I12-JEEP: Joint Engineering, Environmental and Processing
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Fabio
Arzilli
,
Margherita
Polacci
,
Giuseppe
La Spina
,
Nolwenn
Le Gall
,
Edward W.
Llewellin
,
Richard A.
Brooker
,
Rafael
Torres-Orozco
,
Danilo
Di Genova
,
David A.
Neave
,
Margaret E.
Hartley
,
Heidy M.
Mader
,
Daniele
Giordano
,
Robert
Atwood
,
Peter D.
Lee
,
Florian
Heidelbach
,
Mike R.
Burton
Diamond Proposal Number(s):
[16188]
Open Access
Abstract: The majority of basaltic magmas stall in the Earth’s crust as a result of the rheological evolution caused by crystallization during transport. However, the relationships between crystallinity, rheology and eruptibility remain uncertain because it is difficult to observe dynamic magma crystallization in real time. Here, we present in-situ 4D data for crystal growth kinetics and the textural evolution of pyroxene during crystallization of trachybasaltic magmas in high-temperature experiments under water-saturated conditions at crustal pressures. We observe dendritic growth of pyroxene on initially euhedral cores, and a surprisingly rapid increase in crystal fraction and aspect ratio at undercooling ≥30 °C. Rapid dendritic crystallization favours a rheological transition from Newtonian to non-Newtonian behaviour within minutes. We use a numerical model to quantify the impact of rapid dendritic crystallization on basaltic dike propagation, and demonstrate its dramatic effect on magma mobility and eruptibility. Our results provide insights into the processes that control whether intrusions lead to eruption or not.
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Jun 2022
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I12-JEEP: Joint Engineering, Environmental and Processing
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Lorna
Sinclair
,
Yunhui
Chen
,
Samuel J.
Clark
,
Sebastian
Marussi
,
Saurabh
Shah
,
Oxana
Magdysyuk
,
Robert
Atwood
,
Gavin J.
Baxter
,
Martyn
Jones
,
Graham
Mccartney
,
Chu Lun Alex
Leung
,
Peter D.
Lee
Diamond Proposal Number(s):
[20096]
Open Access
Abstract: During directed energy deposition (DED) additive manufacturing, powder agglomeration and sintering can occur outside of the melt pool when using titanium alloy powders. Using in situ synchrotron radiography we investigate the mechanisms by which sintering of Ti6242 powder occurs around the pool, performing a parametric study to determine the influence of laser power and stage traverse speed on sinter build-up. The results reveal that detrimental sinter can be reduced using a high laser power or increased stage traverse speed, although the latter also reduces deposition layer thickness. The mechanism of sinter formation during DED was determined to be in-flight heating of the powder particles in the laser beam. Calculations of particle heating under the processing conditions explored in this study confirm that powder particles can reasonably exceed 700 °C, the threshold for Ti surface oxide dissolution, and thus the powder is prone to sintering if not incorporated into the melt pool. The build-up of sinter powder layer on deposit surfaces led to lack of fusion pores. To mitigate sinter formation and its detrimental effects on DED component quality, it is essential that the powder delivery spot area is smaller than the melt pool, ensuring most powder lands in the melt pool.
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Apr 2022
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I13-2-Diamond Manchester Imaging
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Maximilian
Ackermann
,
Paul
Tafforeau
,
Willi
Wagner
,
Claire
Walsh
,
Christopher
Werlein
,
Mark P.
Kuhnel
,
Florian P.
Länger
,
Catherine
Disney
,
Andrew
Bodey
,
Alexandre
Bellier
,
Stijn E.
Verleden
,
Peter D.
Lee
,
Steven J
Mentzer
,
Danny D.
