DOE News
    Doe Science news source
    The DOE Science News Source is a Newswise initiative to promote research news from the Office of Science of the DOE to the public and news media.
    • 2018-01-30 15:30:35
    • Article ID: 688703

    SLAC Scientists Investigate How Metal 3-D Printing Can Avoid Producing Flawed Parts

    The goal of these X-ray studies is to find ways to improve manufacturing of specialized metal parts for the aerospace, aircraft, automotive and healthcare industries.

    • Credit: Johanna Nelson Weker/SLAC

      A metal 3-D printed sample the team used for experiments.

    • Credit: Dawn Harmer/SLAC

      SLAC staff scientist Johanna Nelson Weker, front, leads a study on metal 3-D printing at SLAC’s Stanford Synchrotron Radiation Lightsource with researchers Andrew Kiss and Nick Calta, back.

    Scientists at the Department of Energy’s SLAC National Accelerator Laboratory are using X-ray light to observe and understand how the process of making metal parts using three-dimensional (3-D) printing can leave flaws in the finished product – and discover how those flaws can be prevented. The studies aim to help manufacturers build more reliable parts on the spot – whether in a factory, on a ship or plane, or even remotely in space – and do it more efficiently, without needing to store thousands of extra parts.

    The work is taking place at the lab’s Stanford Synchrotron Radiation Lightsource (SSRL) in collaboration with scientists from the DOE’s Lawrence Livermore National Laboratory and Ames Laboratory.

    The 3-D printing process, also known as additive manufacturing, builds solid, three-dimensional objects from a computer model by adding material layer by layer. The use of plastics and polymers in 3-D printing has advanced rapidly, but 3-D printing with metals for industrial purposes has been more challenging to sort out.

    “With 3-D printing, you can make parts with very complex geometries that are not accessible for casting like regular metal parts,” says SLAC staff scientist Johanna Nelson Weker, who is leading the project. “Theoretically, it can be a quick turnaround – simply design, send, print from a remote location. But we’re not there yet. We still need to figure out all of the parameters involved in making solid, strong parts.”

    Metal 3-D printing is being developed for making highly specialized parts for the aerospace, aircraft, automotive and healthcare industries. Right now, companies like General Electric and Boeing that create metal parts with 3-D printing have to put each part and 3-D printer through vigorous qualification. But if the process could be better understood so it reliably prints flawless parts, the researchers said, the need for testing would diminish and the manufacturing cost could come down.

    Pits Among the Layers

    In metal 3-D printing, a thin layer of powdered metal, such as titanium alloys, steel, aluminum alloys, or copper, is distributed on a platform and selectively melted by a high-powered laser beam. Then the platform is lowered, a new layer of metal powder is applied and the process is repeated until the object is fully formed.

    This process often results in the formation of pits, or weak spots, when the metal cools and hardens unevenly while building up the layers. In the SLAC X-ray experiments, scientists are analyzing every aspect of the process – the kind of metal used, the level of heat from the laser, the speed at which the metal heats and cools – to find the best combination for eliminating pits, controlling the microstructure, and manufacturing strong metal parts.

    “We are providing the fundamental physics research that will help us identify which aspects of metal 3-D printing are important,” says Chris Tassone, a staff scientist in SSRL’s Materials Science Division. It’s practical information, he says, that could eventually lead to writing recipes for 3-D printer laser settings that manufacturers can use to produce sturdy parts.

    Diving in for a Better View

    Until recently, researchers watched from above as layers were being added to form a part. Because they couldn’t see below the surface of the metal, it was impossible to tell how deeply the laser was melting the layers as each one was applied. They tried imaging the growing layers with thermal radiation, or heat, but this did not give them enough information about what was causing the weak spots. X-rays, however, give researchers an excellent tool to see and record what’s happening inside the part as it’s being built.

    The scientists are using two X-ray methods to see what happens during metal 3-D printing. With one type of X-ray light, they create micron-resolution images of what happens as the layers of metal build up. The second method bounces X-rays off the atoms in the material to analyze its atomic structure as it changes from solid to liquid and back to solid form during the melting and cooling process.

    Thus far, the group has been looking at lasers hitting layers of metal powder, but they also plan to investigate another approach called “directed energy deposition.” In this process, a laser beam hits and melts metal powder or wire as it is being laid down, allowing creation of more complex geometric forms. This sort of 3-D printing is especially useful in making repairs.

