A New Science-Based Paradigm Enabling Microstructure-Tailored Additive Manufacturing of Metals

Project Overview

Metal powder-bed fusion (PBF) additive manufacturing (AM), while continuing to play an important strategic role across a diverse application space both internal and external to Lawrence Livermore National Laboratory, has historically lacked the necessary control to obtain parts that meet strict performance-driven criteria for qualification and certification. Here, a new science-based approach has been developed to address this shortcoming and fundamentally transform metal PBF AM through development of a comprehensive experiment-modeling framework. This new framework has enabled the development of new materials specifically suited to AM and new laser-based processing methods that can mitigate material defects. At its conclusion, this project has further empowered and differentiated Livermore's metals-based AM design capabilities from those that are currently available anywhere else.

We developed and validated ALE3D-CAFE (arbitrary Lagrangian_Eulerian in 3D - cellular automata finite element) model to derive a physics stability criterion which minimizes defects in metal AM and any other laser-driven process. The model capability bridges macroscale physics in space and time (laser-melt pool interaction) with microscale physics models (Phase Field, Cellular Automata). Our work demonstrated 90% reduction in residual stress of AM steel components printed using a hybrid, multi-laser approach. An in-depth analysis of residual stresses using neutron diffraction and contour-displacement-based measurements also led to improved model predictions for residual stress. Novel beam shaping approaches were also used to optimize material microstructure for improved mechanical performance. Finally, we developed a new alloy (TiNbxSny) that solidifies into an isotropic state under metal AM process conditions, in contrast to the anisotropic state usually produced by elongated columnar grain structures in metal AM (i.e., TiNb, Ti-6Al-4V alloy).

Mission Impact

This project established new capabilities in the design and production of additively manufactured metal parts with tailored microstructures that have improved potential to meet stringent performance requirements for certification within Weapons and Complex Integration. The ALE3D-CAFE code work added a basic modular CS framework that allows us to couple different physics packages for future applications including laser programs in the National Ignition Facility & Photon Science and Global Security Directorates. New alloy designs will advance multiple Livermore programs including future needs in hypersonics. This research has broad applications to industry and directly supports national missions in stockpile stewardship.

Publications, Presentations, and Patents

Berry, Joel, Aurelien Perron, Jean-Luc Fattebert, John D. Roehling, Bey Vrancken, Tien Tran Roehling, Debra L. Rosas, et al., "Toward Multiscale Simulations of Tailored Microstructure Formation in Metal Additive Manufacturing," Materials Today (under review). LLNL-JRNL-816741.

DePond, Philip J., John C. Fuller, Saad A. Khairallah, Justin R. Angus, Gabe Guss, Manyalibo J. Matthews, and Aiden A. Martin. "Laser-Metal Interaction Dynamics During Additive Manufacturing Resolved by Detection of Thermally-Induced Electron Emission," Communications Materials 1, no. 1 (2020/11/27 2020): 92. LLNL-JRNL-807184.

Dyatkin, Boris (for B. Vrancken, R. Ganeriwala and M. Matthews). Invited review article: "High-speed video analyzes microcracking during additive manufacturing of tungsten," MRS Bulletin 45, (2020/12/10 2020): 686. LLNL-MI-812548.

Gaikwad, Aniruddha, Brian Giera, Gabriel M. Guss, Jean-Baptiste Forien, Manyalibo J. Matthews, and Prahalada Rao. "Heterogeneous Sensing and Scientific Machine Learning for Quality Assurance in Laser Powder Bed Fusion - a Single-Track Study," Additive Manufacturing (2020/10/15/ 2020): 101659. LLNL-JRNL-808643.

Hackel, Lloyd, Jon R. Rankin, Alexander Rubenchik, Wayne E. King, and Manyalibo Matthews. "Laser Peening: A Tool for Additive Manufacturing Post-Processing," Additive Manufacturing 24 (2018/12/01/ 2018): 67-75. LLNL-JRNL-818382.

Han, I. S., J. T. McKeown, L. Tang, C. Z. Wang, H. Parsamehr, Z. C. Xi, Y. R. Lu, M. J. Kramer, and A. J. Shahani. "Dynamic Observation of Dendritic Quasicrystal Growth Upon Laser-Induced Solid-State Transformation," [In English]. Physical Review Letters 125, no. 19 (Nov 6 2020). LLNL-JRNL-807380.

