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.

X
X
X
  • Filters

  • × Clear Filters

Is Nature Exclusively Left Handed? Using Chilled Atoms to Find Out

Elegant techniques of trapping and polarizing atoms open vistas for beta-decay tests of fundamental symmetries, key to understanding the most basic forces and particles constituting our universe.

Forever Young Catalyst Reduces Diesel Emissions

Atom probe tomography reveals key explanations for stable performance over a cutting-edge diesel-exhaust catalyst's lifetime.

Sense Like a Shark: Saltwater-Submersible Films

A nickelate thin film senses electric field changes analogous to the electroreception sensing organ in sharks, which detects the bioelectric fields of prey.

Enhanced Detection of Nuclear Events, Thanks to Deep Learning

Scientists at Pacific Northwest National Laboratory are exploring deep learning to interpret data related to national security, the environment, the cosmos, and breast cancer. In one project a deep neural network is interpreting data about nuclear events as well as - sometimes better than - today's best automated methods or human experts.

A Bit of Quantum Logic--What Did the Atom Say to the Quantum Dot?

Let's talk! Scientists demonstrate coherent coupling between a quantum dot and a donor atom in silicon, vital for moving information inside quantum computers.

Sodium- and Potassium-based Batteries Hold Promise for Cheap Energy Storage

Researchers at the Georgia Institute of Technology have found new evidence suggesting that batteries based on sodium and potassium hold promise as a potential alternative to lithium-based batteries.

ORNL researchers use AI to improve mammogram interpretation

In an effort to reduce errors in the analyses of diagnostic images by health professionals, a team of researchers from Oak Ridge National Laboratory has improved understanding of the cognitive processes involved in image interpretation, work that has enormous potential to improve health outcomes for the hundreds of thousands of American women affected by breast cancer each year. The ORNL-led team found that analyses of mammograms by radiologists were significantly influenced by context bias, or the radiologist's previous diagnostic experiences.

Scientists Make the First Molecular Movie of One of Nature's Most Widely Used Light Sensors

Scientists have made the first molecular movie of the instant when light hits a sensor that's widely used in nature for probing the environment and harvesting energy from light. The sensor, a form of vitamin A known as retinal, is central to a number of important light-driven processes in people, animals, microbes and algae, including human vision and some forms of photosynthesis, and the movie shows it changing shape in a trillionth of an eye blink.

Scientists isolate protein data from the tiniest of caches - single human cells

Scientists have captured the most information yet about proteins within a single human cell, giving scientists one of their clearest looks yet at the molecular happenings inside a human cell. The team detected on average more than 650 proteins in each cell - many times more than conventional techniques capture from single cells.

Researchers Generate Electricity and Hydrogen from Live Bacteria

Using a family of photosynthetic bacteria that commonly live in lakes and seas, researchers at the Technion have developed a technology to generate electricity and hydrogen energy. The researchers believe their technology can serve as a promising source of clean, environment-friendly energy that will not emit pollutants during production or use (hydrogen fuel).


  • Filters

  • × Clear Filters

Department of Energy Selects 84 Scientists to Receive Early Career Research Program Funding

The Department of Energy (DOE) has selected 84 scientists from across the nation - including 30 from DOE's national laboratories and 54 from U.S. universities - to receive significant funding for research as part of the DOE Office of Science's Early Career Research Program.

Three Argonne Scientists Receive DOE Early Career Awards

Three Argonne researchers have earned the DOE's 2018 Early Career Research Program awards.

Four SLAC Scientists Awarded Prestigious DOE Early Career Research Grants

Four scientists at the Department of Energy's SLAC National Accelerator Laboratory will receive Early Career Research Program awards for research that's developing new ways to study fundamental particles with machine learning and study nanoscale objects and quantum materials with powerful X-ray laser beams.

PPPL Physicists Aim to Unlock Mysteries of Fusion with Early Career Research Awards

Article describes PPPL winner of DOE Early Career Awards.

Ames Laboratory's Ke Earns DOE Early Career Research Award

Ames Laboratory scientist Liqin Ke is one of 30 scientists from the U.S. Department of Energy's (DOE) national laboratories to be selected for funding as part of the DOE's Early Career Research Program.

6 Berkeley Lab Researchers Receive DOE Early Career Research Awards

Six scientists at Lawrence Berkeley National Laboratory (Berkeley Lab) have been selected by the U.S. Department of Energy's (DOE's) Office of Science to receive significant funding for research through its Early Career Research Program.

