS and the monotectic reaction uniformly distribute Cu-rich liquid between the Fe-rich dendrites, leading to MIE and/or liquation cracking. Conducted based on the insights gained from the operando characterisation, further experiments showed that cracking can be drastically reduced by avoiding phase separation. However, the complete elimination of cracking necessitates chemical alterations in the material feedstock, indicating that while process adjustments can mitigate cracking, they may fail to fully prevent it. These findings serve as a guideline for understanding the underlying causes of cracking in steel-copper multi-materials, how process optimisation can effectively mitigate cracking, and to what extent such adjustments in processing can achieve this outcome.https://www.tandfonline.com/doi/10.1080/17452759.2025.2526798Multi-materialCrackingAdditive manufacturingOperando X-rayFunctionally graded materials (FGM) |
| spellingShingle | Andaç Özsoy William A. Hearn Steve Gaudez Rijuta Jeswani Yunhui Chen Alexander Rack Zoltan Hegedüs Nicola Casati Roland E. Logé Steven Van Petegem Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation Virtual and Physical Prototyping Multi-material Cracking Additive manufacturing Operando X-ray Functionally graded materials (FGM) |
| title | Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation |
| title_full | Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation |
| title_fullStr | Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation |
| title_full_unstemmed | Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation |
| title_short | Deconvoluting cracking mechanisms in fusion processing of steel-copper multi-materials via Operando X-ray characterisation |
| title_sort | deconvoluting cracking mechanisms in fusion processing of steel copper multi materials via operando x ray characterisation |
| topic | Multi-material Cracking Additive manufacturing Operando X-ray Functionally graded materials (FGM) |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2526798 |
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