TY - JOUR A1 - Ferrari, Bruno A1 - Fantin, Andrea A1 - Said, D. A1 - Fitch, A. N. A1 - Suárez Ocano, Patricia A1 - Mishurova, Tatiana A1 - Roveda, Ilaria A1 - Kromm, Arne A1 - Darvishi Kamachali, Reza A1 - Bruno, Giovanni A1 - Evans, Alexander A1 - Requena, G. A1 - Agudo Jácome, Leonardo A1 - Serrano Munoz, Itziar T1 - The impact of scanning strategy on cell structures in PBF-LB/M/IN718: an in situ synchrotron x-ray diffraction study N2 - In additive manufacturing, any change of the process parameters, such as scanning strategy, directly affects the cooling rates, heat accumulation, and overall thermal history of the build. Consequently, parts built with different process parameters tend to have different levels of crystallographic texture, residual stress, and dislocation density. These features can influence the properties of the material and their development during post-processing operations. In this study, IN718 prisms were built by laser powder bed fusion (PBF-LB/M) using two different scanning strategies (continuous 67° rotations around the build direction, ROT, and alternating 0°/67° scans, ALT) to provide two different as-built conditions. In situ time-resolved synchrotron diffraction was performed during a solution heat treatment at 1027 °C for 1 h. Ex situ scanning electron microscopy was used to support and complement the in situ observations. An approach to quantify the effect of elemental microsegregation at the cell walls is developed based on the deconvolution of asymmetric γ-nickel matrix peaks. Following this approach, the scanning strategies are shown to affect the as-built fraction of cell walls in the material, resulting in a difference of approximately 5 %, in weight fraction, between ROT and ALT (19 % vs. 24 %, respectively). This microsegregation was observed to be rapidly homogenized during the heating ramp, and no significant changes to the peak shape in the γ peaks occurred during the isothermal part of the heat treatment, regardless of the scanning strategy. KW - Additive manufacturing KW - Inconel 718 KW - Synchrotron x-ray diffraction KW - Heat treatment KW - Laser powder bed fusion KW - Cellular microstructure PY - 2026 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-650958 DO - https://doi.org/10.1016/j.jmrt.2025.11.214 SN - 2238-7854 VL - 41 SP - 593 EP - 608 PB - Elsevier B.V. AN - OPUS4-65095 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Evans, Alexander A1 - Schröder, Jakob A1 - Pirling, T. A1 - Ulbricht, Alexander A1 - Suárez Ocaño, Patricia A1 - Bruno, Giovanni T1 - Resolving the Subsurface Residual Stress Maximum in Laser Powder Bed-Fused 316L Stainless Steel by Diffraction-Based Analysis N2 - Laser powder bed fusion (PBF-LB/M) is a metal additive manufacturing process. Due to the complex nature of the layer-wise, repeated heating and cooling cycles, it tends to generate high-magnitude residual stresses. If not correctly understood and mitigated through in- or post-process approaches, these residual stresses can be detrimental as they are often tensile at the surface. However, determining the magnitude and location of peak tensile residual stresses is not trivial as they are often located subsurface. This work focuses on determining the magnitude and location of these deleterious tensile residual stresses in a PBF-LB/316L specimen. Two diffraction-based Methods are used to reveal the relationship between the residual stresses and the underlying microstructure. On the one hand, high spatial resolution Neutron diffraction is used to determine triaxial stresses from the bulk to a depth of 0.15 mm. On the other hand, laboratory X-ray diffraction coupled with electrolytical layer removal allows the biaxial residual stress depth profile to be probed from the surface to a depth of about 0.6 mm. The results show a good agreement between the two methods. The peak residual stress is shown to be 500 MPa, which appears as a plateau between 0.08 and 0.35 mm in depth. KW - Residual stress KW - Diffraction KW - Laser Powder Bed Fusion KW - 316L KW - Additive manufacturing KW - Microstructure KW - AGIL PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-652138 DO - https://doi.org/10.1007/s11837-025-07719-y SN - 1543-1851 VL - 77 IS - 12 SP - 9726 EP - 9737 PB - Springer Nature AN - OPUS4-65213 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Han, Ying A1 - Fritsch, Tobias A1 - Hejazi, Bardia A1 - Ulbricht, Alexander A1 - Skrotzki, Birgit A1 - Bruno, Giovanni T1 - X-ray computed tomography quantifies primary phases and reveals crack morphology in high-cycle fatigue of aluminum alloy EN AW-2618A N2 - Since the introduction of high-strength aluminum alloys