Jonigk
Diamond Proposal Number(s):
[27025, 27094]
Open Access
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Nov 2021
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I12-JEEP: Joint Engineering, Environmental and Processing
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Diamond Proposal Number(s):
[20096]
Open Access
Abstract: To prevent oxygen contamination, additive manufacturing (AM) techniques normally operate in an inert gas chamber (GC). An alternative method, useful for large builds and components repair, is the application of localised shielding gas (LSG). The effect of oxygen contamination on Ti6242 during directed energy deposition (DED) AM using an inert GC compared to LSG was investigated by in situ synchrotron X-ray experiments. When processing in LSG mode, the amount of oxygen absorbed from the atmosphere was sufficient to reverse the Marangoni flow leading to an alteration of the molten pool geometry and strongly influencing defect formation. Microstructural analysis reveals that, at high oxygen levels, the commonly developed α' martensitic microstructure was completely suppressed, forming precipitation of a tetra modal microstructure of α phase consisting of globular, primary and secondary lamellae (in colonies) and basketweave structure. These results help elucidate the influence of oxygen contamination in additively manufactured Ti alloys, potentially enabling improved industrial practices for AM of titanium alloy.
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Nov 2021
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I13-2-Diamond Manchester Imaging
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Diamond Proposal Number(s):
[23760]
Abstract: We present a dynamic implementation of the beam-tracking x-ray imaging method providing absorption, phase, and ultrasmall angle scattering signals with microscopic resolution and high frame rate. We demonstrate the method’s ability to capture dynamic processes with 22-ms time resolution by investigating the melting of metals in laser additive manufacturing, which has so far been limited to single-modality synchrotron radiography. The simultaneous availability of three contrast channels enables earlier segmentation of droplets, tracking of powder dynamic, and estimation of unfused powder amounts, demonstrating that the method can provide additional information on melting processes.
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Nov 2021
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I13-2-Diamond Manchester Imaging
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Diamond Proposal Number(s):
[13241]
Abstract: Additive manufacturing (AM) platforms allow the production of patient tissue engineering scaffolds with desirable architectures. Although AM platforms offer exceptional control on architecture, post-processing methods such as sintering and freeze-drying often deform the printed scaffold structure. In-situ 4D imaging can be used to analyze changes that occur during post-processing. Visualization and analysis of changes in selected volumes of interests (VOIs) over time are essential to understand the underlining mechanisms of scaffold deformations. Yet, automated detection and tracking of VOIs in the 3D printed scaffold over time using 4D image data is currently an unsolved image processing task. This paper proposes a new image processing technique to segment, detect and track volumes of interest in 3D printed tissue engineering scaffolds. The method is validated using a 4D synchrotron sourced microCT image data captured during the sintering of bioactive glass scaffolds in-situ. The proposed method will contribute to the development of scaffolds with controllable designs and optimum properties for the development of patient-specific scaffolds.
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Nov 2021
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I13-2-Diamond Manchester Imaging
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Diamond Proposal Number(s):
[13241]
Abstract: We propose a novel image analysis framework to automate analysis of X-ray micro-tomography images of sintering ceramics and glasses, using open-source toolkits and machine learning. Additive manufacturing (AM) of glasses and ceramics usually requires sintering of green bodies. Sintering causes shrinkage, which presents a challenge for controlling the metrology of the final architecture. Therefore, being able to monitor sintering in 3D over time (termed 4D) is important when developing new porous ceramics or glasses. Synchrotron X-ray tomographic imaging allows in situ, real-time capture of the sintering process at both micro and macro scales using a furnace rig, facilitating 4D quantitative analysis of the process. The proposed image analysis framework is capable of tracking and quantifying the densification of glass or ceramic particles within multiple volumes of interest (VOIs) along with structural changes over time using 4D image data. The framework is demonstrated by 4D quantitative analysis of bioactive glass ICIE16 within a 3D printed scaffold. Here, densification of glass particles within 3 VOIs were tracked and quantified along with diameter change of struts and inter-strut pore size over the 3D image series, delivering new insights on the sintering mechanism of ICIE16 bioactive glass particles in both micro and macro scales.