Heo, Tae Wook, Saad A. Khairallah, Rongpei Shi, Joel Berry, Aurelien Perron, Nicholas P. Calta, Aiden A. Martin, et al., "A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures," Journal of Physics: Materials (under review). LLNL-JRNL-816984.

Khairallah, Saad A., Aiden A. Martin, Jonathan R. I. Lee, Gabe Guss, Nicholas P. Calta, Joshua A. Hammons, Michael H. Nielsen, et al. "Controlling Interdependent Meso-Nanosecond Dynamics and Defect Generation in Metal 3d Printing," Science 368, no. 6491 (2020): 660-65. LLNL-JRNL-774900.

Landau, E., E. Tiferet, Y. I. Ganor, R. K. Ganeriwala, M. J. Matthews, D. Braun, M. Chonin, and G. Ziskind. "Thermal Characterization of the Build Chamber in Electron Beam Melting," Additive Manufacturing (2020/09/19/ 2020): 101535. LLNL-JRNL-808338.

Martin, Aiden A., Nicholas P. Calta, Joshua A. Hammons, Saad A. Khairallah, Michael H. Nielsen, Richard M. Shuttlesworth, Nicholas Sinclair, et al. "Ultrafast Dynamics of Laser-Metal Interactions in Additive Manufacturing Alloys Captured by in Situ X-Ray Imaging," Materials Today Advances 1 (2019/03/01/ 2019): 100002. LLNL-JRNL-756599.

Matthews, Manyalibo J., Johannes Trapp, Gabe Guss, and Alexander M. Rubenchik. "Direct Measurements of Laser Absorptivity During Metal Melt Pool Formation Associated with Powder Bed Fusion Additive Manufacturing Processes," Journal of Laser Applications 30, no. 3 (2018): 032302. LLNL-JRNL-740801.

Matthews, M. J., T. T. Roehling, S. A. Khairallah, G. Guss, S. Q. Wu, M. F. Crumb, J. D. Roehling, and J. T. McKeown. "Spatial Modulation of Laser Sources for Microstructural Control of Additively Manufactured Metals," Procedia CIRP 74 (2018/01/01/ 2018): 607-10. LLNL-PROC-748826.

Matthews, M. J., T. T. Roehling, S. A. Khairallah, T. U. Tumkur, G. Guss, R. Shi, J. D. Roehling, et al. "Controlling Melt Pool Shape, Microstructure and Residual Stress in Additively Manufactured Metals Using Modified Laser Beam Profiles," Procedia CIRP 94 (2020/01/01/ 2020): 200-04. LLNL-JRNL-818383.

McKeown, J. T., A. J. Clarke, and J. M. K. Wiezorek. "Imaging Transient Solidification Behavior," [In English]. MRS Bulletin 45, no. 11 (Nov 2020): 916-26. LLNL-JRNL-812481.

McKeown, J. T., J. D. Roehling, A. Perron, J. L. Fattebert, J. M. K. Wiezorek, A. J. Clarke, D. J. Bober, et al. "Melt Pool and Microstructure Characterization for Am Model Development," Microscopy and Microanalysis 25, no. S2 (2019): 2562-63. LLNL-ABS-767607.

Pinomaa, T., J. M. McKeown, J. M. K. Wiezorek, N. Provatas, A. Laukkanen, and T. Suhonen. "Phase Field Modeling of Rapid Resolidification of Al-Cu Thin Films," [In English]. Journal of Crystal Growth 532 (Feb 15 2020). LLNL-JRNL-789578.

Qu, Dong-Xia, Joel Berry, Nicholas P. Calta, Michael F. Crumb, Gabe Guss, and Manyalibo J. Matthews. "Temperature Measurement of Laser-Irradiated Metals Using Hyperspectral Imaging," Physical Review Applied 14, no. 1 (07/10/ 2020): 014031. LLNL-JRNL-801599.

Roehling, J. D., A. Perron, J. L. Fattebert, T. Haxhimali, G. Guss, T. T. Li, D. Bober, et al. "Rapid Solidification in Bulk Ti-Nb Alloys by Single-Track Laser Melting," [In English]. JOM 70, no. 8 (Aug 2018): 1589-97. LLNL-JRNL-743642.