understanding their fatigue behavior is of high interest for the structural integrity of engineering components, in this context, the alloy EN AW-2618A gains its high strength from both nanometer size precipitates and micrometer size primary phases. The latter phases are often identified as crack initiation sites. In this study, it uses a combination of synchrotron and laboratory-based X-ray computed tomography to image and quantify such primary phases and the fatigue cracks appearing in interrupted tests. Based on the gray-level differences in the synchrotron X-ray computed tomography scans, this study is able to distinguish low- and high-absorbing particles. The dominant (volume fraction >99%) high absorbing primary phase can be quantified in good agreement with results of Thermo-Calc calculations. To image the fatigue crack, laboratory X-ray computed tomography scans are performed at different tensile loads to open the crack. The results show that with an appropriate crack opening tensile load, the fatigue crack morphology can be reliably revealed. Based on these results, the influence of the primary phases on the fatigue crack initiation and propagation are discussed. KW - X-ray computed tomography KW - Fatigue KW - Aluminum KW - Primary phases PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-632724 DO - https://doi.org/10.1002/adem.202500235 SN - 1527-2648 SP - 1 EP - 9 PB - Wiley-VCH CY - Weinheim AN - OPUS4-63272 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Beygi Narsabadi, Hossein A1 - Vafaeenezhad, H. A1 - Klotz, U.E. A1 - Tiberto, D. A1 - Hosseinabadi, F. A1 - Mishurova, Tatiana A1 - Bruno, Giovanni A1 - Skrotzki, Birgit T1 - XCT-assisted micromechanical modeling of the effect of pores on the plastic deformation and mechanical characteristics of PBF-LB/M-produced copper alloys N2 - Due to the low absorption of fiber laser by copper particles, the laser-based powder bed fusion (PBF-LB/M) processing of copper components is accompanied by the development of different types of porosities within the printed samples. This research aims to assess the consequences of various process-induced pores on the me chanical characteristics and deformation of PBF-LB/M-produced copper alloys. Several copper alloys were processed using metal-coated particles and varied laser intensities, yielding samples with different types and amounts of porosities. For instance, CuCrZr alloys processed at 325 J/mm³ and 257 J/mm³ had 0.009 % and 1.117 % porosities, dominated by keyhole and lack-of-fusion pores, respectively. Moreover, PBF-LB/M pro cessing of Cr- and Nb-coated CuNi3SiCr particles accompanied by the generation of 0.004 % and 1.861 % porosities within the samples, predominantly featuring metallurgical and oxidation pores, respectively. Compression and nanoindentation tests revealed that the CuNi3SiCr alloy exhibited superior mechanical properties compared to the CuCrZr sample (nanoindentation hardness values 2.2 GPa and 1.4 GPa, respectively), while the presence of lack-of-fusion pores notably diminished their mechanical performance. X-ray computed tomography (XCT) reconstruction slices and scanning electron microscopy (SEM) images were then used for developing the representative volume elements (RVEs) based micromechanical models. The micromechanical simulations established a structure-property correlation that can simulate the compressive deformation and mechanical characteristics of PBF-LB/M-produced copper alloys as a function of their incorporated pore characteristics. Due to the closure of the pores at the first stages of deformation, samples with minimal keyhole and metallurgical porosities exhibited homogeneous plastic deformation. On the other side, based on the JohnsonCook model, strain concentration and crack propagation around the lack-of-fusion pores lead to damage initi ation in the printed samples at a strain level of 5 % KW - X-ray Computed tomography KW - Defects KW - Copper alloys KW - PBF-LB/M KW - Micromechanics PY - 2025 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-624004 DO - https://doi.org/10.1016/j.msea.2025.147836 SN - 0921-5093 VL - 924 PB - Elsevier B.V. AN - OPUS4-62400 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ulbricht, Alexander A1 - Ávila Calderón, Luis A1 - Sommer, Konstantin A1 - Mohr, Gunther A1 - Evans, Alexander A1 - Skrotzki, Birgit A1 - Bruno, Giovanni T1 - Evolution of Creep Damage of 316L Produced by Laser Powder Bed Fusion N2 - The damage mechanisms of metallic components produced by process laser powder bed fusion differ significantly from those typically observed in conventionally manufactured variants of the same alloy. This is