    They also want to incorporate a high-speed camera into their experimental setup so they can collect photographs and video of the manufacturing process and correlate what they see with their X-ray data.

    This is important to manufacturers and other researchers who use cameras to observe the process but don’t have access to an X-ray synchrotron, Nelson Weker says: “We want people to be able to connect what they see on their cameras with what we are measuring here so they can infer what’s happening below the surface of the growing metal material. We want to put meaning to those signatures.”

    Other researchers on the metal 3-D printing project include Kevin Stone, Anthony Fong, Andrew Kiss and Vivek Thampy. SSRL is a DOE Office of Science user facility. The research was funded by the DOE Office of Energy Efficiency and Renewable Energy’s Advanced Manufacturing Office.


    SLAC is a multi-program laboratory exploring frontier questions in photon science, astrophysics, particle physics and accelerator research. Located in Menlo Park, Calif., SLAC is operated by Stanford University for the U.S. Department of Energy's Office of Science.

    SLAC National Accelerator Laboratory is supported by the Office of Science of the U.S. Department of Energy. The Office of Science is the single largest supporter of basic research in the physical sciences in the United States, and is working to address some of the most pressing challenges of our time. For more information, please visit science.energy.gov.

    • other-fb
    • other-tw
    X
    X
    X
    • Filters

    • × Clear Filters
    Silicon and a State of Shock

    Silicon and a State of Shock

    A novel experimental geometry at the Linac Coherent Light Source reveals, for the first time, how silicon responds to shocks similar to those in a planet's core.

    New research identifies causes for defects in 3D printing and paves way for better results

    New research identifies causes for defects in 3D printing and paves way for better results

    New research, led by teams from Carnegie Mellon University and the U.S. Department of Energy's (DOE) Argonne National Laboratory, has identified how and when tiny gas pockets in manufactured products, which lead to cracks and other failures, form. The team has also developed a methodology to predict their formation - information that could dramatically improve the 3D printing process.

    Do Alpha Particle Condensates Exist in Oxygen Nuclei?

    Do Alpha Particle Condensates Exist in Oxygen Nuclei?

    Yes. Such condensates, analogous to those in carbon-12, in heavier nuclei could change how we describe certain elements.

    Not All Ions in Tokamaks Go with the Flow

    Not All Ions in Tokamaks Go with the Flow

    Spectroscopic measurements reveal that main ions flow much faster than impurities at the edge of fusion-relevant plasmas.

    Researchers watch molecules in a light-triggered catalyst ring 'like an ensemble of bells'

    Researchers watch molecules in a light-triggered catalyst ring 'like an ensemble of bells'

    An international team has used an X-ray laser at the Department of Energy's SLAC National Accelerator Laboratory to get an incredibly detailed look at what happens to the structure of a model photocatalyst when it absorbs light.

    Measuring the Impossible: X-ray Photoelectron Spectroscopy of Hydrogen and Helium

    Measuring the Impossible: X-ray Photoelectron Spectroscopy of Hydrogen and Helium

    The two most abundant elements in the universe, hydrogen and helium, were previously thought to be impossible to measure by X-ray photoelectron spectroscopy.

    New Model Sheds Light on Key Physics of Magnetic Islands that Can Halt Fusion Reactions

    New Model Sheds Light on Key Physics of Magnetic Islands that Can Halt Fusion Reactions

    Surprisingly, a magnetic island does not necessarily perturb the plasma current in a dangerous way and destroy fusion performance.

    Correlated Nucleons May Solve 35-Year-Old Mystery

    Correlated Nucleons May Solve 35-Year-Old Mystery

    A careful re-analysis of data taken at the Department of Energy's Thomas Jefferson National Accelerator Facility has revealed a possible link between correlated protons and neutrons in the nucleus and a 35-year-old mystery. The data have led to the extraction of a universal function that describes the EMC Effect, the once-shocking discovery that quarks inside nuclei have lower average momenta than predicted, and supports an explanation for the effect. The study has been published in the journal Nature.

    Early "Fossils" Formed by Tectonics, not Life

    Early "Fossils" Formed by Tectonics, not Life

    The 3.7-billion-year-old structures were considered the first evidence for life on the planet; new evidence suggests differently.

