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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 Microstructural Evolution during Additive Manufacturing of Functionally Graded Materials from Structural to Refractory Alloys: Integrated Computational-Experimental Framework
Author(s) Kaila Morgen Bertsch, Nicholas Ury, Brandon Bocklund, Jennifer Glerum, Benjamin Ellyson, Michael Juhasz, Aurelien Perron
On-Site Speaker (Planned) Kaila Morgen Bertsch
Abstract Scope Additive manufacturing (AM) of functionally graded materials (FGMs) enables novel design and joining capabilities for next-generation energy technologies. However, predicting microstructures and properties is challenging due to complex thermal histories, especially as material properties change spatially. To address this, we systematically investigated the microstructural evolution in AM FGMs from titanium to tantalum. Multiple builds with the same gradient step size were produced, each terminating at a different intermediate layer, then cross-sectioned perpendicular to the “terminal” melt pool to capture slices of microstructure in each layer development across build stages. Characterization using SEM, EDS, EPMA, and EBSD enabled tracking of phase formation, interdiffusion, and grain structure changes throughout the build. In situ thermocouple data was compared to analytical simulations to inform temperature-dependent property models to track phenomena. These insights provide a foundation for optimizing AM for FGMs to achieve precise spatial tailoring of properties for performance in advanced energy environments.
Proceedings Inclusion? Undecided

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