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Oct 2021
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I12-JEEP: Joint Engineering, Environmental and Processing
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Diamond Proposal Number(s):
[22627]
Abstract: Ductile cast irons (DCIs) are of increasing importance in the renewable energy and transportation sectors. The distribution and morphology of the graphite nodules, in particular the formation of degenerate features during solidification, dictate the mechanical performance of DCIs. In situ high-speed synchrotron X-ray tomography was used to capture the evolution of graphite nodules during solidification of DCI, including degenerate features and the effect of the carbon concentration field. The degeneration of nodules is observed to increase with re-melting cycles, which is attributed to Mg-loss. The dendritic primary austenite and carbon concentration gradients in the surrounding liquid phase were found to control nodule morphology by locally restricting and promoting growth.
A coupled diffusion-mechanical model was developed, confirming the experimentally informed hypothesis that protrusions form through liquation cracking of the austenite shell and subsequent localised growth. These results provide valuable insights into the solidification kinetics of cast irons, supporting the design of advanced alloys.
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Oct 2021
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I13-2-Diamond Manchester Imaging
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Diamond Proposal Number(s):
[19322]
Open Access
Abstract: Many soft tissues, such as the intervertebral disc (IVD), have a hierarchical fibrous composite structure which suffers from regional damage. We hypothesise that these tissue regions have distinct, inherent fibre structure and structural response upon loading. Here we used synchrotron computed tomography (sCT) to resolve collagen fibre bundles (∼5μm width) in 3D throughout an intact native rat lumbar IVD under increasing compressive load. Using intact samples meant that tissue boundaries (such as endplate-disc or nucleus-annulus) and residual strain were preserved; this is vital for characterising both the inherent structure and structural changes upon loading in tissue regions functioning in a near-native environment. Nano-scale displacement measurements along >10,000 individual fibres were tracked, and fibre orientation, curvature and strain changes were compared between the posterior-lateral region and the anterior region. These methods can be widely applied to other soft tissues, to identify fibre structures which cause tissue regions to be more susceptible to injury and degeneration. Our results demonstrate for the first time that highly-localised changes in fibre orientation, curvature and strain indicate differences in regional strain transfer and mechanical function (e.g. tissue compliance). This included decreased fibre reorientation at higher loads, specific tissue morphology which reduced capacity for flexibility and high strain at the disc-endplate boundary.
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Oct 2021
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I12-JEEP: Joint Engineering, Environmental and Processing
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Chaoling
Xu
,
Tim
Wigger
,
Mohammed
Azeem
,
Tito
Andriollo
,
Søren
Fæster
,
Samuel
Clark
,
Zhixuan
Gong
,
Robert
Atwood
,
Jean-Claude
Grivel
,
Jesper H.
Hattel
,
Peter D.
Lee
,
Niels S.
Tiedje
Diamond Proposal Number(s):
[22627]
Open Access
Abstract: In spite of many years of research, the physical phenomena leading to the evolution of compacted graphite (CG) during solidification is still not fully understood. In particular, it is unknown how highly branched CG aggregates form and evolve in the semi-solid, and how local microstructural variations at micrometer length scale affect this growth process. We present here the first time-resolved synchrotron tomography combined with a bespoke high-temperature environmental cell that allows direct observation of the evolution of CG and relates this dynamic process to the local surrounding microstructures in a cast iron sample during repeated melting and solidification. Distinct processes are identified for the formation of CG involving the nucleation, growth, development of branches and interconnection of graphite particles, ultimately evolving into highly branched graphite aggregates with large sizes and low sphericities. CG is found to nucleate with a spheroidal or a plate-like shape, developing branches induced by high carbon concentration, e.g. thin melt channels. Additionally, CG grows much faster than spheroidal graphite during subsequent cooling in solid state. The direct visualization of the dynamic solidification process provides unprecedented new insights into formation mechanisms of CG and correlating factors such as local microstructural variations, and guides the development of CG iron solidification models.
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Sep 2021
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