Materials Science Division

Advanced Materials Process Science Group

Studying the effects of advanced manufacturing approaches, especially additive manufacturing, on materials properties and part performance.

Our expertise in laser-based advanced manufacturing is informed by a detailed understanding of the physics of laser-materials interactions. We focus primarily—but not exclusively—on metal manufacturing, and we also work with ceramics.

Material being ejected from the melt pool.
Material is ejected from the melt pool during laser powder bed fusion, a metal additive manufacturing process

Our goal is to understand how materials evolve throughout the manufacturing process, which we achieve by developing and implementing high-speed diagnostics. We study how advanced manufacturing processes influence thermal history, materials chemistry, mechanical deformation, and other key process features. What we learn from these studies provides insight into how and why the final manufactured product behaves as it does.

To determine impacts on final component function, we perform microstructure characterization and macroscopic feature identification, as well as mechanical testing to understand materials behavior. These studies allow us to link information about processing to performance and are a critical part of understanding how manufacturing influences part behavior.

In the news

Our research areas

In this high-speed video, liquid metal and unmelted powder particles are ejected from the melt pool during laser powder bed fusion, a type of metal additive manufacturing.
This high-speed video shows a top view of liquid metal motion and powder particle entrainment during laser powder bed fusion.

Process monitoring for metal additive manufacturing
We are developing tools that monitor additive manufacturing processes to detect anomalies or defects as they are formed; this accelerates inspection and improves our ability to qualify components.

Microstructure control during metal additive manufacturing
We are developing a variety of approaches to control and tailor microstructures that form during metal additive manufacturing. These methods provide tools to adjust microstructure, and therefore properties, as a function of location in a fabricated part.

In situ x-ray experiments to understand laser materials processing
We use high speed x-ray imaging to understand fluid flow and subsurface material transport during laser material processing. We also use high speed x-ray diffraction to gain insight into microstructure and temperature evolution on short timescales.

Developing novel manufacturing approaches
We investigate and develop new advanced manufacturing approaches, both additive and subtractive, in collaboration with partners in the Engineering directorate.

Advanced ceramics and coatings
We undertake research and development activities to modify the surface functionality of manufactured components.

Our team

Leadership

Calta, Nick
Martin, Aiden Alexander

Group members

Bertsch, Kaila Morgen
DePond, Philip James
Philip DePond
Glerum, Jennie
Gorgannejad, Sanam
Griffiths, Joey
Juhasz, Michael John
Michael Juhasz
Nicolino, Jenny Wang
Strantza, Maria
Maria Strantza
Tumkur Umanath, Thej

Select publications

Dynamics of pore formation during laser powder bed fusion additive manufacturing
Nature Communications, 2019
A. A. Martin, N. P. Calta, S. A. Khairallah, J. Wang, P. J. Depond, A. Y. Fong, V. Thampy, G. M. Guss, A. M. Kiss, K. H. Stone, C. J. Tassone, J. Nelson Weker, M. F. Toney, T. van Buuren, M. J. Matthews

Localized keyhole pore prediction during laser powder bed fusion via multimodal process monitoring and X-ray radiography
Additive Manufacturing, 2023
S. Gorgannejad, A. A. Martin, J. W. Nicolino, M. Strantza, G. M. Guss, S. Khairallah, J.-B. Forien, V. Thampy, S. Liu, P. Quan, C. J. Tassone, N. P. Calta

A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource
Rev. Sci. Instrum., 2022
A. A. Martin, J. Wang, P, J. DePond, M. Strantza, J.-B. Forien, S. Gorgannejad, G. M. Guss, V. Thampy, A. Y. Fong, J. Nelson Weker, K. H. Stone, C. J. Tassone, M. J. Matthews, N. P. Calta