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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing: Advanced Characterization With Synchrotron, Neutron, and In Situ Laboratory-scale Techniques IV
Presentation Title Environmental gas effect on bubble dynamics in metal additive manufacturing with XFEL-based microscopy
Author(s) Lichao Fang, Zane Taylor, Tharun Reddy, Jayanath Koliyadu, Tokushi Sato, Steven van Petegem, Patrik Vagovic, Leora Dresselhaus-Marais
On-Site Speaker (Planned) Lichao Fang
Abstract Scope Bubble formation and keyhole dynamics are unclear in LPBF due to the complex competing physics between heat transfer, fluid flow, evaporation, phase change, solidification, and interaction with environmental gas. We use operando MHz X-ray radiography at the European XFEL to reveal bubble and keyhole dynamics under different environmental gas. We observe and compare bubble formation and keyhole dynamics to investigate the bubble formation and evolution mechanisms under air vs argon gas environments. We compare our results of keyhole and bubble migration to those predicted with multi-physics simulations to guide the design of metal additive manufacturing.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Characterization, Modeling and Simulation

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

Additive Manufacturing at the Materials Solutions Network at CHESS
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AI-Driven Spectral Sensing for Distributed Born-Qualified Additive Manufacturing
Bayesian Calibration of Phase Fractions in Additively Manufactured Nickel Alloy 718
Characterization Capabilities of Additively Manufactured Materials at SSRL
Coarsening of Si particles during heat treatment of LPBF AlSi10Mg characterized by a combination of synchrotron nanotomography and laboratory 3D micro-beam X-Ray diffraction
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CW Laser-SEM: A novel continuous-wave laser and SEM coupling
Deconvoluting Thermomechanical Effects in X-ray Diffraction Data using Machine Learning
Development of residual stresses in an additively manufactured Al-Ce based alloy with a high fraction of intermetallic particles
Direct Observation of Balling Defects in Laser Melting using X-ray Radiography
Effect of Scanning Strategies on Residual Stress Mitigation in Laser Powder Bed Fusion
Enhancing Defect Detection in Additive Manufacturing Using In Situ Thermal Imaging and Acoustic Data
Environmental gas effect on bubble dynamics in metal additive manufacturing with XFEL-based microscopy
Estimating elastic and thermal contributions to lattice strains from operando X-ray diffraction measurements using fast simulations
Evolution of Dislocations during the Rapid Solidification in Additive Manufacturing
Harnessing Intermediate Metastable Phase Formations to Engineer Alloy microstructures in Additive Manufacturing
Heating Rate Dependent Microstructural Evolution of Laser Powder Bed Fusion Additively Manufactured Ti-6Al-4V
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High-Speed Diffraction to Unravel Phase Transformation Pathways and Kinetics in Laser-Melted Fe-Cr-Ni Alloys
High-throughput microstructure evolution via Gleeble thermomechanical simulator
Hybrid CFD–Acoustic Modeling of Acoustic Emissions in Laser Powder Bed Fusion of AlSi10Mg
Imaging External Fields’ Influence on Additive Manufacturing
In-situ characterization of defect formation and elimination dynamics during electron beam melting using high-speed X-ray imaging
In-Situ Process Monitoring: Quality Assurance, Process Development and Closed-Loop Control
In-situ studies of AMed High Entropy Alloys
In-situ X-ray characterization of electron beam powder bed fusion (PBF-EB)
In Situ Monitoring during Additive Friction Stir Deposition to Unravel Hidden Process Physics and Mechanics
In Situ Synchrotron Imaging of Hydrogen Bubble Dynamics in a Recycled Aluminum Alloy during Laser Directed Energy Deposition
Influence of Injector Geometrical Feature on Residual Stress in LPBF IN625 Components
Insights into Additive Manufacturing Processes from Operando Synchrotron X-ray Imaging and Diffraction
Integrating In-Situ Strain Sensing and Neutron Diffraction to Realize Residual Stress–Microstructure Relationships in Laser Powder Bed Fusion
Investigation of solidification behaviour and high-temperature performance of Al-Ce-Fe-Ni-Mn aluminium alloys in additive manufacturing
Keyhole driven mixing mechanisms revealed by XFEL-based multiscale MHz microscopy
Laser-powder bed fusion of 8xxx-series aluminum alloys containing Fe
Mechanisms of phase evolution and grain refinement during fusion-based metal additive manufacturing revealed by in-situ high-speed x-ray diffraction and imaging
Microstructural Evolution and Property Optimization in DED of M2 Tool Steel: A Comparative Assessment with Binder Jetting and Powder Bed Fusion
Multi-Sensor Process Monitoring for Blue Laser Directed Energy Deposition of Copper
Multimodal in-situ sensing and microstructural properties in Wire Arc Additive Manufacturing
Neutron Phase and Internal Stresses Characterization in Metal Additive Manufacturing: From 3D Mapping to Real-Time Evolution
Operando Characterization of the Spattering Process in Laser Powder Bed Fusion
Operando Multiscale X-ray Imaging of Defects & Alloying at XFELs in LPBF
Part-Scale Evolution of Microstructural Heterogeneity Quantified at Fine Length-Scale in Solid-State Additive Manufacturing Process
Phase transformation dynamics during laser additive manufacturing of high-entropy alloys via high-speed synchrotron imaging and diffraction
Placeholder - TBD
Powder Particle Impact Behavior in Laser, Powder-blown Directed Energy Deposition
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Real-Time Analysis of Phase Transformations in FeCrNiCo-Based High-Entropy Alloys with Varying Aluminum Content Using In-Situ Synchrotron Techniques
Real-Time Detection and Analysis of Spatter-Induced Defects in Laser-Based Powder Bed Fusion Using Optical and Long Wave Infrared Imaging and Machine Learning
Real-Time Observation of Ti-6Al-4V Powder Particle Impact in Laser Directed Energy Deposition
Residual Strain Measurement of AM Parts Using Synchrotron X-Ray Based Diffraction Techniques
Revealing cracking mechanisms and interfacial dynamics in dissimilar alloy additive manufacturing
Revealing the Complex Relationships Between Composition and Phase Transformation Route Under 17-4 PH Stainless Steel Through In Situ High Speed XRD of Custom Manufactured Compositions
Role of In-situ Diffraction Studies in Understanding Microstructure and Property Evolution During Manufacturing
The AM BAG at ESRF: A Collaborative Platform for Operando Characterization of Laser Additive Manufacturing
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Towards high-throughput in-situ SAXS and WAXS measurement of precipitation kinetics – a case study on selective laser melted maraging steels
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Ultrasound-assisted Directed Energy Deposition rig for in-situ investigations via synchrotron and infrared imaging
Understanding ductility-controlling strain-hardening mechanisms in an additively manufactured Al-7Si-0.3Mg-0.5Cu-1Fe alloy using in-situ synchrotron tensile testing
Uniaxial loading of AM materials at various strain rates during synchrotron based high-speed 3D tomography.
Using synchrotron radiation to understand microstructure and defect formation in additive manufacturing
X-ray Computed Tomography to Inform Near Net Shape-Manufactured Components
X-ray imaging of Blown-powder Directed Energy Deposition with melt pool flow control via magnetic fields
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