Revealing dynamic processes in laser powder bed fusion with in situ X-ray diffraction at PETRA III - Vol. 93 - Abstract

Oct 28, 2026

The high flux and monochromatic synchrotron radiation available at modern facilities enable fundamental metal-processing research. For laser powder bed fusion (LPBF), in situ approaches are required to capture the highly dynamic thermal, mechanical, and metallurgical processes forming complex metallic parts. At PETRA III, an industrial-functional LPBF system supports in situ X-ray diffraction. Three experimental use cases are presented, covering strain and internal stress in Inconel 625 under varied substrate pre-heating and scan patterns, γ′ precipitate formation and dissolution in CMSX-4, and phase transitions in a γ-TiAl-based alloy during melting and solidification.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages28

Reading Time1 h 11 min

AccessFree to download

Abstract

I. Introduction

Final Draft of the original manuscript Krohmer, E.; Schmeiser, F.; Wahlmann, B.; Rosigkeit, J.; Graf, G.; Spoerk-Erdely, P.; Clemens, H.; Staron, P.; Körner, C.; Reimers, W.; Uhlmann, E.: Revealing dynamic processes in laser powder bed fusion within situ X-ray diffraction at PETRA III. In: Review of Scientific Instruments. Vol. 93 (2022) 6, 065104. First published online by AIP: 10.06.2022 [https://dx.doi.org/10.1063/5.0077105](https://dx.doi.org/10.1063/5.0077105) PLEASE CITE THIS ART ICLE AS DOI: 10. 1063/5.0077105 1 Revealing dynamic processes in laser powder bed fusion with 2 in situ X-ray diffraction at PETRA III 3 4 Erwin Krohmer1 , Felix Schmeiser2 , Benjamin Wahlmann3 , Jan Rosigkeit4 , Gloria Graf5 , 5 Petra Spoerk-Erdely5 , Helmut Clemens5 , Peter Staron4 , Carolin Körner3 , Walter Reimers2 , 6 Eckart Uhlmann 1 ,6 7 AFFILIATIONS: 8 1 Institute for Machine Tools and Factory Management (IWF), Technische Universität 9 Berlin, Pascalstraße 8-9, 10587 Berlin, Germany 10 2 Institute for Materials Science and Technology, Metallic Materials, Technische Universität 11 Berlin , Ernst-Reuter-Platz 1, 10587 Berlin, Germany 12 3 Chair of Materials Science and Engineering for Metals, Friedrich-Alexander-Universität 13 Erlangen-Nürnberg (FAU), Martensstraße 5, 91058 Erlangen, Germany 14 4 Institute of Materials Physics , Helmholtz-Zentrum Hereon , Max-Planck-Straße 1 , 15 21502 Geesthacht , Germany 16 5 Department of Materials Science, Montanuniversität Leoben, Franz Josef-Straße 18, 17 8700 Leoben, Austria 18 6 Fraunhofer Institute for Production Systems and Design Technology (IPK) , 19 Pascalstraße 8-9, 10587 Berlin , Germany 20 ABSTRACT 21 The high flux combined with the high energy of the monochromatic synchrotron radiation 22 available at modern synchrotron facilities offers vast possibilities for fundamental research on 23 metal processing technologies. Especially in the case of laser powder bed fusion (LPBF), an 24 additive manufacturing technology for the manufacturing of complex-shaped metallic parts, in 25 situ methods are necessary to understand the highly dynamic thermal, mechanical and 26 metallurgical processes involved in the creation of the parts. At PETRA III, Deutsches 27 Elektronen-Synchrotron (DESY), a customized LPBF system featuring all essential functions 28 of an industrial LPBF system is used for in situ X-ray diffraction research. Three use cases 29 with different experimental setups and research questions are presented to demonstrate 30 research opportunities. Firstly , the influence of substrate pre-heating and a complex scan 31 pattern on the strain and internal stress progression during the manufacturing of Inconel 625 32 parts is investigated. Secondly , a study on the nickel-base superalloy CMSX-4 reveals the 33 formation and dissolution of γ′ precipitates depending on the scan pattern in different part 34 locations. Thirdly , phase transitions during melting and solidification of an intermetallic γ-TiAl 35 based alloy are examined, and the advantages of using thin platelet-shaped specimens to 36 resolve the phase components are discussed. The presented cases give an overview of in situ 37 X-ray diffraction experiments at PETRA III for research on the LPBF technology and provide 38 information on specific experimental procedures. 39 I. INTRODUCTION 40 Additive manufacturing (AM) technologies offer vast possibilities in designing and producing 41 complex-shaped parts made of different materials such as metals, intermetallics, ceramics, 42 and polymers. One of the leading technologies for metal parts is laser powder bed 43 fusion (LPBF) . In LPBF, metal parts are manufactured from loose metal powder deposited in 44 thin single layers on a metal substrate plate. A highly focused laser beam locally fuses the 45 metal powder one melt track after another onto the substrate until one thin cross-sectional area 4

FAQs

Why are in situ diffraction methods important for LPBF research?

LPBF involves highly dynamic thermal, mechanical, and metallurgical processes on microsecond to millisecond timescales, producing temperature-dependent microstructures, phases, and stresses. In situ diffraction with synchrotron radiation enables temporally resolved information about these processes.

What experimental capabilities were used at PETRA III?

A customized LPBF system with essential industrial functions was used for in situ X-ray diffraction studies. PETRA III (DESY) provides the high flux synchrotron radiation needed for these measurements.

What three use cases are presented in the study?

The work presents: (1) strain and internal stress progression in Inconel 625 influenced by substrate pre-heating and scan pattern, (2) γ′ precipitate formation and dissolution in the nickel-base superalloy CMSX-4 depending on scan pattern and location, and (3) phase transitions in a γ-TiAl-based intermetallic alloy during melting/solidification, including advantages of thin platelet-shaped specimens.

Oct 28, 2026

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