    High-Energy X-Ray Bursts from Low-Energy Plasma

    High-Energy X-Ray Bursts from Low-Energy Plasma

    Scientists discover why solar flares produce X-rays; a few electrons avoid collisions and accelerate to produce a microsecond burst.


    • Filters

    • × Clear Filters
    DOE launches its first lithium-ion battery recycling R&D center: ReCell

    DOE launches its first lithium-ion battery recycling R&D center: ReCell

    The launch of the Energy Department's first lithium-ion battery recycling center, called the ReCell Center, will help the United States grow a globally competitive recycling industry and reduce our reliance on foreign sources of battery materials.

    James Wishart Awarded Maria Skłodowska-Curie Medal

    James Wishart Awarded Maria Skłodowska-Curie Medal

    James Wishart, a chemist at the U.S. Department of Energy's (DOE) Brookhaven National Laboratory, has been awarded the Maria Skłodowska-Curie Medal by the Polish Radiation Research Society (PRRS). The award recognizes his distinguished achievements in the field of radiation chemistry and his long-lasting and productive interactions with Polish scientists.

    Lynbrook High wins 2019 SLAC Regional Science Bowl competition

    Lynbrook High wins 2019 SLAC Regional Science Bowl competition

    Twenty-eight teams from 17 Bay Area high schools faced off Feb. 9 in the SLAC Regional DOE Science Bowl, a series of fast-paced question-and-answer matches that test knowledge in biology, chemistry, physics, earth and space sciences, energy and math. The competition is hosted annually by the Department of Energy's SLAC National Accelerator Laboratory.

    UNLV Among 11 Teams Worldwide To Compete in 2020 Solar Decathlon

    UNLV Among 11 Teams Worldwide To Compete in 2020 Solar Decathlon

    Students to build sustainable home of healing for military veterans for U.S. Department of Energy contest; UNLV competed in 2013 and 2017.

    Three Brookhaven Scientists Named Highly Cited Researchers

    Three Brookhaven Scientists Named Highly Cited Researchers

    Three scientists from the U.S. Department of Energy's (DOE) Brookhaven National Laboratory have been named to the 2018 Highly Cited Researchers List, which recognizes influential researchers whose work ranks in the top one percent of the world's most-cited scientific papers. Brookhaven's Radoslav Adzic, Mark Hybertsen, and Xiao-Qing Yang are among only 4,000 researchers from around the world whom achieved the distinction in 2018.

    New tools in transportation

    New tools in transportation

    A new version of the AFLEET Tool from the U.S. Department of Energy's (DOE) Argonne National Laboratory calculates and compares the costs and environmental benefits of a broad range of alternative fuel technologies. Covering 18 fuel/vehicle technologies, AFLEET Online offers an easy-to-use web-based platform.

    Remote-Control Plasma Physics Experiment is Named One of Top Webcams of 2018

    Remote-Control Plasma Physics Experiment is Named One of Top Webcams of 2018

    EarthCam names remote-control experiment at PPPL one of 25 most interesting Webcams of 2018.

    Jefferson Lab Scientist Awarded Distinguished Lectureship

    Jefferson Lab Scientist Awarded Distinguished Lectureship

    Cynthia Keppel, leader of Jefferson Lab's Halls A&C, has been honored with the APS 2019 Distinguished Lectureship Award on the Applications of Physics.

    Journal Special Issues Honor Chemists Radoslav Adzic and Jan Hrbek

    Journal Special Issues Honor Chemists Radoslav Adzic and Jan Hrbek

    The Journal of the Electrochemical Society and Surface Science recognized the contributions of Brookhaven Lab chemists Radoslav Adzic and Jan Hrbek to electrocatalysis and catalysis.

    Argonne scientist elected as SAE Fellow

    Argonne scientist elected as SAE Fellow

    Scientist Michael Wang from the U.S. Department of Energy's (DOE) Argonne National Laboratory was recently inducted as a Fellow of the professional engineering organization SAE (Society of Automotive Engineers). The organization reserves this prestigious grade of membership for thosewho have made significant contributions to mobility technology and have demonstrated leadership in their field.


