The 7th International Congress on 3D Materials Science (3DMS 2025): 3D Characterization and Modeling in Advanced Manufacturing
Program Organizers: Henry Proudhon, Mines Paris Centre Des Materiaux; Can Yildirim, European Synchrotron Radiation Facility
Thursday 8:00 AM
June 19, 2025
Room: Platinum Ballroom 7&8
Location: Anaheim Marriott
Session Chair: Matthew Dantin, Naval Surface Warfare Center Carderock Division
8:00 AM
Measuring Intragranular Orientation-Strain Fields and Residual Stresses in As-Built Additively Manufactured Stainless Steel Using Scanning 3DXRD: Jerard Gordon1; 1University of Michigan
Although laser-based metal additive manufacturing (LAM) is a disruptive technology enabling near-net shaped part production of metallic materials, its widespread adoption has been largely stymied due the occurrence of process-induced thermal residual stresses. To better understand the incidence of microscale residual stresses within bulk metal LAM materials, we employed novel 3d scanning x-ray diffraction (s3DXRD) to directly measure the full elastic strain tensor and orientation for ~500 grains within a bulk LAM sample. This measured strain data was used to estimate the residual elastic stress tensor components and von Mises stresses within the sample volume using the single crystal elastic constants. Interestingly, von Mises stress distributions appear to follow grain boundary networks and show significant localizations in regions of the microstructure containing fine grains. Overall, these results suggest that residual stress distributions within LAM materials are intimately connected to local solidification behaviors.
8:30 AM
Strain Field Mapping of a New Generation of Polycrystalline Chromium Coated Zirconium Claddings for Nuclear Application by Synchrotron Based Laue Microdiffraction: Clement Ribart1; Jean-Sebastien Micha2; Raphaelle Guillou3; Samuel Tardif1; Joel Eymery1; Jean-Luc Bechade4; 1CEA Grenoble DEPHY/MEM/NRX; 2UMR SYMMES CRNS CEA; 3CEA Saclay SRMA; 4CEA Saclay SRMP
We present a study probing the local in bulk micro-mechanical fields at the chromium-zirconium interface of a new generation of coated nuclear fuel claddings designed for improved resistance to hypothetic accidental high temperature transients Light Water Reactors. The chromium is deposited by DC-MS and/or HiPIMS-PVD processes, which results in a complex polycrystalline microstructure, textured and with heterogeneous internal stress state. The scanning diffraction µLaue technique, available at the ESRF on beamline BM32, is able to discriminate contributions of each crystallographic phase and to reconstruct raster maps of the locally integrated orientation and strain fields for each grain along the depth. Furthermore, the DAXM variant allows to resolve the signal along this latter direction, leading to 3D maps down to sub-micron voxel resolution. These techniques give valuable insight on the mechanical state of complex interfaces, which is an important parameter to further rely on the coated materials mechanical behavior.
8:50 AM
The Interest of Lab-Based DCT for the 3D Characterization of Monocrystalline Nickel-Based Alloys: Alexiane Arnaud1; Jun Sun2; Florian Bachmann2; Vladimir Esin3; Henry Proudhon4; 1Safran Group; 2Xnovo Technology; 3Université de Lorraine; 4Mines Paris - Centre des Matériaux
In the aerospace industry, single crystal nickel-based is used to manufacture high-pressure turbine blades, which are the most critical part of the engine. These alloys have a dendritic microstructure, usually produced by Bridgman furnace, where each dendrite can be associated with a crystalline orientation. Thus, this dendritic network is actually represented by subgrains separated by low-angle grain boundaries. The 3D characterization of a monocrystalline René N5 superalloy has been performed by lab-based diffraction contrast tomography (DCT). This experiment has demonstrated the precise capabilities of lab-based DCT in resolving subgrain boundaries with a misorientation angle of less than 1°, achieving an angular accuracy as fine as 0.1°. A slice from the 3D reconstruction has been compared with standard electron backscatter diffraction (EBSD) mapping. Obtaining the 3D microstructure non-destructively enabled the segmentation of the network of single-crystal dendrites, opening up new opportunities for studying crystal mosaicity.
9:10 AM
Analysis of 3D Grain Orientations in Additively Manufactured 316L: David Rowenhorst1; 1Naval Research Laboratory
The additive manufacturing process promises to provide new and highly customized processing methods for metal alloy components. Due to the large thermal gradients and resultant residual stresses built up in the printing process, the grain morphologies and structures are far from the typical alloy microstructures. In this presentation, we will examine the orientation gradients present in additively manufactured 316L, as measured by automated mechanical serial-sectioning with electron backscattered diffraction (EBSD) maps, with a data set that encompasses over 30,000 grains. We will show that while the grain sizes can have a very wide distribution, with the largest grains reaching over millimeters in length, the local orientation gradients within those grains lead to grain-spread distributions of over 20°. We will also discuss proper metrics for analyzing these gradients by normalizing for the local grain size within the structure.
9:30 AM Break
9:50 AM
Three-Dimensional Characterization of Dislocation Networks and Orientation Gradients in LPBF CoNi-Based Superalloys: James Lamb1; Evan Raeker1; Nicolò Maria della Ventura1; McLean Echlin1; Tresa Pollock1; 1University of California Santa Barbara
Laser powder bed fusion (LPBF) creates complex thermomechanical conditions that introduce significant residual stresses in printed parts. As a result, dense cellular dislocation networks and severe orientation gradients develop in the as-printed material, often leading to increased strength and work hardening when compared to traditionally manufactured components. Grain-scale and cell-scale misorientations are characterized in 3D using TriBeam tomography on LPBF prints of a CoNi-based superalloy. The resulting EBSD data enables calculation of geometrically necessary dislocation (GND) densities and grain-based misorientation metrics. Dislocation cells are observed to transition between orthogonal growth directions across melt pool boundaries. Concurrently, significant intracellular orientation gradients develop along the growth axis of solidification cells and between neighboring cells. Cell-scale misorientations accumulate along the build direction, creating larger orientation gradients, upwards of 50° over 500 µm, at the grain scale. These findings reveal fundamental relationships between processing conditions, microstructural evolution, and residual stress development during LPBF.
10:10 AM
A Crystal Plasticity Finite Element Study on the Strengthening Mechanisms in Additively Manufactured Precipitate Strengthened Alloys: Ezra Mengiste1; Jacob Strain1; Luke Brewer1; Matthew Kasemer1; 1University of Alabama
The design of modern engineering components requires the development of innovative manufacturing techniques. In parallel, design engineers increasingly design components closer to their failure limits due to sustainability and performance demands, necessitating better predictions of mechanical behavior. Additive friction stir deposition (AFSD) has emerged as a solid-state additive manufacturing method which allows for the construction of near-net-shape components. When employed with precipitate-strengthened alloys, AFSD tends to lead to a loss of material strength due to changes in the morphology of the precipitates. In our work we utilize a crystal plasticity finite element model informed by experimental material characterization and mechanical testing performed on samples before and after AFSD processing. We discuss the contribution of the crystallographic texture on the yield strength of the material and the implementation of a precipitate strengthening model used to account for the effects due to the presence of precipitates.