Stony Brook's AERTC Selected for Leadership Role in Nationwide Consortium on Offshore Wind Industry

Stony Brook's Advanced Energy Research and Technology Center (AERTC) will play a key role in a nationwide research and development consortium for the offshore wind industry. The New York State Energy Research and Development Authority was awarded a $18.5 million U.S. Department of Energy grant to establish the National Offshore Wind Research and Development Consortium, Governor Andrew M. Cuomo announced last week. New York State, through NYSERDA, has committed an additional $20.5 million to fund the consortium supporting Gov. Cuomo's initiative Reforming the Energy Vision (REV).

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

Li (Emily) Liu, associate professor of nuclear engineering and engineering physics in the Department of Mechanical, Aerospace, and Nuclear Engineering at Rensselaer Polytechnic Institute, has been selected by the U.S. Department of Energy Solar Energy Technologies Office (SETO) to receive a $1.8 million award to study high-temperature molten-salt properties and corrosion mechanisms.

Vasilis Fthenakis Receives IEEE's William R. Cherry Award

UPTON, NY; Vasilis Fthenakis, a Senior Scientist Emeritus at the U.S. Department of Energy's (DOE) Brookhaven National Laboratory and Founder and Director of the Center for Life Cycle Analysis at Columbia University, will receive the 2018 William R. Cherry Award from the Institute of Electrical & Electronics Engineers (IEEE).

New PPPL director Steve Cowley is honored with knighthood by Queen Elizabeth II

Steven Cowley, newly named director of the U.S. Department of Energy's (DOE) Princeton Plasma Physics Laboratory (PPPL) effective July 1, has received a knighthood from Queen Elizabeth "for services to science and the development of nuclear fusion."


  • Filters

  • × Clear Filters

Is Nature Exclusively Left Handed? Using Chilled Atoms to Find Out

Elegant techniques of trapping and polarizing atoms open vistas for beta-decay tests of fundamental symmetries, key to understanding the most basic forces and particles constituting our universe.

As Future Batteries, Hybrid Supercapacitors Are Super-Charged

A new supercapacitor could be a competitive alternative to lithium-ion batteries.

Forever Young Catalyst Reduces Diesel Emissions

Atom probe tomography reveals key explanations for stable performance over a cutting-edge diesel-exhaust catalyst's lifetime.

Sense Like a Shark: Saltwater-Submersible Films

A nickelate thin film senses electric field changes analogous to the electroreception sensing organ in sharks, which detects the bioelectric fields of prey.

A Bit of Quantum Logic--What Did the Atom Say to the Quantum Dot?

Let's talk! Scientists demonstrate coherent coupling between a quantum dot and a donor atom in silicon, vital for moving information inside quantum computers.

New Tech Uses Isomeric Beams to Study How and Where the Galaxy Makes One of Its Most Common Elements

A new measurement using a beam of aluminum-26 prepared in a metastable state allows researchers to better understand the creation of the elements in our galaxy.

Simulations of Magnetically Confined Plasmas Reveal a Self-Regulating Stabilizing Mechanism

A mysterious mechanism that prevents instabilities may be similar to the process that maintains the Earth's magnetic field.

Seeing All the Colors of the Plasma Wind

2-D velocity imaging helps fusion researchers understand the role of ion winds (aka flows) in the boundary of tokamak plasmas.

Renewable Solvents Derived From Lignin Lowers Waste in Biofuel Production

New class of solvents breaks down plant biomass into sugars for biofuels and bioproducts in a closed-loop biorefinery concept.

Scientists Studying Nuclear Spin Make a Surprising Discovery

The size of a nucleus appears to influence the direction of certain particles emitted from collisions with spinning protons.


Spotlight

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)

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)

Thursday June 07, 2018, 03:05 PM

Celebrating 40 years of empowerment in science

Argonne National Laboratory

Monday May 07, 2018, 10:30 AM

Introducing Graduate Students Across the Globe to Photon Science

Brookhaven National Laboratory

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

Thursday April 12, 2018, 07:05 PM

The Race for Young Scientific Minds

Argonne National Laboratory

Wednesday March 14, 2018, 02:05 PM

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

SLAC National Accelerator Laboratory

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

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

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)

Wednesday January 17, 2018, 12:05 PM

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

Fermi National Accelerator Laboratory (Fermilab)

Wednesday December 20, 2017, 01:05 PM

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

SLAC National Accelerator Laboratory

Monday December 18, 2017, 01:05 PM

The Future of Today's Electric Power Systems

Rensselaer Polytechnic Institute (RPI)

Monday December 18, 2017, 12:05 PM

Supporting the Development of Offshore Wind Power Plants

Rensselaer Polytechnic Institute (RPI)

