Additive manufacturing, also known as 3D printing, is a bottom-up approach in which a part is manufactured layer by layer from a 3D computer model. In the SMAM group, we study the influence of the processing parameters on the microstructural evolution during the printing process. This is achieved by fast operando X-ray diffraction, radiography and small-angle scattering, combined with state-of-the-art post-processing characterisation techniques.
In situ monitoring based on artificial intelligence
Laser powder bed fusion is a very complex technique, with many variables. To ensure an optimal build quality, in situ process monitoring is crucial. In a SNF funded Sinergia project, the SMAM group, in collaboration with research groups from EPFL, EMPA and PSI aim to develop an online monitoring strategy for additive manufacturing.
Multi-Material Laser Powder Bed Fusion
Laser powder-bed fusion (LPBF) is the most widely used additive manufacturing process for monolithic metal parts. Many applications would greatly profit if more then one materials could be co-processed in the powder bed. Besides offering a much wider design space, multi-material LPBF would allow for producing functional parts without joining and assembly operations, and add 'function for free' as a new dimension to LPBF. In this project, we explore laser exposure strategies that allow controlled 3D printing of multi-material.
In situ alloying studied by operando X-ray diffraction
Laser powder bed fusion has great potential to design advanced alloys in situ during the printing process. We explore by operando X-ray diffraction the phase evolution during 3D printing of powder mixtures.
Selected publications
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Navarre C, Van Petegem S, Schlenger L, Cayron C, Hamidi-Nasab M, Esmaeilzadeh R, et al.
Monitoring of laser-induced fast recrystallization in SS-316L through synchrotron X-ray diffraction
Materials and Design. 2024; 238: 112628 (14 pp.). https://doi.org/10.1016/j.matdes.2023.112628
DORA PSI -
Yang J, Schlenger LM, Nasab MH, Van Petegem S, Marone F, Logé RE, et al.
Experimental quantification of inward Marangoni convection and its impact on keyhole threshold in laser powder bed fusion of stainless steel
Additive Manufacturing. 2024; 84: 104092 (11 pp.). https://doi.org/10.1016/j.addma.2024.104092
DORA PSI -
de Formanoir C, Hamidi Nasab M, Schlenger L, Van Petegem S, Masinelli G, Marone F, et al.
Healing of keyhole porosity by means of defocused laser beam remelting: Operando observation by X-ray imaging and acoustic emission-based detection
Additive Manufacturing. 2024; 79: 103880 (18 pp.). https://doi.org/10.1016/j.addma.2023.103880
DORA PSI -
Esmaeilzadeh R, Hamidi-Nasab M, de Formanoir C, Schlenger L, Van Petegem S, Navarre C, et al.
In-situ selective laser heat treatment for microstructural control of additively manufactured Ti-6Al-4V
Additive Manufacturing. 2023; 78: 103882 (14 pp.). https://doi.org/10.1016/j.addma.2023.103882
DORA PSI -
Hamidi Nasab M, Masinelli G, de Formanoir C, Schlenger L, Van Petegem S, Esmaeilzadeh R, et al.
Harmonizing sound and light: X-ray imaging unveils acoustic signatures of stochastic inter-regime instabilities during laser melting
Nature Communications. 2023; 14: 8008 (14 pp.). https://doi.org/10.1038/s41467-023-43371-3
DORA PSI -
Gao S, Li Z, Van Petegem S, Ge J, Goel S, Vas JV, et al.
Additive manufacturing of alloys with programmable microstructure and properties
Nature Communications. 2023; 14(1): 6752 (11 pp.). https://doi.org/10.1038/s41467-023-42326-y
DORA PSI -
Gh Ghanbari P, Markovic P, Van Petegem S, Makowska MG, Wrobel R, Mayer T, et al.
A close look at temperature profiles during laser powder bed fusion using operando X-ray diffraction and finite element simulations
Additive Manufacturing Letters. 2023; 6: 100150 (9 pp.). https://doi.org/10.1016/j.addlet.2023.100150
DORA PSI -
König H-H, Holländer Pettersson N, Durga A, Van Petegem S, Grolimund D, Chuang AC, et al.
Solidification modes during additive manufacturing of steel revealed by high-speed X-ray diffraction
Acta Materialia. 2023; 246: 118713 (11 pp.). https://doi.org/10.1016/j.actamat.2023.118713
DORA PSI -
Chen M, Van Petegem S, Zou Z, Simonelli M, Tse YY, Chang CST, et al.
Microstructural engineering of a dual-phase Ti-Al-V-Fe alloy via in situ alloying during laser powder bed fusion
Additive Manufacturing. 2022; 59: 103173 (10 pp.). https://doi.org/10.1016/j.addma.2022.103173
DORA PSI -
Chen M, Simonelli M, Van Petegem S, Tse YY, Chang CST, Makowska MG, et al.
A quantitative study of thermal cycling along the build direction of Ti-6Al-4V produced by laser powder bed fusion
Materials and Design. 2023; 225: 111458 (11 pp.). https://doi.org/10.1016/j.matdes.2022.111458
DORA PSI -
Pandiyan V, Masinelli G, Claire N, Le-Quang T, Hamidi-Nasab M, de Formanoir C, et al.
Deep learning-based monitoring of laser powder bed fusion process on variable time-scales using heterogeneous sensing and operando X-ray radiography guidance
Additive Manufacturing. 2022; 58: 103007 (15 pp.). https://doi.org/10.1016/j.addma.2022.103007
DORA PSI -
Glerum JA, Hocine S, Chang CST, Kenel C, Van Petegem S, Casati N, et al.
Operando X-ray diffraction study of thermal and phase evolution during laser powder bed fusion of Al-Sc-Zr elemental powder blends
Additive Manufacturing. 2022; 55: 102806 (12 pp.). https://doi.org/10.1016/j.addma.2022.102806
DORA PSI -
Ghasemi-Tabasi H, de Formanoir C, Van Petegem S, Jhabvala J, Hocine S, Boillat E, et al.
Direct observation of crack formation mechanisms with operando laser powder bed fusion X-ray imaging
Additive Manufacturing. 2022; 51: 102619 (11 pp.). https://doi.org/10.1016/j.addma.2022.102619
DORA PSI -
Hocine S, Van Swygenhoven H, Van Petegem S
Verification of selective laser melting heat source models with operando X-ray diffraction data
Additive Manufacturing. 2021; 37: 101747 (16 pp.). https://doi.org/10.1016/j.addma.2020.101747
DORA PSI -
Hocine S, Van Petegem S, Frommherz U, Tinti G, Casati N, Grolimund D, et al.
A miniaturized selective laser melting device for operando X-ray diffraction studies
Additive Manufacturing. 2020; 34: 101194 (9 pp.). https://doi.org/10.1016/j.addma.2020.101194
DORA PSI -
Hocine S, Van Swygenhoven H, Van Petegem S, Chang CST, Maimaitiyili T, Tinti G, et al.
Operando X-ray diffraction during laser 3D printing
Materials Today. 2020; 34: 30-40. https://doi.org/10.1016/j.mattod.2019.10.001
DORA PSI
Contact
Dr. Steven Van Petegem
Structure and Mechanics of Advanced Materials
Photon Science Division
Paul Scherrer Institute
Forschungsstrasse 111, 5232 Villigen PSI, Switzerland
Telephone: +41 56 310 2537
E-mail: [email protected]