Roehling, John D., William L. Smith, Tien T. Roehling, Bey Vrancken, Gabriel M. Guss, Joseph T. McKeown, Michael R. Hill, and Manyalibo J. Matthews. "Reducing Residual Stress by Selective Large-Area Diode Surface Heating During Laser Powder Bed Fusion Additive Manufacturing," Additive Manufacturing 28 (2019/08/01/ 2019): 228-35. LLNL-JRNL-766658.

Roehling, Tien T., Rongpei Shi, Saad A. Khairallah, John D. Roehling, Gabe M. Guss, Joseph T. McKeown, and Manyalibo J. Matthews. "Controlling Grain Nucleation and Morphology by Laser Beam Shaping in Metal Additive Manufacturing," Materials & Design 195 (2020/10/01/ 2020): 109071. LLNL-JRNL-805378.

Shi, Rongpei, Saad A. Khairallah, Tien T. Roehling, Tae Wook Heo, Joseph T. McKeown, and Manyalibo J. Matthews. "Microstructural Control in Metal Laser Powder Bed Fusion Additive Manufacturing Using Laser Beam Shaping Strategy," Acta Materialia 184 (2020/02/01/ 2020): 284-305. LLNL-JRNL-782838.

Shi, Rongpei, Saad Khairallah, Tae Wook Heo, Matthew Rolchigo, Joseph T. McKeown, and Manyalibo J. Matthews. "Integrated Simulation Framework for Additively Manufactured Ti-6al-4v: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response," JOM 71, no. 10 (October 01 2019): 3640-55. LLNL-JRNL-767762.

Turchi, P. E. A. "Viscosity and Surface Tension of Metals," In LLNL Technical Report, 2018. LLNL-TR-750486.

Voisin, T., J. B. Forien, J. T. McKeown, M. J. Matthews, and Y. M. Wang. "Understanding the High Strength of L-Pbf Metals Using in and Ex Situ Characterization by Tem and Synchrotron Xrd," Microscopy and Microanalysis 25, no. S2 (2019): 2560-61. LLNL-CONF-767641.

Vrancken, Bey, Rishi K. Ganeriwala, and Manyalibo J. Matthews. "Analysis of Laser-Induced Microcracking in Tungsten under Additive Manufacturing Conditions: Experiment and Simulation," Acta Materialia 194 (2020/08/01/ 2020): 464-72. LLNL-JRNL-805870.

Vrancken, B., W. E. King, and M. J. Matthews. "In-Situ Characterization of Tungsten Microcracking in Selective Laser Melting," Procedia CIRP 74 (2018/01/01/ 2018): 107-10. LLNL-CONF-748304.

Ye, J. C., A. M. Rubenchik, M. F. Crumb, G. Guss, and M. J. Matthews. "Laser Absorption and Scaling Behavior in Powder Bed Fusion Additive Manufacturing of Metals," [In English]. 2018 Conference on Lasers and Electro-Optics (CLEO) (2018). LLNL-ABS-743281.

Ye, Jianchao, Saad A. Khairallah, Alexander M. Rubenchik, Michael F. Crumb, Gabe Guss, Jim Belak, and Manyalibo J. Matthews. "Energy Coupling Mechanisms and Scaling Behavior Associated with Laser Powder Bed Fusion Additive Manufacturing," Advanced Engineering Materials 21, no. 7 (2019): 1900185. LLNL-JRNL-763217.

Tien Roehling, Gabe Guss, Saad Khairallah, Manyalibo Joseph Matthews, Sheldon S Wu, "System and method for grain refinement and general control of grain morphology in laser additive manufacturing," U.S. Patent 10,888,956, 2020.

William Smith, Manyalibo Joseph Matthews, Joseph T Mckeown, John Roehling, "System and method for performing laser powder bed fusion using controlled, supplemental in situ surface heating to control microstructure and residual stresses in formed part," U.S. Patent App. 16/365,029, 2020.

Nicholas P Calta, Gabe Guss, Manyalibo Joseph Matthews, "Two-color high speed thermal imaging system for laser-based additive manufacturing process monitoring," U.S. Patent App. 16/273,953, 2020.

