Evolution of dislocations during the rapid solidification in additive manufacturing
Abstract Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem micro...
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| Format: | Article |
| Language: | English |
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Nature Portfolio
2025-05-01
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| Series: | Nature Communications |
| Online Access: | https://doi.org/10.1038/s41467-025-59988-5 |
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| author | Lin Gao Yan Chen Xuan Zhang Sean R. Agnew Andrew C. Chuang Tao Sun |
| author_facet | Lin Gao Yan Chen Xuan Zhang Sean R. Agnew Andrew C. Chuang Tao Sun |
| author_sort | Lin Gao |
| collection | DOAJ |
| description | Abstract Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem microstructure characterizations of AM materials cannot capture the dynamic evolution of dislocations during the manufacturing process, thereby offering limited mechanism-based guidance for further advancing AM techniques and facilitating the qualification and certification of AM products. In this study, we conduct operando high-energy synchrotron X-ray diffraction experiments on wire-laser directed energy deposition of 316 L stainless steel. Through a unique configuration, our operando synchrotron experiments semi-quantitatively probe the dislocation density in solid phases and their dynamic changes during solidification and subsequent cooling. By integrating this advanced synchrotron technique with multi-physics simulation, in-situ neutron diffraction, and multi-scale electron microscopy characterization, our mechanistic study aims to elucidate the effects of rapid cooling and subsequent thermal cycling on the dislocation generation and evolution. |
| format | Article |
| id | doaj-art-c2e0a76053b944e5b58b1b5ce3d6dfe3 |
| institution | OA Journals |
| issn | 2041-1723 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Nature Communications |
| spelling | doaj-art-c2e0a76053b944e5b58b1b5ce3d6dfe32025-08-20T02:29:51ZengNature PortfolioNature Communications2041-17232025-05-0116111310.1038/s41467-025-59988-5Evolution of dislocations during the rapid solidification in additive manufacturingLin Gao0Yan Chen1Xuan Zhang2Sean R. Agnew3Andrew C. Chuang4Tao Sun5Department of Materials Science and Engineering, University of VirginiaNeutron Scattering Division, Oak Ridge National LaboratoryNuclear Science and Engineering Division, Argonne National LaboratoryDepartment of Materials Science and Engineering, University of VirginiaX-ray Science Division, Argonne National LaboratoryDepartment of Materials Science and Engineering, University of VirginiaAbstract Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem microstructure characterizations of AM materials cannot capture the dynamic evolution of dislocations during the manufacturing process, thereby offering limited mechanism-based guidance for further advancing AM techniques and facilitating the qualification and certification of AM products. In this study, we conduct operando high-energy synchrotron X-ray diffraction experiments on wire-laser directed energy deposition of 316 L stainless steel. Through a unique configuration, our operando synchrotron experiments semi-quantitatively probe the dislocation density in solid phases and their dynamic changes during solidification and subsequent cooling. By integrating this advanced synchrotron technique with multi-physics simulation, in-situ neutron diffraction, and multi-scale electron microscopy characterization, our mechanistic study aims to elucidate the effects of rapid cooling and subsequent thermal cycling on the dislocation generation and evolution.https://doi.org/10.1038/s41467-025-59988-5 |
| spellingShingle | Lin Gao Yan Chen Xuan Zhang Sean R. Agnew Andrew C. Chuang Tao Sun Evolution of dislocations during the rapid solidification in additive manufacturing Nature Communications |
| title | Evolution of dislocations during the rapid solidification in additive manufacturing |
| title_full | Evolution of dislocations during the rapid solidification in additive manufacturing |
| title_fullStr | Evolution of dislocations during the rapid solidification in additive manufacturing |
| title_full_unstemmed | Evolution of dislocations during the rapid solidification in additive manufacturing |
| title_short | Evolution of dislocations during the rapid solidification in additive manufacturing |
| title_sort | evolution of dislocations during the rapid solidification in additive manufacturing |
| url | https://doi.org/10.1038/s41467-025-59988-5 |
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