Abstract
Solidification processing offers the first opportunity to control microstructure, properties, and performance in metallic alloy components. Until recently, microstructural evaluations were limited to post-solidification characterization by destructive methods. We review the development of time-resolved, in situ imaging techniques capable of capturing solid–liquid interfacial evolution in metallic alloys with high spatial and temporal resolution under diverse solidification conditions relevant for applications ranging from conventional directional solidification, crystal growth, and casting, to welding and additive manufacturing. These experiments enable direct visualization of transient behaviors that would otherwise remain unknown, uniquely providing insights into the physics that impact microstructure and defect development, and strategies for microstructural control and defect mitigation. Understanding microstructural evolution and the characteristics that form under various solidification conditions is essential for the development of multiscale, experimentally informed predictive modeling. This is highlighted by solidification simulations that utilize in situ measurements of solidification dynamics from state-of-the-art experimental techniques.
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Acknowledgments
Lawrence Livermore National Laboratory (LLNL) is operated by Lawrence Livermore National Security, LLC, for the US Department of Energy, National Nuclear Security Administration (NNSA) under Contract No. DE-AC52-07NA27344. Work at LLNL was supported by the Laboratory Directed Research and Development (LDRD) Program under project tracking code 18-SI-003. Preparation of this manuscript at the Colorado School of Mines (Mines) was supported by the US Department of Energy (DOE), Office of Science, Basic Energy Sciences (BES) under Award No. DE-SC0020870. Synchrotron x-ray imaging of solidification and pRad imaging of metal casting were supported by the US DOE Office of Science, BES, under Award No. DE-SC001606 and A.J.C.’s Early Career Research Program Award. A.J.C. acknowledges the support of the US Department of the Navy, Office of Naval Research under ONR Award No. N00014-18-1-2794 for selected simulated AM experiments. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research. This research used resources of the Advanced Photon Source, a US DOE Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. pRad was performed at the Los Alamos Neutron Science Center (LANSCE), a NNSA User Facility operated for the US DOE by Los Alamos National Laboratory (LANL) (Contract No. 89233218CNA000001). The research activities at the University of Pittsburgh received support from the National Science Foundation, Division of Materials Research, Metals, and Metallic Nanostructures program through Grant No. DMR 1607922.
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Joseph T. McKeown leads the Metallurgy and Advanced Microscopy Group in the Materials Science Division at Lawrence Livermore National Laboratory (LLNL). He earned his PhD degree in materials science and engineering from the University of California, Berkeley. He completed a postdoctoral fellowship in the Department of Physics at Arizona State University. His research includes in situ studies of phase transformations using dynamic transmission electron microscopy. His research focuses on transmission electron microscopy, alloy design, and process–structure–property–performance relationships in metals and alloys. McKeown can be reached by email at mckeown3@llnl.gov.
Amy J. Clarke is an associate professor in the George S. Ansell Department of Metallurgical and Materials Engineering at the Colorado School of Mines. She received her BS degree from Michigan Technological University, and MS and PhD degrees in metallurgical and materials engineering from the Colorado School of Mines. Her research focuses on physical metallurgy, and making, measuring, and modeling metallic alloys during processing to realize advanced manufacturing. Her awards include a Presidential Early Career Award for Scientists and Engineers. She served on the Board of Directors for The Minerals, Metals & Materials Society and the Association for Iron and Steel Technology, and is a Fellow of ASM International. Clarke can be reached by email at amyclarke@mines.edu.
Jörg M.K. Wiezorek is a professor of mechanical engineering and materials science at the University of Pittsburgh. He received his PhD degree in materials science and metallurgy from the University of Cambridge, UK, and BS and MS degrees in physics from the University of Münster, Germany. His research focuses on processing–microstructure–property–performance relationships primarily in metallic materials using advanced microcharacterization methods. His awards include the National Science Foundation CAREER Award, the Microanalysis Society Birks Award, and the William Kepler Whiteford Faculty Fellowship. He has held visiting positions at Lawrence Berkeley National Laboratory, Westinghouse Electric Corporation, and the ETH Zürich. Wiezorek can be reached by email at wiezorek@pitt.edu.
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McKeown, J.T., Clarke, A.J. & Wiezorek, J.M. Imaging transient solidification behavior. MRS Bulletin 45, 916–926 (2020). https://doi.org/10.1557/mrs.2020.273
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DOI: https://doi.org/10.1557/mrs.2020.273