    • Filters

    • × Clear Filters
    Silicon and a State of Shock

    Silicon and a State of Shock

    A novel experimental geometry at the Linac Coherent Light Source reveals, for the first time, how silicon responds to shocks similar to those in a planet's core.

    Do Alpha Particle Condensates Exist in Oxygen Nuclei?

    Do Alpha Particle Condensates Exist in Oxygen Nuclei?

    Yes. Such condensates, analogous to those in carbon-12, in heavier nuclei could change how we describe certain elements.

    Not All Ions in Tokamaks Go with the Flow

    Not All Ions in Tokamaks Go with the Flow

    Spectroscopic measurements reveal that main ions flow much faster than impurities at the edge of fusion-relevant plasmas.

    Measuring the Impossible: X-ray Photoelectron Spectroscopy of Hydrogen and Helium

    Measuring the Impossible: X-ray Photoelectron Spectroscopy of Hydrogen and Helium

    The two most abundant elements in the universe, hydrogen and helium, were previously thought to be impossible to measure by X-ray photoelectron spectroscopy.

    New Model Sheds Light on Key Physics of Magnetic Islands that Can Halt Fusion Reactions

    New Model Sheds Light on Key Physics of Magnetic Islands that Can Halt Fusion Reactions

    Surprisingly, a magnetic island does not necessarily perturb the plasma current in a dangerous way and destroy fusion performance.

    Early "Fossils" Formed by Tectonics, not Life

    Early "Fossils" Formed by Tectonics, not Life

    The 3.7-billion-year-old structures were considered the first evidence for life on the planet; new evidence suggests differently.

    High-Energy X-Ray Bursts from Low-Energy Plasma

    High-Energy X-Ray Bursts from Low-Energy Plasma

    Scientists discover why solar flares produce X-rays; a few electrons avoid collisions and accelerate to produce a microsecond burst.

    Taking Diamond Qubits for a Spin

    Taking Diamond Qubits for a Spin

    Scientists use implanted silicon ions and electricity to increase the spin time of quantum bits, moving closer to the tech needed for quantum networks.

    Newly Discovered Design Rules Lead to Better Fuel Cell Catalyst

    Newly Discovered Design Rules Lead to Better Fuel Cell Catalyst

    Optimized oxides made from common metals use less energy and show the potential of new design approach.

    Too Close for Comfort: Nanoparticles Need Some Space to Transfer Energy

    Too Close for Comfort: Nanoparticles Need Some Space to Transfer Energy

    Particle crowding interferes with moving energy efficiently along promising molecular chains.


    Spotlight

    Lynbrook High wins 2019 SLAC Regional Science Bowl competition
    Wednesday February 13, 2019, 02:05 PM

    Lynbrook High wins 2019 SLAC Regional Science Bowl competition

    SLAC National Accelerator Laboratory

    Equipping the next generation for a technological revolution
    Thursday January 24, 2019, 01:05 PM

    Equipping the next generation for a technological revolution

    Argonne National Laboratory

    Chemistry intern inspired by Argonne's real-world science
    Friday January 18, 2019, 05:05 PM

    Chemistry intern inspired by Argonne's real-world science

    Argonne National Laboratory

    Chasing a supernova
    Friday January 18, 2019, 04:05 PM

    Chasing a supernova

    Argonne National Laboratory

    Argonne intern streamlines the beamline
    Tuesday January 08, 2019, 02:05 PM

    Argonne intern streamlines the beamline

    Argonne National Laboratory

    Research on Light-Matter Interaction Could Lead to Improved Electronic and Optoelectronic Devices
    Thursday October 11, 2018, 04:00 PM

    Research on Light-Matter Interaction Could Lead to Improved Electronic and Optoelectronic Devices

    Rensselaer Polytechnic Institute (RPI)

    Innovating Our Energy Future
    Wednesday October 03, 2018, 07:05 PM

    Innovating Our Energy Future

    Oregon State University, College of Engineering

    Physics graduate student takes her thesis research to a Department of Energy national lab
    Tuesday October 02, 2018, 03:05 PM

    Physics graduate student takes her thesis research to a Department of Energy national lab

    University of Alabama at Birmingham

    Friday September 21, 2018, 01:05 PM

    "Model" students enjoy Argonne campus life

    Argonne National Laboratory

    Writing Code for a More Skilled and Diverse STEM Workforce
    Thursday September 06, 2018, 01:05 PM