due to the unique microstructures of additively manufactured materials. Herein, the focus is on the study of the evolution of creep damage in stainless steel 316L specimens produced by laser powder bed fusion. X-ray computed tomography is used to unravel the influence of the process-specific microstructure from the influence of the initial void distribution on creep damage mechanisms. The void distribution of two specimens tested at 600 °C and 650 °C is analyzed before a creep test, after an interruption, and after fracture. The results indicate that the formation of damage is not connected to the initial void distribution. Instead, damage accumulation at grain boundaries resulting from intergranular cracking is observed. KW - Creep KW - Computed Tomography KW - PBF-LB/M/316L KW - Laser Powder Bed Fusion KW - Microstructure KW - AISI 316L KW - Additive Manufacturing PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-574127 DO - https://doi.org/10.1002/adem.202201581 SP - 1 EP - 9 PB - Wiley-VCH GmbH CY - Weinheim AN - OPUS4-57412 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröder, Jakob A1 - Evans, Alexander A1 - Polatidis, E. A1 - Čapek, J. A1 - Mohr, Gunther A1 - Serrano-Munoz, Itziar A1 - Bruno, Giovanni T1 - Understanding the impact of texture on the micromechanical anisotropy of laser powder bed fused Inconel 718 N2 - The manufacturability of metallic alloys using laser-based additive manufacturing methods such as laser powder bed fusion has substantially improved within the last decade. However, local melting and solidification cause hierarchically structured and crystallographically textured microstructures possessing large residual stress. Such microstructures are not only the origin of mechanical anisotropy but also pose metrological challenges for the diffraction-based residual stress determination. Here we demonstrate the influence of the build orientation and the texture on the microstructure and consequently the mechanical anisotropy of as-built Inconel 718. For this purpose, we manufactured specimens with [001]/[011]-, [001]- and [011]/[111]-type textures along their loading direction. In addition to changes in the Young’s moduli, the differences in the crystallographic textures result in variations of the yield and ultimate tensile strengths. With this in mind, we studied the anisotropy on the micromechanical scale by subjecting the specimens to tensile loads along the different texture directions during in situ neutron diffraction experiments. In this context, the response of multiple lattice planes up to a tensile strain of 10% displayed differences in the load partitioning and the residual strain accumulation for the specimen with [011]/[111]-type texture. However, the relative behavior of the specimens possessing an [001]/[011]- and [001]-type texture remained qualitatively similar. The consequences on the metrology of residual stress determination methods are discussed. KW - Laser powder bed fusion KW - Additive manufacturing KW - Electron backscatter diffraction KW - Tensile testing KW - Diffraction PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-555840 DO - https://doi.org/10.1007/s10853-022-07499-9 SN - 1573-4803 VL - 2022 IS - 57 SP - 15036 EP - 15058 PB - Springer Science + Business Media B.V. CY - Dordrecht AN - OPUS4-55584 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mishurova, Tatiana A1 - Artzt, K. A1 - Rehmer, Birgit A1 - Haubrich, J. A1 - Ávila Calderón, Luis A1 - Schoenstein, F. A1 - Serrano-Munoz, Itziar A1 - Requena, G. A1 - Bruno, Giovanni T1 - Separation of the impact of residual stress and microstructure on the fatigue performance of LPBF Ti-6Al-4V at elevated temperature N2 - Manufacturing defects, high residual stress (RS), and microstructures affect the structural integrity of laser powder bed fusion (LPBF) Ti-6Al-4V. In this study, the individual effect of these factors on fatigue performance at elevated temperature (300 °C) was evaluated. Material in as-built condition and subjected to post-processing, including two heat treatments and hot isostatic pressing, was investigated. It was found that in the absence of tensile RS, the fatigue life at elevated temperature is primary controlled by the defects; and densification has a much stronger effect than the considered heat treatments on the improvement of the mechanical performance. KW - Additive manufacturing KW - Ti-6Al-4V KW - Residual stress KW - Fatigue performance KW - Computed tomography PY - 2021 DO - https://doi.org/10.1016/j.ijfatigue.2021.106239 SN - 0142-1123 VL - 148 SP - 106239 PB - Elsevier Ltd. AN - OPUS4-52369 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -