Evolution of dislocations during the rapid solidification in additive manufacturing

Lin Gao (), Yan Chen, Xuan Zhang, Sean R. Agnew, Andrew C. Chuang and Tao Sun ()
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Lin Gao: University of Virginia
Yan Chen: Oak Ridge National Laboratory
Xuan Zhang: Argonne National Laboratory
Sean R. Agnew: University of Virginia
Andrew C. Chuang: Argonne National Laboratory
Tao Sun: University of Virginia

Nature Communications, 2025, vol. 16, issue 1, 1-13

Abstract: Abstract Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem microstructure characterizations of AM materials cannot capture the dynamic evolution of dislocations during the manufacturing process, thereby offering limited mechanism-based guidance for further advancing AM techniques and facilitating the qualification and certification of AM products. In this study, we conduct operando high-energy synchrotron X-ray diffraction experiments on wire-laser directed energy deposition of 316 L stainless steel. Through a unique configuration, our operando synchrotron experiments semi-quantitatively probe the dislocation density in solid phases and their dynamic changes during solidification and subsequent cooling. By integrating this advanced synchrotron technique with multi-physics simulation, in-situ neutron diffraction, and multi-scale electron microscopy characterization, our mechanistic study aims to elucidate the effects of rapid cooling and subsequent thermal cycling on the dislocation generation and evolution.

Date: 2025
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DOI: 10.1038/s41467-025-59988-5

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