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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Beyond the Melt Pool: Heterogeneous Behavior in Processing and Properties of Functionally Gradient Materials
Author(s) Clayton Perbix, Maximalian Kephart, Leslie Lamberson, Samantha Webster, Joy Gockel
On-Site Speaker (Planned) Joy Gockel
Abstract Scope Directed energy deposition of functionally graded materials (FGMs) requires process control to ensure reproducibility. However, this study reveals that geometry-driven effects persist despite closed-loop melt pool control in a FGM of 316L stainless steel and nickel superalloy 625. Microhardness showed a 9% hardness decrease when reducing part size, while primary dendrite arm spacing remained constant. These results indicate that property variations are driven by part-scale thermal histories beyond the solidification front. To further interrogate the mechanical heterogeneity, we adopted a “Materials Testing 2.0” framework that combines nontraditional coupon geometries, full-field deformation measurements, and digital-twin-informed inverse analysis. Quasi-static full-field experiments provided strain maps that are processed using the Virtual Fields Method (VFM) to extract spatially resolved stiffness and yield properties. This integration of experimental and virtual testing decodes the heterogeneous behavior of FGM systems and establishes predictive relationships among composition, processing, and mechanical performance, enabling the design of next-generation multifunctional structures.
Proceedings Inclusion? Undecided

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