Tuesday October 03, 2017, 01:05 PM

Stairway to Science

Argonne National Laboratory

Thursday September 28, 2017, 12:05 PM

After-School Energy Rush

Argonne National Laboratory

Thursday September 28, 2017, 10:05 AM

Bringing Diversity Into Computational Science Through Student Outreach

Brookhaven National Laboratory

Thursday September 21, 2017, 03:05 PM

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

SLAC National Accelerator Laboratory

Thursday September 07, 2017, 02:05 PM

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

SLAC National Accelerator Laboratory

Thursday August 31, 2017, 05:05 PM

Binghamton University Opens $70 Million Smart Energy Building

Binghamton University, State University of New York

Wednesday August 23, 2017, 05:05 PM

Widening Horizons for High Schoolers with Code

Argonne National Laboratory

Saturday May 20, 2017, 12:05 PM

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

Rensselaer Polytechnic Institute (RPI)

Monday May 15, 2017, 01:05 PM

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

Oak Ridge National Laboratory

Friday April 07, 2017, 11:05 AM

Champions in Science: Profile of Jonathan Kirzner

Department of Energy, Office of Science

Wednesday April 05, 2017, 12:05 PM

High-Schooler Solves College-Level Security Puzzle From Argonne, Sparks Interest in Career

Argonne National Laboratory

Tuesday March 28, 2017, 12:05 PM

Champions in Science: Profile of Jenica Jacobi

Department of Energy, Office of Science

Friday March 24, 2017, 10:40 AM

Great Neck South High School Wins Regional Science Bowl at Brookhaven Lab

Brookhaven National Laboratory

Wednesday February 15, 2017, 04:05 PM

Middle Schoolers Test Their Knowledge at Science Bowl Competition

Argonne National Laboratory

Friday January 27, 2017, 04:00 PM

Haslam Visits ORNL to Highlight State's Role in Discovering Tennessine

Oak Ridge National Laboratory

Tuesday November 08, 2016, 12:05 PM

Internship Program Helps Foster Development of Future Nuclear Scientists

Oak Ridge National Laboratory

Friday May 13, 2016, 04:05 PM

More Than 12,000 Explore Jefferson Lab During April 30 Open House

Thomas Jefferson National Accelerator Facility

Monday April 25, 2016, 05:05 PM

Giving Back to National Science Bowl

Ames Laboratory

Friday March 25, 2016, 12:05 PM

NMSU Undergrad Tackles 3D Particle Scattering Animations After Receiving JSA Research Assistantship

Thomas Jefferson National Accelerator Facility

Tuesday February 02, 2016, 10:05 AM

Shannon Greco: A Self-Described "STEM Education Zealot"

Princeton Plasma Physics Laboratory

Monday November 16, 2015, 04:05 PM

Rare Earths for Life: An 85th Birthday Visit with Mr. Rare Earth

Ames Laboratory

Tuesday October 20, 2015, 01:05 PM

Meet Robert Palomino: 'Give Everything a Shot!'

Brookhaven National Laboratory

Tuesday April 22, 2014, 11:30 AM

University of Utah Makes Solar Accessible

University of Utah

Wednesday March 06, 2013, 03:40 PM

Student Innovator at Rensselaer Polytechnic Institute Seeks Brighter, Smarter, and More Efficient LEDs

Rensselaer Polytechnic Institute (RPI)

Friday November 16, 2012, 10:00 AM

Texas Tech Energy Commerce Students, Community Light up Tent City

Texas Tech University

Wednesday November 23, 2011, 10:45 AM

Don't Get 'Frosted' Over Heating Your Home This Winter

Temple University

Wednesday July 06, 2011, 06:00 PM

New Research Center To Tackle Critical Challenges Related to Aircraft Design, Wind Energy, Smart Buildings

Rensselaer Polytechnic Institute (RPI)

Friday April 22, 2011, 09:00 AM

First Polymer Solar-Thermal Device Heats Home, Saves Money

Wake Forest University

Friday April 15, 2011, 12:25 PM

Like Superman, American University Will Get Its Energy from the Sun

American University

Thursday February 10, 2011, 05:00 PM

ARRA Grant to Help Fund Seminary Building Green Roof

University of Chicago

Tuesday December 07, 2010, 05:00 PM

UC San Diego Installing 2.8 Megawatt Fuel Cell to Anchor Energy Innovation Park

University of California San Diego

Monday November 01, 2010, 12:50 PM

Rensselaer Smart Lighting Engineering Research Center Announces First Deployment of New Technology on Campus

Rensselaer Polytechnic Institute (RPI)

Friday September 10, 2010, 12:40 PM

Ithaca College Will Host Regional Clean Energy Summit

Ithaca College

Tuesday July 27, 2010, 10:30 AM

Texas Governor Announces $8.4 Million Award to Create Renewable Energy Institute

Texas Tech University





Showing results

0-4 Of 2215