On the formation of spherical metastable BCC single crystal spatter particles during laser powder bed fusion

Daniel Galicki; B. C. Chakoumakos; Simon P. Ringer; Mehdi Eizadjou; Claudia J. Rawn; Keita Nomoto; Sudarsanam S. Babu

doi:10.1016/j.mtla.2020.100584

On the formation of spherical metastable BCC single crystal spatter particles during laser powder bed fusion

Daniel Galicki, B. C. Chakoumakos, Simon P. Ringer, Mehdi Eizadjou, Claudia J. Rawn, Keita Nomoto, Sudarsanam S. Babu

Single Crystal Diffraction

Research output: Contribution to journal › Article › peer-review

9 Scopus citations

Abstract

Spatter particles, created during laser powder-bed-fusion (L-PBF) additive manufacturing process of 316 L stainless steel, solidified as single-crystal, non-equilibrium, body-centered cubic (BCC) ferrite, which has not been reported before. This phenomenon is unusual considering that the composition of stainless steel 316 L typically ensures primarily austenitic (face-centered-cubic, FCC) solidification. These particles were analyzed with multi-length scale microscopy and diffraction methods. Mechanisms for the competition between BCC and FCC phases were evaluated with computational thermodynamic and interface response function theories, as a function of thermal boundary conditions. These results indicate that the particles solidify at rapid rates and/or that conditions exist during solidification that allow for the nucleation and growth of the BCC phase that outcompete the FCC phase. The novelties of the work pertain to three aspects (i) discovery of fully single crystal BCC particles residing within spatter, (ii) rationalization of the mechanisms for this phenomenon with suites of characterization and modeling tools, as well as, (iii) the suggestion that L-PBF and associated spattering processes can be used as a synthesis route to produce metastable, single-crystal structures.

Original language	English
Article number	100584
Journal	Materialia
Volume	9
DOIs	https://doi.org/10.1016/j.mtla.2020.100584
State	Published - Mar 2020

Funding

Scientific advice and technical support from the Microscopy Australia node at the University of Sydney (Sydney Microscopy and Microanalysis) and funding from the Department of Industry, Innovation and Science under the auspices of the AUSMURI program are gratefully acknowledged. Part of the research is sponsored by the Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794 . Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research. Research at University of Tennessee, Knoxville is also sponsored by the UT- ORNL Governor's Chair program for Advanced Manufacturing. This work of authorship and those incorporated wherein were prepared by Consolidated Nuclear Security, LLC (CNS) as accounts of work sponsored by an agency of the United States Government under Contract DE-NA0001942. Neither the United States Government nor any agency thereof, nor CNS, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility to any nongovernmental recipient hereof for the accuracy, completeness, use made, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency or contractor thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency or contractor (other than the authors) thereof. A portion of this research used resources at the Spallation Neutron Source, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. Research was sponsored the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. This manuscript has been authored by00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for the United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads /doe-public-access-plan). Scientific advice and technical support from the Microscopy Australia node at the University of Sydney (Sydney Microscopy and Microanalysis) and funding from the Department of Industry, Innovation and Science under the auspices of the AUSMURI program are gratefully acknowledged. Part of the research is sponsored by the Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research. Research at University of Tennessee, Knoxville is also sponsored by the UT- ORNL Governor's Chair program for Advanced Manufacturing. This work of authorship and those incorporated wherein were prepared by Consolidated Nuclear Security, LLC (CNS) as accounts of work sponsored by an agency of the United States Government under Contract DE-NA0001942. Neither the United States Government nor any agency thereof, nor CNS, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility to any nongovernmental recipient hereof for the accuracy, completeness, use made, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency or contractor thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency or contractor (other than the authors) thereof. A portion of this research used resources at the Spallation Neutron Source, a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. Research was sponsored the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. This manuscript has been authored by00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for the United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads /doe-public-access-plan).

