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Instruments / Technical Area	Publication Details	Published	Actions
I12-JEEP: Joint Engineering, Environmental and Processing	Synchrotron imaging derived relationship between process parameters and build quality for directed energy deposition additively manufactured IN718 S. V. Notley , Y. Chen , N. A. Thacker , P. D. Lee , G. Panoutsos Additive Manufacturing Letters volume 861 DOI: 10.1016/j.addlet.2023.100137 Diamond Proposal Number(s): [20096] Open Access Show Abstract ▼ Abstract: Laser additive manufacturing is transforming several industrial sectors, especially the directed energy deposition process. A key challenge in the widespread uptake of this emerging technology is the formation of undesirable microstructural features such as pores, cracks, and large epitaxial grains. The trial and error approach to establish the relationship between process parameters and material properties is problematic due to the transient nature of the process and the number of parameters involved. In this work, the relationship between process parameters, melt pool geometry and quality of build measures, using directed energy deposition additive manufacturing for IN718, is quantified using neural networks as generalised regressors in a statistically robust manner. The data was acquired using in-situ synchrotron x-ray imaging providing unique and accurate measurements for our analysis. An analysis of the variations across repeated measurements show heteroscedastic error characteristics that are accounted for using a principled nonlinear data transformation method. The results of the analysis show that surface roughness correlates with melt pool geometry while the track height directly correlates with process parameters indicating a potential to directly control efficiency and layer thickness while independently minimising surface roughness.	Mar 2023
I12-JEEP: Joint Engineering, Environmental and Processing	Oxidation induced mechanisms during directed energy deposition additive manufactured titanium alloy builds Caterina Iantaffi , Chu Lun Alex Leung , Yunhui Chen , Shaoliang Guan , Robert C. Atwood , Jedsada Lertthanasarn , Minh-Son Pham , Martina Meisnar , Thomas Rohr , Peter D. Lee Additive Manufacturing Letters 143 DOI: 10.1016/j.addlet.2021.100022 Diamond Proposal Number(s): [20096] Open Access Show Abstract ▼ 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.	Nov 2021

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