Saad A Khairallah, Gabe Guss, Wayne E King, Sonny S Ly, Manyalibo Joseph Matthews, Alexander M Rubenchik, "Controlling AM spatter and conduction," U.S. Patent App. 16/217,351, 2020.

Alexander M Rubenchik, Manyalibo Joseph Matthews, Johannes Trapp, "Compact absorptivity measurement system for additive manufacturing," U.S. Patent 10,646,960, 2020.

Nicholas Calta, Gabe Guss, Manyalibo Joseph Matthews, "System and method for portable multi-band black body simulator," U.S. Patent 10,564,039, 2020.

Calta, N. P., G. M. Guss, D. Qu, S. Khairallah, M. J. Matthews, "Determination of temperature distribution in and around the melt pool during laser powder bed fusion by hyperspectral thermal imaging," TMS 2019, 2018, LLNL-PRES-769461.

Calta, N., A. Martin, P. Depond, S. Khairallah, A. Fong, V. Thampy, A. Kiss, G. Guss, K. Stone, C. Tassone, J. Weker, M. Toney, A. van Buuren, M. Matthews, "In situ synchrotron X-ray imaging and diffraction characterization of the laser powder bed fusion process," 4th AM Cross JOWOG, 2018, LLNL-PRES-759727.

Calta, N. P.; Forien, J.-B.; Guss, G.; Depond, P.; Matthews, M. J. "Quantifying defect signatures in laser powder bed fusion using in situ diagnostics." In situ sensing and process monitoring workshop, Los Alamos, 2020, LLNL-PRES-813958.

Khairallah, S. A., S. Rongpei, T. T. Roehling, J. Roehling, J. Chao, A. M. Rubenchik, M. J. Matthews, "Controlling defects and microstructure evolution in single tracks," TMS 2019, 2018, LLNL-ABS-754140.

Khairallah, S., R. Shi, J. Chao, A. M. Rubenchik, M. J. Matthews, T. T. Roehling, A. Martin, N. Calta, A. Anderson, "Laser Powder Bed Fusion Additive Manufacturing: Keyhole mitigation and microstructure control using a high-fidelity powder scale model," 4th AM Cross JOWOG, 2018, LLNL-ABS-757502.

Khairallah, S., R. Shi, J. Ye, A. M. Rubenchik, T. T. Roehling, J. T. Mckeown, M. J. Matthews, "Tailoring microstructure through laser beam shaping," Solid Freeform Fabrication Symposium 2019, LLNL-PRES-785719.

Khairallah, S., R. Nourgaliev, B. Weston, R. Shi, A. M. Rubenchik, A. A. Martin, N. P. Calta, T. Roehling, J. T. Mckeown, M. J. Matthews, A. Anderson, W. King, "Laser powder bed fusion additive manufacturing: Feedforward mitigation and microstructure control," USNCCM 2019, LLNL-PRES-781238.

Khairallah, S., R. Shi, A. M. Rubenchik, A. A. Martin, N. P. Calta, T. Roehling, J. T. Mckeown, M. J. Matthews, "Laser powder bed fusion additive manufacturing: Keyhole mitigation and microstructure control," TMS 2019, LLNL-PRES-758503.

Khairallah, S., R. Shi, A. M. Rubenchik, T. Wook Heo, J. Ye, T. Thumkur, J. T. Mckeown, M. J. Matthews, "Tailoring microstructure through laser beam shaping," TMS 2020, LLNL-PRES-801722.

Matthews, M. J., G. Guss, N. P. Calta, B. Giera, S. A. Khairallah, S. A. Shevchik, C. Leinenbach, K. Wasmer, T. Achee, A. Elwany, "Characterization of in situ diagnostics using high speed imaging," Solid Freeform Fabrication Symposium 2018, LLNL-PRES-759726.

Matthews, M., "Experimental advances in laser-based additive manufacturing of metal components," 4th AM Cross JOWOG, LLNL-PRES-759732.

Matthews, M. J., "Laser-Assisted Advanced Manufacturing," LANE 2018, LLNL-PRES-751323.

Matthews, M. J., "Keynote Presentation: Development of a Digital Twin to Enable Tailoring of the Metal Additive Manufacturing Process," Digital Twin Symposium 2019, LLNL-PRES-793067.

