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Instruments / Technical Area	Publication Details	Published
I15-Extreme Conditions	The mechanical performance of additively manufactured 316L austenitic stainless steel Andrew Wisbey , David Coon , Mark Chatterton , Josh Barras , Da Guo , Kun Yan , Mark Callaghan , Wajira Mirihanage Pressure Vessels & Piping Conference PVP2022 DOI: 10.1115/PVP2022-84543 Show Abstract ▼ Abstract: Additive manufacturing (AM) offers the potential for significantly reducing the time and cost of new nuclear components. This process may also permit unique design features, for example internal geometries. However, the limitations of the technology need to be better understood to enable implementation and accreditation. Here a “blown powder” and laser melting process, within a helium shielded environment, was used to fabricate austenitic stainless steel 316L walls of ∼2.4 mm thickness, with the deposition parameters minimizing the surface roughness. A key aim was to evaluate the effect of the as-deposited surface finish and the bulk material on the tensile and fatigue properties. In addition, the effect of material orientation was also considered to be important. Microstructural characterization demonstrated the complex nature of the grain morphology arising from the as-manufactured AM process, including elongated grains following the thermal gradients. However, areas of equiaxed grains were also observed at the sample surfaces. Si-Mn-O particles, up to ∼20 μm in diameter, were noted throughout the samples produced. Residual strains have also been measured and correlated with microstructural features. The tensile performance was generally similar to wrought 316L material but exhibited some anisotropy. The fatigue endurance of as-deposited AM 316L was significantly lower than wrought material. However, surface grinding of the AM 316L was shown to be beneficial. It was noted that in all cases examined, fatigue crack initiation was found to occur at the Si-Mn-O particles, in both surface finishes — clearly a performance limitation.	Jul 2022
I15-Extreme Conditions	Solidification microstructure and residual stress correlations in direct energy deposited type 316L stainless steel Da Guo , Kun Yan , Mark D. Callaghan , Dominik Daisenberger , Mark Chatterton , Jiadong Chen , Andrew Wisbey , Wajira Mirihanage Materials & Design DOI: 10.1016/j.matdes.2021.109782 Diamond Proposal Number(s): [20605] Open Access Show Abstract ▼ Abstract: Localized fluctuation in residual stress distribution for direct energy deposited 316L stainless steel thin plate was revealed through high-energy synchrotron X-ray diffraction. The macroscopic residual stress levels are changed steadily across the article according to the characteristic cooling rates, as implied by the measured dendrite arm lengths. Localized fluctuations of residual stress in the length scale, between 500 to 600 µm, coincides well with the morphological variations of the solidification microstructure that formed during direct energy deposition. Computations indicate a greater propensity for related mesoscopic thermal gradient fluctuations along the solidification front of the moving melt pool. Novel perspectives on residual stress across multiple length-scales and its relevance to the formation of solidification microstructure in metal additive manufacturing is analysed by considering the experimental results.	May 2021
I13-2-Diamond Manchester Imaging	Fast synchrotron X-ray tomographic quantification of dendrite evolution during the solidification of MgSn alloys Sansan Shuai , Enyu Guo , Andre Phillion , Mark Callaghan , Tao Jing , Peter D. Lee Acta Materialia 118, 260 - 269 DOI: 10.1016/j.actamat.2016.07.047 Diamond Proposal Number(s): [11837] Open Access Show Abstract ▼ Abstract: The evolution of dendritic microstructures during the solidification of a Mg-15 wt%Sn alloy was investigated in situ via fast synchrotron X-ray microtomography. To enable these in situ observations a novel encapsulation method was developed and integrated into a fast, pink beam, imaging beamline at Diamond Light Source. The dendritic growth was quantified with time using: solid volume fraction, tip velocity, interface specific surface area, and surface curvature. The influence of cooling rate upon these quantities and primary phase nucleation was investigated. The primary dendrites grew with an 18-branch, 6-fold symmetry structure, accompanied by coarsening. The coarsening process was assessed by the specific surface area and was compared with the existing models. These results provide the first quantification of dendritic growth during the solidification of Mg alloys, confirming existing analytic models and providing experimental data to inform and validate more complex numeric models.	Oct 2016

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