Assessing and controlling microstructure heterogeneity in fusion-based additive manufacturing

Abstract One of the de*ining features of fusion-based additive manufacturing (AM) is the localized melting of metal by a high-energy source, which fuses the material together point by point and layer by layer into a 3D object. The rapid solidi*ication velocity, directional thermal gradients, and site-speci*ic thermal build-ups produced by this process yield parts with complex and heterogeneous microstructure. This heterogeneity is a double-edged sword. On the one hand, it leads to large property scatter and casts uncertainty over parts performance, hindering the adoption of additive technologies by the industry. On the other hand, it may impart exceptional mechanical properties and new functionalities, which are not found in conventionally produced materials. In this paper, we present two ongoing research endeavours aimed at mitigating the detrimental effects of microstructure heterogeneity in AM, and at capitalizing on the opportunities it offers in the design of novel metal alloys, respectively. The *irst consists of developing a high-throughput characterization technique to enable large-scale microstructure analysis of AM builds. The second consists of a new strategy to control the material’s microstructure site-speci*ically during laser powder bed fusion.