A second-generation apparatus for in situ synchrotron characterisation of directed energy deposition additive manufacturing with multi-modal monitoring and external forces
Year: 2026
Type: article
Abstract: In situ synchrotron studies of Directed Energy Deposition (DED) additive manufacturing provide unique process insights, using high-resolution spatial and temporal observations to reveal melt pool dynamics, phase evolution, and defect formation mechanisms. Here, a second-generation DED apparatus is presented that replicates industrially relevant process conditions whilst enabling multi-modal in situ monitoring, including synchrotron X-ray radiography and diffraction, infrared (IR) imaging, inline coherent imaging (ICI), and optical imaging. The equipment, termed the Blown-powder Additive Manufacturing Process Replicator-II (BAMPR-II), also facilitates a range of unique process adaptations including the application of heat, magnetic fields, and ultrasound. Two case studies are described demonstrating how BAMPR-II reveals the underlying phenomena controlling DED, including: (1) simultaneous X-ray and ICI imaging to capture cracking mechanisms during DED; and (2) X-ray imaging of DED illustrating how magnetic fields can control flow in the melt pool.
Source: Materials & Design
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,650
Awards: Tailored Microstructures via Thermoelectric-Magnetohydrodynamics for Additive Manufacturing (TEAM), G2158781270, G2259944664, MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes, CREATE-Materials for Advanced Photonics and Sensing, G3095033208, G3370613760, G5355199242, Performance-driven design of aluminium alloys for additive manufacturing (PAAM), G5400532823, Made Smarter Innovation - Materials Made Smarter Research Centre, Manufacturing by Design, G8754403244
OpenAlex ID: W7124217837