MicroAM

With MicroAM, we will introduce microstructural engineering into the field of additive manufacturing (AM) of metals. This will set the stage for optimizing metals microstructures in-situ during the AM process, as well as ex-situ during post-AM treatments, and enable predictions of the microstructural evolution, and thus the changes in properties, while AM components are in use.

About

AM is at present revolutionizing metal manufacturing, but the huge potential of microstructural engineering, used for decades in conventional manufacturing, has not been systematically explored for AM. Voids are hard to avoid, and local stresses are always present. An additional main task of MicroAM is thus to incorporate the individual and combined effects of voids and local stress into microstructural engineering - this represents a major fundamental challenge and has never been done before, but opens new design opportunities.

It is the our dream to use this opportunity to demonstrate how our knowledge acquired during long careers within advanced 2D, 3D and 4D characterization and modelling of conventionally manufactured metals can be transferred and applied to the new and rapidly growing AM field, and that we may thereby contribute to metals research and development for the future.

Dorte Juul Jensen Professor, Project Leader

MicroAM will introduce the following novel, key elements, which we foresee to be essential to the future of metal AM:

A laboratory-based X-ray microscope capable of mapping local residual stress non-destructively in 3D with a spatial and strain resolution better than 5 μm and 5×10−4, respectively.
A multi-scale AM process–microstructure–property–performance simulation platform that includes models for simulations of the microstructural dynamics for all of the following stages:
1) during the AM process,
2) while exposed to post-AM stimuli (as selected for microstructural engineering), and
3) when loaded during in-service operation.
A theoretical framework that includes the effects of multi-scale voids and local residual stresses in microstructural engineering, and that addresses the local microstructural evolution during exposure to mechanical, thermal and corrosive stimuli/loads, thus laying the foundation for design of AM-defect tolerant microstructures.
An exploitation of the microstructural engineering potential for AM of metals by two demonstration cases.

Read about the members within each area of the project

Highlights

group photo Risø Symposium 2024 — During the week Sep 2nd to 6th 2024, we hosted the 44th Risø International Symposium on Materials Science. The theme was Metal Microstructures and Additive Manufacturing. We were happy to have 77 participants from 12 countries. We consider this to be an optimal size for a specialty conference, allowing excellent networking and in-depth discussions, initiating extended as well as new collaborations.

Application of Finite Volume Method (FVM) and Computational Fluid Dynamics (CFD) to Laser Powder Bed Fusion (L-PBF)

A Numerical modeling framework based on the Finite Volume Method (FVM) and Computational Fluid Dynamics (CFD) illustrates a 3D temperature isosurface of a powder bed during laser scanning of a single track. The laser beam has a ring-spot shape and is distinctly highlighted. Validation of the model's prediction accuracy is achieved by comparing the numerically predicted melt pool shape and size with experimental data.

Inauguration of MicroAM

On Feb 1st 2024 we celebrated the inauguration of the MicroAM project, with a lab tour and presentations.

3D printed (L-PBF) AlSi10Mg sample characterized by X-ray nano-tomography

The experiment was performed at the FXI beamline at NSLSII in USA. The aim of the work is to characterized the evolution in the AlSi network towards Si particles during annealing. The experiment is especially challenging because of the very small difference in X-ray absorption contrast between Al and Si. But as this figure shows, it can be done.

Workshop in January 2024

On Jan 31st to Feb 1st we held a small workshop on Metal AM activities at Danish Universities, with 17 participants from SDU, AAU and DTU with 15 presentations.

Members

Events

Here, we will display events, hosted by DTU and with relevance to metal microstructures and Additive Manufacturing.

2nd - 6th of September 2024

44th Risø International Symposium on Materials Science

Metal Microstructures and Additive Manufacturing

Read about the event and how to register (PDF)

This Symposium focusses on the microstructures of metallic samples and components prepared by additive manufacturing (AM), but covers also comparative aspects of microstructural evolution during conventional thermomechanical processing, where this is informative for understanding microstructures resulting from AM.

The format of the Symposium will follow its traditional scheme, with all presentations being given in the Auditorium at the DTU Risø Campus near Roskilde. There will be no parallel sessions and the participants will have ample time for in-depth discussions both in plenum and during coffee breaks, lunches and dinners. All presentations must be accompanied by a paper published in open access format by IOP, and in a printed Symposium Proceedings book, which will be provided to all participants upon arrival at the Symposium.

This symposium is supported by Villum FONDEN (MicroAM - grant agreement No 54495).

Completed

Workshop on Metal AM activities at DK Universities

This workshop took place 31 January - 1 February 2024.

See the program (PDF)

Funding

MicroAM was funded with DKK 30 million by Villum Investigator.

The project started October 1st, 2023, and will run until September 30th, 2029.

Would you like to do a student project with MicroAM?

Voids in Binder-Jet 3D Printed 316L Steel Samples with supervisors Prof. Dorte Juul Jensen and Lead Engineer Dagny Primdal, Grundfos.

Microstructural engineering of additive manufactured metals – MicroAM