    Writing Code for a More Skilled and Diverse STEM Workforce

    Brookhaven National Laboratory

    New graduate student summer school launches at Princeton Plasma Physics Laboratory
    Tuesday September 04, 2018, 11:30 AM

    New graduate student summer school launches at Princeton Plasma Physics Laboratory

    Princeton Plasma Physics Laboratory

    The Gridlock State
    Friday August 31, 2018, 06:05 PM

    The Gridlock State

    California State University (CSU) Chancellor's Office

    Meet Jasmine Hatcher and Trishelle Copeland-Johnson
    Friday August 31, 2018, 02:05 PM

    Meet Jasmine Hatcher and Trishelle Copeland-Johnson

    Brookhaven National Laboratory

    Argonne hosts Modeling, Experimentation and Validation Summer School
    Friday August 24, 2018, 11:05 AM

    Argonne hosts Modeling, Experimentation and Validation Summer School

    Argonne National Laboratory

    Students affected by Hurricane Maria bring their research to SLAC
    Wednesday August 22, 2018, 01:05 PM

    Students affected by Hurricane Maria bring their research to SLAC

    SLAC National Accelerator Laboratory

    Brookhaven Lab Pays Tribute to 2018 Summer Interns
    Wednesday August 22, 2018, 10:05 AM

    Brookhaven Lab Pays Tribute to 2018 Summer Interns

    Brookhaven National Laboratory

    Changing How Buildings Are Made
    Monday August 20, 2018, 12:05 PM

    Changing How Buildings Are Made

    Washington University in St. Louis

    CSUMB Selected to Host Architecture at Zero Competition in 2019
    Thursday August 16, 2018, 12:05 PM

    CSUMB Selected to Host Architecture at Zero Competition in 2019

    California State University, Monterey Bay

    Department of Energy Invests $64 Million in Advanced Nuclear Technology
    Friday July 20, 2018, 03:00 PM

    Department of Energy Invests $64 Million in Advanced Nuclear Technology

    Rensselaer Polytechnic Institute (RPI)

    Professor Miao Yu Named the Priti and Mukesh Chatter '82 Career Development Professor
    Thursday July 19, 2018, 05:00 PM

    Professor Miao Yu Named the Priti and Mukesh Chatter '82 Career Development Professor

    Rensselaer Polytechnic Institute (RPI)

    2018 RHIC & AGS Annual Users' Meeting: 'Illuminating the QCD Landscape'
    Tuesday July 03, 2018, 11:05 AM

    2018 RHIC & AGS Annual Users' Meeting: 'Illuminating the QCD Landscape'

    Brookhaven National Laboratory

    Argonne welcomes <em>The Martian</em> author Andy Weir
    Friday June 29, 2018, 06:05 PM

    Argonne welcomes The Martian author Andy Weir

    Argonne National Laboratory

    Creating STEM Knowledge and Innovations to Solve Global Issues Like Water, Food, and Energy
    Monday June 18, 2018, 09:55 AM

    Creating STEM Knowledge and Innovations to Solve Global Issues Like Water, Food, and Energy

    Illinois Mathematics and Science Academy (IMSA)

    Professor Emily Liu Receives $1.8 Million DoE Award for Solar Power Systems Research
    Friday June 15, 2018, 10:00 AM

    Professor Emily Liu Receives $1.8 Million DoE Award for Solar Power Systems Research

    Rensselaer Polytechnic Institute (RPI)

    Celebrating 40 years of empowerment in science
    Thursday June 07, 2018, 03:05 PM

    Celebrating 40 years of empowerment in science

    Argonne National Laboratory

    Introducing Graduate Students Across the Globe to Photon Science
    Monday May 07, 2018, 10:30 AM

    Introducing Graduate Students Across the Globe to Photon Science

    Brookhaven National Laboratory

    Students from Massachusetts and Washington Win DOE's 28th National Science Bowl(r)
    Wednesday May 02, 2018, 04:05 PM

    Students from Massachusetts and Washington Win DOE's 28th National Science Bowl(r)

