Publications

Feb, 2026

Journal

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to…

Nov, 2025

Journal

Preliminary hyperspectral neutron radiography of binder jet 3D printed and melt infiltrated Si–SiC

The preliminary results of hyperspectral neutron radiography of Si–SiC made with binder jet additive manufacturing, subsequent carbon addition, and silicon melt infiltration are presented. The samples were measured in the processing states before and after the melt infiltration to determine if neutrons would help characterize the microstructure to better understand the mel…

Aug, 2025

Journal

Phase Selection During Solidification and Solid-State Phase Transformations in an Al-10Ce-8Mn (wt pct) Alloy

In multicomponent Al-Ce alloys, and especially after additive manufacturing (AM), complex and metastable solidification microstructures are frequently observed. In this research, the relationship between solidification conditions and phase selection are explored for an Al-10Ce-8Mn (wt pct) alloy using a systematic study of laser melting conditions. Three solidification mod…

Aug, 2024

Journal

Oil-Pressure Based Apparatus for In-Situ High-Energy Synchrotron X-Ray Diffraction Studies During Biaxial Deformation

Aug, 2024

Journal

Lifelike metallic structures using origami and compliant mechanisms

In nature, materials and designs are smart i.e., they achieve the desired shape or size to optimize different processes without needing external devices. However, in the design of mechanical metallic structures, gaining such behavior without using special materials or external sources is still a visionary thought. Here the concept of lifelike metallic structures is introdu…

May, 2024

Journal

Characterization and Rationalization of Microstructural Evolution in GRCop-84 Processed by Laser-Powder Bed Fusion (L-PBF)

Prismatic geometries of GRCop-84 [Cu-8Cr-4Nb (at. pct)] were built with laser-powder bed fusion (L-PBF) process. The samples were sectioned parallel or perpendicular to the build direction and characterized in the as-built and after post-processing with a hot-isostatically pressing (HIP) treatment. The microstructure and phase evolutions were evaluated with optical microsc…

Mar, 2024

Journal

Reduction kinetics of hematite powder using argon/hydrogen plasma with prospects for near net shaping of sustainable iron

Direct reduction of iron ore using hydrogen plasma is being explored as a potential solution to decarbonize the iron and steel sector. The current state-of-the-art demonstrated reduction of hematite pellets via hydrogen plasma using Ar + 10% H2 but had slow reduction kinetics, requiring 30 minutes of plasma exposure for complete reduction. Here we show that using hematite…

Dec, 2023

Journal

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can…

Dec, 2023

Journal

Process-Defect-Structure-Property Correlations During Laser Powder Bed Fusion of Alloy 718: Role of In Situ and Ex Situ Characterizations

Components made by laser powder bed fusion (L-PBF) additive processes require extensive trial and error optimization to minimize defects and arrive at targeted microstructure and properties. In this work, in situ infrared thermography and ex situ surface roughness measurements were explored as methodologies to ensure Inconel® 718-part quality. For a given laser energy of 2…

Dec, 2023

ORNL Report

Additive Manufacturing (AM) for Advanced Tooling – Workshop Report

Dec, 2023

Journal

Ultrasonic additive manufacturing of 4130 steel using Ni interlayers

Ultrasonic additive manufacturing (UAM) is a solid-state manufacturing process for making complex components. However, fabrication of ferritic (body centered cubic) steels has been challenging for UAM due to its high hardness. This research successfully joined AISI 4130 steel sheets by using soft Ni (face centered cubic) interlayers. The localisation of plastic deformation…

Dec, 2023

Journal

On the potential mechanisms of β to α′ + β decomposition in two phase titanium alloys during additive manufacturing: a combined transmission Kikuchi diffraction and 3D atom probe study

This paper focuses on the mechanisms of phase transformations in additively manufactured Ti–6Al–4V during cooling. In particular, the goal is to understand if the imposed thermal cycles during fabrication results in the complete transformation of the α′ to the β phase or the sub-transus decomposition of α′ (martensite) to α + β. To this effect, samples fabricated using ele…