Funders	Funder number
DOE Public Access Plan
United States Government	DE-NA0001942
Office of Naval Research	N00014-18-1-2794
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Science
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory
University of Texas System
University of Tennessee
U.S. Navy
University of Sydney
Department of Industry, Innovation and Science, Australian Government

Keywords

Additive manufacturing
Ferrite
L-PBF
Oxide
Solidification
Steel

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.mtla.2020.100584

Cite this

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title = "On the formation of spherical metastable BCC single crystal spatter particles during laser powder bed fusion",

abstract = "Spatter particles, created during laser powder-bed-fusion (L-PBF) additive manufacturing process of 316 L stainless steel, solidified as single-crystal, non-equilibrium, body-centered cubic (BCC) ferrite, which has not been reported before. This phenomenon is unusual considering that the composition of stainless steel 316 L typically ensures primarily austenitic (face-centered-cubic, FCC) solidification. These particles were analyzed with multi-length scale microscopy and diffraction methods. Mechanisms for the competition between BCC and FCC phases were evaluated with computational thermodynamic and interface response function theories, as a function of thermal boundary conditions. These results indicate that the particles solidify at rapid rates and/or that conditions exist during solidification that allow for the nucleation and growth of the BCC phase that outcompete the FCC phase. The novelties of the work pertain to three aspects (i) discovery of fully single crystal BCC particles residing within spatter, (ii) rationalization of the mechanisms for this phenomenon with suites of characterization and modeling tools, as well as, (iii) the suggestion that L-PBF and associated spattering processes can be used as a synthesis route to produce metastable, single-crystal structures.",

keywords = "Additive manufacturing, Ferrite, L-PBF, Oxide, Solidification, Steel",

author = "Daniel Galicki and Chakoumakos, {B. C.} and Ringer, {Simon P.} and Mehdi Eizadjou and Rawn, {Claudia J.} and Keita Nomoto and Babu, {Sudarsanam S.}",

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year = "2020",

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AU - Galicki, Daniel

AU - Chakoumakos, B. C.

AU - Ringer, Simon P.

AU - Eizadjou, Mehdi

AU - Rawn, Claudia J.

AU - Nomoto, Keita

AU - Babu, Sudarsanam S.

PY - 2020/3

Y1 - 2020/3

N2 - Spatter particles, created during laser powder-bed-fusion (L-PBF) additive manufacturing process of 316 L stainless steel, solidified as single-crystal, non-equilibrium, body-centered cubic (BCC) ferrite, which has not been reported before. This phenomenon is unusual considering that the composition of stainless steel 316 L typically ensures primarily austenitic (face-centered-cubic, FCC) solidification. These particles were analyzed with multi-length scale microscopy and diffraction methods. Mechanisms for the competition between BCC and FCC phases were evaluated with computational thermodynamic and interface response function theories, as a function of thermal boundary conditions. These results indicate that the particles solidify at rapid rates and/or that conditions exist during solidification that allow for the nucleation and growth of the BCC phase that outcompete the FCC phase. The novelties of the work pertain to three aspects (i) discovery of fully single crystal BCC particles residing within spatter, (ii) rationalization of the mechanisms for this phenomenon with suites of characterization and modeling tools, as well as, (iii) the suggestion that L-PBF and associated spattering processes can be used as a synthesis route to produce metastable, single-crystal structures.

AB - Spatter particles, created during laser powder-bed-fusion (L-PBF) additive manufacturing process of 316 L stainless steel, solidified as single-crystal, non-equilibrium, body-centered cubic (BCC) ferrite, which has not been reported before. This phenomenon is unusual considering that the composition of stainless steel 316 L typically ensures primarily austenitic (face-centered-cubic, FCC) solidification. These particles were analyzed with multi-length scale microscopy and diffraction methods. Mechanisms for the competition between BCC and FCC phases were evaluated with computational thermodynamic and interface response function theories, as a function of thermal boundary conditions. These results indicate that the particles solidify at rapid rates and/or that conditions exist during solidification that allow for the nucleation and growth of the BCC phase that outcompete the FCC phase. The novelties of the work pertain to three aspects (i) discovery of fully single crystal BCC particles residing within spatter, (ii) rationalization of the mechanisms for this phenomenon with suites of characterization and modeling tools, as well as, (iii) the suggestion that L-PBF and associated spattering processes can be used as a synthesis route to produce metastable, single-crystal structures.

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On the formation of spherical metastable BCC single crystal spatter particles during laser powder bed fusion

Abstract

Funding

Keywords

UN SDGs

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