    Department of Energy, Office of Science

    The Race for Young Scientific Minds
    Thursday April 12, 2018, 07:05 PM

    The Race for Young Scientific Minds

    Argonne National Laboratory

    Q&A: Al Ashley Reflects on His Efforts to Diversify SLAC and Beyond
    Wednesday March 14, 2018, 02:05 PM

    Q&A: Al Ashley Reflects on His Efforts to Diversify SLAC and Beyond

    SLAC National Accelerator Laboratory

    Insights on Innovation in Energy, Humanitarian Aid Highlight UVA Darden's Net Impact Week
    Thursday February 15, 2018, 12:05 PM

    Insights on Innovation in Energy, Humanitarian Aid Highlight UVA Darden's Net Impact Week

    University of Virginia Darden School of Business

    Ivy League Graduate, Writer and Activist with Dyslexia Visits CSUCI to Reframe the Concept of Learning Disabilities
    Friday February 09, 2018, 11:05 AM

    Ivy League Graduate, Writer and Activist with Dyslexia Visits CSUCI to Reframe the Concept of Learning Disabilities

    California State University, Channel Islands

    Photographer Adam Nadel Selected as Fermilab's New Artist-in-Residence for 2018
    Wednesday January 17, 2018, 12:05 PM

    Photographer Adam Nadel Selected as Fermilab's New Artist-in-Residence for 2018

    Fermi National Accelerator Laboratory (Fermilab)

    Fermilab Computing Partners with Argonne, Local Schools for Hour of Code
    Wednesday January 17, 2018, 12:05 PM

    Fermilab Computing Partners with Argonne, Local Schools for Hour of Code

    Fermi National Accelerator Laboratory (Fermilab)

    Q&A: Sam Webb Teaches X-Ray Science from a Remote Classroom
    Wednesday December 20, 2017, 01:05 PM

    Q&A: Sam Webb Teaches X-Ray Science from a Remote Classroom

    SLAC National Accelerator Laboratory

    The Future of Today's Electric Power Systems
    Monday December 18, 2017, 01:05 PM

    The Future of Today's Electric Power Systems

    Rensselaer Polytechnic Institute (RPI)

    Supporting the Development of Offshore Wind Power Plants
    Monday December 18, 2017, 12:05 PM

    Supporting the Development of Offshore Wind Power Plants

    Rensselaer Polytechnic Institute (RPI)

    Stairway to Science
    Tuesday October 03, 2017, 01:05 PM

    Stairway to Science

    Argonne National Laboratory

    After-School Energy Rush
    Thursday September 28, 2017, 12:05 PM

    After-School Energy Rush

    Argonne National Laboratory

    Bringing Diversity Into Computational Science Through Student Outreach
    Thursday September 28, 2017, 10:05 AM

    Bringing Diversity Into Computational Science Through Student Outreach

    Brookhaven National Laboratory

    From Science to Finance: SLAC Summer Interns Forge New Paths in STEM
    Thursday September 21, 2017, 03:05 PM

    From Science to Finance: SLAC Summer Interns Forge New Paths in STEM

    SLAC National Accelerator Laboratory

    Students Discuss 'Cosmic Opportunities' at 45th Annual SLAC Summer Institute
    Thursday September 07, 2017, 02:05 PM

    Students Discuss 'Cosmic Opportunities' at 45th Annual SLAC Summer Institute

    SLAC National Accelerator Laboratory

    Binghamton University Opens $70 Million Smart Energy Building
    Thursday August 31, 2017, 05:05 PM

    Binghamton University Opens $70 Million Smart Energy Building

    Binghamton University, State University of New York

    Widening Horizons for High Schoolers with Code
    Wednesday August 23, 2017, 05:05 PM

    Widening Horizons for High Schoolers with Code

    Argonne National Laboratory

    Rensselaer Polytechnic Institute Graduates Urged to Embrace Change at 211th Commencement
    Saturday May 20, 2017, 12:05 PM

    Rensselaer Polytechnic Institute Graduates Urged to Embrace Change at 211th Commencement

    Rensselaer Polytechnic Institute (RPI)

    ORNL, University of Tennessee Launch New Doctoral Program in Data Science
    Monday May 15, 2017, 01:05 PM

    ORNL, University of Tennessee Launch New Doctoral Program in Data Science

    Oak Ridge National Laboratory





    Showing results

    0-4 Of 2215