Unveiling 3D sub-grain residual stresses in as-built additively manufactured steel using scanning 3DXRD

Non-destructive mapping of 3D microstructures in metal additive manufacturing (AM) remains challenging due to large orientation gradients and residual stress (RS) magnitudes. We leveraged scanning 3D X-ray diffraction (s3DXRD) to non-destructively resolve intragranular orientation-strain states and...

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Main Authors: Yaozhong Zhang, James Ball, Axel Henningsson, Jon Wright, Lucero Lopez, Dillon Jobes, Henry Proudhon, Jerard V. Gordon
Format: Article
Language:English
Published: Taylor & Francis Group 2025-07-01
Series:Materials Research Letters
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Online Access:https://www.tandfonline.com/doi/10.1080/21663831.2025.2502502
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Summary:Non-destructive mapping of 3D microstructures in metal additive manufacturing (AM) remains challenging due to large orientation gradients and residual stress (RS) magnitudes. We leveraged scanning 3D X-ray diffraction (s3DXRD) to non-destructively resolve intragranular orientation-strain states and RS in laser powder bed fusion (L-PBF) SS316L for the first time. Type III von Mises RS displayed significant variation with proximity to grain boundaries, and in some locations, exceeded the macroscopic yield strength of L-PBF SS316L. Interestingly the spatial distribution of RS showed no correlation with orientation gradients, suggesting that stress relaxation during solidification is accommodated by lattice rotation.
ISSN:2166-3831