Matthews, M. J., "Absorptivity and energy scaling associated with laser powder bed fusion additive manufacturing," Conference on Lasers and Electro-Optics, 2019, LLNL-ABS-764074.

Matthews, M. J., "Plenary Talk: Light-matter interaction, melt pool dynamics and solidification behavior in laser powder bed fusion processes," Solid Freeform Fabrication Symposium 2020, LLNL-VIDEO-814554.

McKeown, J. T., A. Perron, N. P. Calta, J. D. Roehling, T. T. Roehling, S. Khairallah, M. J. Matthews, "Alloy Design and Rapid Solidification Processing for Tailored AM Materials," 4th AM Cross JOWOG, LLNL-ABS-757676.

McKeown, J. T., A. J. Clarke, C. Leinenbach, J. D. Roehling, J. Wiezorek, M. J. Matthews, "Rapid Solidification of Al-based Alloys Using In Situ Dynamic Transmission Electron Microscopy," MS&T 2018, LLNL-ABS-748404.

McKeown, J. T., "Developing Optimized Design Routes for Laser-Based Additive Manufacturing of Metals," 2019, LLNL-ABS-766367.

McKeown, J. T., T. Pinomaa, T. Suhonen, A. Laukkanen, N. Provatas, J. Wiezorek, "In Situ Dynamic TEM Combined with Phase Field Modeling to Quantitatively Describe Rapid Alloy Solidification," Euromat 2019, LLNL-ABS-770229.

McKeown J. T., J. D Roehling, S. Griffiths, K. Zweiacker, A. J. Clarke, C. Leinenbach, J. Wiezorek, M. J. Matthews, "Measurements of microstructure evolution and kinetics during laser-induced rapid solidification of Al-based alloys," TMS 2019, LLNL-ABS-753513.

McKeown, J. T., J. D. Roehling, A. Perron, J. L. Fattebert, A. J. Clarke, A. W. Stokes, T. Haxhimali, S. Khairallah, P. E. Turchi, M. J. Matthews, "Microstructure Evolution During Rapid Solidification: Developing Predictive Modeling Capabilities for Additive Manufacturing," TMS 2018, LLNL-PRES-747662.

Perron, A., P. E. A. Turchi, V. Lordi, J. McKeown, M. Matthews, "Development of a Thermodynamics-Informed Materials Design Simulator," TMS 2019, LLNL-ABS-753907.

Perron, A., J. -L. Fattebert, P. E. A. Turchi, T. Haxhimali, J. D. Roehling, M. J. Matthews, J. T. McKeown, "Realistic Phase-Field Modeling: A Path Towards Microstructure Tailoring," SIAM 2018, LLNL-PRES-754458.

Qu, D., N. P. Calta, G. Guss, M. J. Matthews, "Hyperspectral Thermal Imaging in Laser Powder Bed Fusion Additive Manufacturing," Solid Freeform Fabrication Symposium 2018, LLNL-POST-756139.

Roehling, T. T., J. D. Roehling, G. Guss, R. Shi, S. A. Khairallah, W. L. Smith, B. K. Vrancken, N. P. Calta, S. S. Q. Wu, J. Ye, J. T. McKeown, M. J. Matthews, A Photonics-Based Approach to Microstructural and Residual Stress Control during Metals Additive Manufacturing, 4th AM Cross JOWOG, LLNL-ABS-757581.

Roehling, J. D., W. L. Smith, B. Vrancken, G. M. Guss, J. T. McKeown, M. J. Matthews, "Controlling residual stress through changes to thermal history in additively manufactured SS316L," TMS 2019, LLNL-ABS-754105.

Roehling, J. D., W. L. Smith, G. M. Guss, T. T. Roehling, B. K. Vrancken, J. T. McKeown, M. J. Matthews, "Controlling residual stresses through selective wide-area surface heating," 4th AM Cross JOWOG, LLNL-ABS-757783.

Roehling, J. D., T. Haxhimali, A. Perron, A. W. Stokes, A. J. Clarke, M. J. Matthews, J. T. McKeown, "Observing nanometer-scale dendrite growth in aluminum alloys," MS&T 2018, LLNL-ABS-748741.

