Publications

Sep, 2026

Journal

Microstructure evolution during creep testing of HK30Nb steel fabricated by laser powder bed fusion

High temperature cast HK30Nb (Fe-25Cr-20Ni-1.4Nb-0.2C) alloy was fabricated by laser powder bed fusion (LPBF) and creep tested in the as-printed condition between 700 and 800°C. Significant microstructure evolution took place during long-term testing at 700 and 800°C, with the formation of coarse Cr-rich carbides, sigma phase precipitates and creep cavities at grain bounda…

Jul, 2026

ORNL Report

Implementing 3D printed ceramic cores into metal castings for improved wear and lifetime of comminution parts

Jul, 2026

Journal

Influence of microstructure and temperature on impact toughness of H13 steel produced by binder jet additive manufacturing

Binder Jet Additive Manufacturing (BJAM) is a promising manufacturing pathway to produce H13 steel dies and tooling with complex geometries for applications in high pressure aluminum die casting, hot stamping, and injection molding. While fully dense H13 coupons produced using BJAM have been subjected to detailed microstructure characterization, properties which are critic…

Jun, 2026

Journal

Binder-jetted AISI M2 tool steel during hot isostatic pressing: Densification and carbide transformation

Binder jetting (BJ) enables fabrication of complex components from high-alloy steels such as AISI M2; however, residual porosity after sintering limits mechanical performance. This study investigates the coupled effects of binder chemistry, sintering conditions, cooling rate, and subsequent hot isostatic pressing (HIP) on densification, microstructure, and mechanical respo…

Apr, 2026

Journal

Tailoring Thermal and Mechanical Performance Through Multimaterial Laser Powder Directed Energy Deposition of Copper and 17-4PH Stainless Steel

This study investigates the additive manufacturing (AM) processing, microstructural evolution, and resulting mechanical and thermal properties of multi-material components combining 17-4PH stainless steel and pure copper (Cu) fabricated via laser powder directed energy deposition (LP-DED). Conventional tooling steels exhibit limited thermal conductivity, significantly con…

Mar, 2026

Journal

An Integrated Computational Materials Engineering (ICME) Approach to Design Nonlinear Transition Zones Between Dissimilar Metals

Current approaches to designing graded transition joints (GTJs) between dissimilar metals often rely on linear changes in both composition profiles and thickness of each sublayer. This increases fabrication cost and may not be optimal with respect to residual stress or the formation of undesirable phases. In this study, GTJs between P91 ferritic/martensitic steel and 347H…

Mar, 2026

Conference Paper

Effect of Blown Powder Directed Energy Deposition Angle On Overspray Contamination

Blown powder directed energy deposition (DED) hybrid machine tools are particularly beneficial when the net shape of a component is to be manufactured in an additive and machined interleaved fashion. This investigation seeks to analyze the effect of the additive head lean angle relative to the part on blown powder DED surface contamination due to overspray. These hybrid DE…

Mar, 2026

Journal

Spatially resolved phase transformation mapping in 410 Stainless Steel During Additive Manufacturing Visualized via Real-Time Infrared Data

In this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite s…

Mar, 2026

Journal

Residual strain and microstructure evolution in 316L stainless steel fabricated by hybrid additive/subtractive manufacturing

The extreme thermal gradients in additive manufacturing (AM) result in residual strains. Subsequent machining operations can relieve the AM strains but can introduce additional strains. AM and machining on the same platform, also called interleaving, during hybrid manufacturing has been shown to improve productivity. However, the impacts of these operations on the resultin…

Mar, 2026

Journal

Hydrogen-based ore-to-part manufacturing of near-net-shape stainless steel

Decarbonizing iron and steelmaking, combined with global disruptions to raw material supply chains, necessitates novel approaches to iron and steel production. In this work, we demonstrate a direct ore-to-part manufacturing route using a mixture of ore-derived oxide powders of Fe2O3, Cr2O3, NiO, and MoO3 as feedstock for additive manufacturing, combined with sintering unde…

Jan, 2026

Journal

Extended Continuous Cooling Transformation Diagram for 410 Stainless Steel encompassing δ→γ and γ→α′ Transformations Determined by Dilatometry

In this study, we use dilatometry to construct an extended Continuous Cooling Transformation (CCT) diagram for 410 stainless steel, capturing both δ→γ and γ→α′ transformations specifically for directed energy deposition (DED) additive manufacturing (AM) applications. To ensure that the findings are representative of AM specific microstructures and compositions, dilatometry…

Dec, 2025

Journal

Electroslag additive manufacturing: A pathway for high throughput near net shape production

Electroslag Additive Manufacturing (ESAM), a new high-throughput additive manufacturing (AM) method that combines Electroslag Strip Cladding (ESC) and wire arc AM (WAAM) is introduced. This combination enables the high deposition rate of ESC (more than 20 kg/h with a 60 mm strip electrode) to benefit from the precise geometric control of WAAM. As a precursor to ESAM, the E…