Publications

Mar, 2026

Conference Paper

Wire Arc Additive Manufacturing of Multi-material Parts Using H-13 Tool Steel

H-13 tools steel’s relative hardness, resistance to thermal fatigue, and high tolerance of thermal shock, make it very desirable for use in forging, pressing, casting, and extrusion processes[1]. H-13 is however typically quite expensive when compared to many other steel compositions. It is therefore desirable to encase a lower cost steel composition with H-13. This config…

Feb, 2026

ORNL Report

COST EFFECTIVENESS OF LASER POWDER BED FUSION FOR HEAVY DUTY APPLICATIONS

Feb, 2026

Journal

Metastable formation and disordering kinetics of body-centered orthorhombic CrNi2 laths in a Cr-Ni binary alloy

Chromium (Cr) alloys combine low density with high-temperature strength but suffer from brittleness and rapid softening. Body-centered orthorhombic (BCO) CrNi2 laths have been shown to improve Cr-alloy high-temperature strength retention, yet their thermal stability and transformation behavior remain unclear. CrNi2 conventionally forms through long-range ordering from a fa…

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…

Oct, 2025

Journal

Age hardening response of Cu-30Ni alloys: The role of Si microalloying additions

Cu-30Ni alloys offer high strength and excellent corrosion resistance for maritime applications. While primarily a solid solution system, industrial alloys typically include microalloying additions of Fe, Mn, Nb and/or Si to enable age hardening. However, an understanding of the microstructural evolution during age hardening remains incomplete. Here, we conduct systematic…

Oct, 2025

Journal

Suppressing Ordering in Equiatomic Fe-Co via Laser Powder Bed Fusion

Neutron and electron diffraction was employed to evaluate the effectiveness of thermal management strategies in suppressing the formation of the equilibrium-ordered B2 (CsCl) phase in equiatomic binary Fe-Co specimens fabricated by laser powder bed fusion additive manufacturing. Specimens with a tensile dogbone geometry were fabricated using various combinations of process…

Oct, 2025

Journal

Multi-Physics Melt Pool Modeling and Process Optimization for Laser Direct Energy Deposition of Nb-Based Refractory C103: Defect Formation, Geometric Precision, and Process Mapping

Recent developments in additive manufacturing (AM) technology have reignited interest in the fabrication of the Nb-based refractory C103 alloy offering solutions to the challenges posed by traditional manufacturing methods. However, the limited numerical and experimental studies on laser direct energy deposition (DED) of C103 have hindered the understanding of the relation…

Aug, 2025

Journal

Influence of Solidification Velocity on Partitioning and Precipitate Evolution in a Multicomponent, Soft Magnetic Alloy Processed by Laser Melting

Multicomponent alloys have recently been shown to overcome the structural-functional barrier associated with soft magnetic materials. Here, single laser tracks have been used to investigate the effects of solidification velocity on the Al7Fe32.6Co27.7Ni27.7Ta5 (at pct) alloy. Ta-rich cell wall partitioning was shown to affect the final distribution and size of the precipit…

Mar, 2025

Journal

Formation mechanisms of Sn-rich δ phase and its role in strengthening Cu-10Sn manufactured by laser powder bed fusion

Cu-Sn alloys produced via laser powder bed fusion (L-PBF) additive manufacturing (AM) have gained significant attention because they combine the advantages of AM relevant to intricate component design with outstanding combinations of strength, ductility, and resistance to wear and corrosion. However, a detailed understanding of the microstructure that contributes to the en…

Mar, 2025

Journal

A highly wear resistant nanostructured bainitic steel with accelerated transformation kinetics

A coupled Calculation of Phase Diagrams (CALPHAD), machine learning, and data mining approach was used to design a new, highly wear-resistant nanostructured bainitic steel. Arc melting of the designed compositions, dilatometry, and advanced microscopy indicate that the designed steel had a nanoscale dual-phase structure of ferrite and austenite (approximately 50 nm) with k…

Mar, 2025

Journal

Microstructural features underpinning the mechanical behavior of powder metallurgy Cr-based alloys

Refractory materials such as Cr-based alloys offer the potential of enhanced elevated temperature performance but have been limited by their poor formability. However, powder metallurgy has been shown to be a viable pathway to fabricate these alloys. Nanophase separation sintering (NPSS) in particular has been used in the literature to accelerate the densification of powde…

Jul, 2024

Journal

On dysprosium utilisation in multi-main-phase Nd–Dy–Fe–B magnets with core–shell microstructures

The development of high-performance Nd–Dy–Fe–B magnets that minimise the consumption of the scarce rare earth (RE) element Dy remains a major global scientific and technological quest. Here, we designed an alloy microstructure comprising of a uniform Dy-lean core–Dy-rich shell in a series of multi-main-phase (MMP) Nd–Dy–Fe–B magnets. The resulting MMP Dy1 and Dy3 magnets w…