Roehling, T. T., S. Wu, S. A. Khairallah, J. D. Roehling, M. F. Crumb, G. Guss, M. J. Matthews, "Spatial Laser Beam Modulation for Microstructural Control," MS&T 2017, LLNL-PRES-739602.

Roehling, T. T., S. S. Q. Wu, S. A. Khairallah, J. D. Roehling, M. F. Crumb, G. Guss, M. J. Matthews, "Laser Modulation Effects on the Morphology and Microstructure of Additively Manufactured Metals," TMS 2018,  LLNL-PRES-747565.

Roehling, T. T., J. D. Roehling, S. A. Khairallah, G. Guss, J. T. McKeown, M. J. Matthews, "Microstructural Refinement using Tailored Beam Shapes during Laser Additive Manufacturing," TMS 2019 Annual Meeting and Exhibition, LLNL-ABS-753991.

Roehling, T.T., S. A. Khairallah, J. D. Roehling, R. Shi, G. M. Guss, J. T. McKeown, M. J. Matthews, "Controlling grain morphology, grain size, and texture by laser beam shaping," TMS 2020, LLNL-PRES-802387.

Shi, R., "Applications of Mesoscale Microstructure Modeling in Metal Additive Manufacturing and Hydrogen Storage," LLNL Postdoc Poster Symposium, 2018, LLNL-POST-752653.

Shi, R., T. Heo, S. A. Khairallah, J. T. Mckeown, M. J. Matthews, "Development of a quantitative microstructure simulator to decipher composition-processing-microstructure relationships in titanium alloys," MS&T 2018, LLNL-PRES-759479.

Shi, R., S. A. Khairallah, T. T. Roehling, J. T. Mckeown, M. J. Matthews, "Shaping laser beam for microstructural control during metal additive manufacturing," TMS 2019, LLNL-PRES-768979.

Smith, W. L., J. D. Roehling, G. M. Guss, T. T. Roehling, M. R. Hill, M. J Matthews, "Residual Stress Reduction of Laser Powder Bed Fusion Processes using in situ Laser Diode Annealing," Solid Freeform Fabrication Symposium 2018, LLNL-PRES-756370.

Voisin, T., M. D. Grapes, T. Li, M. Santala, G. H. Campbell, Y. Zhang, N. J. Lorenzo, J. P. Ligda, B. E. Schuster, T. P. Weihs, "Characterization of Defect Motion at High Strain Rate In Situ inside a TEM," TMS 2018, LLNL-CONF-747642.

Voisin T., J. McKeown, J. Ye, N. Calta, Z. Li, W. Chen, T. Roehling, M. Santala, P. Depond, M. Matthews, A. Hamza, Y. Wang, "Deformation mechanisms of L-PBF 316L stainless steels," MS&T 2018, LLNL-ABS-749546.

Voisin, T., J. McKeown, J. Ye, N. Calta, Z. Li, T. Roehling, M. Santala, P. Depond, M. Matthews, A. Hamza, Y. Wang, "In situ characterization of deformation mechanisms in L-PBF 316L stainless steels," TMS 2019, LLNL-ABS-753972.

Vrancken, B., R. Ganeriwala, A. Martin, B. Giera, W. E. King, M. J. Matthews, "High-speed, in-situ monitoring of W microcracking during SLM," Solid Freeform Fabrication Symposium 2018, 2018, LLNL-PRES-756094.

Vrancken, B., R. Ganeriwala, W. E. King, M. J. Matthews, "In-situ characterization of tungsten microcracking in Selective Laser Melting," LANE 2018, 2018, LLNL-PRES-757043.

Vrancken, B., W. E. King, M. J. Matthews, "Microcrack mitigation during Selective Laser Melting of Tungsten," LLNL Postdoc Poster Symposium, 2018, LLNL-POST-752649.

Vrancken, B., R. Ganeriwala, W. E. King, M. J. Matthews, "Tungsten alloying to reduce cracking during laser powder bed fusion," Euromat, 2019, LLNL-PRES-788857.

Ye, J., S. A. Khairallah, A. M. Rubenchik, M. F. Crumb, G. Guss, J. Roehling, M. J. Matthews, "Laser Absorption and Scaling Behavior in Powder Bed Fusion Additive Manufacturing of Metals," CLEO 2018, LLNL-POST-751339.