Influence of solidification history and particle size on defect evolution in Al2024 alloy additive manufacturing powder.
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| Title: | Influence of solidification history and particle size on defect evolution in Al2024 alloy additive manufacturing powder. |
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| Authors: | Azersky, Colby1 (AUTHOR) colbyazersky@gmail.com, Jeon, Sangho2 (AUTHOR), Kolbe, Matthias3 (AUTHOR), Walde, Caitlin4 (AUTHOR), Matson, Douglas5 (AUTHOR) |
| Source: | Journal of Applied Crystallography. Oct2026, Vol. 59 Issue 5, p1384-1392. 9p. |
| Subjects: | Dislocation density, Solidification, Aluminum powder, Rapid solidification processing of metals, Powder bed fusion, Heat treatment, Electron backscattering, Particle size determination |
| Abstract: | This study investigates the impact of solidification history on defect evolution in Al2024 alloy additive manufacturing powder. A measurement utilizing synchrotron powder X‐ray diffraction (XRD) was performed with a photon energy of 105.7 keV (0.1173 Å). XRD measurements were completed for six distinct particle diameter ranges from 20 to 63 µm of both as‐atomized and annealed Al2024 samples. The dislocation density was determined using X‐ray line profile analysis and ranged between 3.1 × 1014 and 7.4 × 1014 m−2 for as‐atomized samples, and between 1.3 × 1014 and 4.0 × 1014 m−2 for annealed samples. The results of this investigation suggest a trend of decreasing dislocation density in as‐atomized samples as the particle size increases, demonstrating the influence of particle size on defect formation. The annealed samples show a weak size dependence on the dislocation density across all particle sizes, affirming the efficacy of the annealing process in healing microstructural defects. The reduction in dislocation density upon annealing confirms that the dislocations in the as‐atomized samples were introduced during rapid solidification and are largely removed by heat treatment. Field‐emission scanning electron microscopy and electron backscatter diffraction (EBSD) were used in conjunction with image analysis tools to quantify the grain interface areas of the as‐atomized samples and estimate cooling rates during solidification. Cooling rates were found to vary with particle size within a range of roughly 22000 to 164000 K s−1. Results from both XRD analysis and metallography were used to predict average misorientation angles between grains; the predicted angles range from roughly 0.68° to 0.83°. EBSD was utilized to quantify average misorientation angles and compare them with the predicted values. The EBSD measured angles ranged from roughly 0.74° to 0.95° and followed the same trend as the predictions, linking the dislocation density to the cooling rate and solidification history of the powder. Quantifying the dislocation density and average misorientation angle provides a deeper understanding of the microstructure produced during rapid solidification. These results establish a physical relationship between particle size, cooling rate, dislocation density and grain misorientation during rapid solidification of Al2024 powder. This relationship is relevant to the study of solidification and to applications where gas‐atomized powder is utilized without necessarily being fully remelted. [ABSTRACT FROM AUTHOR] |
| Copyright of Journal of Applied Crystallography is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Header | DbId: egs DbLabel: Engineering Source An: 197591981 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Influence of solidification history and particle size on defect evolution in Al2024 alloy additive manufacturing powder. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Azersky%2C+Colby%22">Azersky, Colby</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> colbyazersky@gmail.com</i><br /><searchLink fieldCode="AR" term="%22Jeon%2C+Sangho%22">Jeon, Sangho</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kolbe%2C+Matthias%22">Kolbe, Matthias</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Walde%2C+Caitlin%22">Walde, Caitlin</searchLink><relatesTo>4</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Matson%2C+Douglas%22">Matson, Douglas</searchLink><relatesTo>5</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Journal+of+Applied+Crystallography%22">Journal of Applied Crystallography</searchLink>. Oct2026, Vol. 59 Issue 5, p1384-1392. 9p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Dislocation+density%22">Dislocation density</searchLink><br /><searchLink fieldCode="DE" term="%22Solidification%22">Solidification</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+powder%22">Aluminum powder</searchLink><br /><searchLink fieldCode="DE" term="%22Rapid+solidification+processing+of+metals%22">Rapid solidification processing of metals</searchLink><br /><searchLink fieldCode="DE" term="%22Powder+bed+fusion%22">Powder bed fusion</searchLink><br /><searchLink fieldCode="DE" term="%22Heat+treatment%22">Heat treatment</searchLink><br /><searchLink fieldCode="DE" term="%22Electron+backscattering%22">Electron backscattering</searchLink><br /><searchLink fieldCode="DE" term="%22Particle+size+determination%22">Particle size determination</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: This study investigates the impact of solidification history on defect evolution in Al2024 alloy additive manufacturing powder. A measurement utilizing synchrotron powder X‐ray diffraction (XRD) was performed with a photon energy of 105.7 keV (0.1173 Å). XRD measurements were completed for six distinct particle diameter ranges from 20 to 63 µm of both as‐atomized and annealed Al2024 samples. The dislocation density was determined using X‐ray line profile analysis and ranged between 3.1 × 1014 and 7.4 × 1014 m−2 for as‐atomized samples, and between 1.3 × 1014 and 4.0 × 1014 m−2 for annealed samples. The results of this investigation suggest a trend of decreasing dislocation density in as‐atomized samples as the particle size increases, demonstrating the influence of particle size on defect formation. The annealed samples show a weak size dependence on the dislocation density across all particle sizes, affirming the efficacy of the annealing process in healing microstructural defects. The reduction in dislocation density upon annealing confirms that the dislocations in the as‐atomized samples were introduced during rapid solidification and are largely removed by heat treatment. Field‐emission scanning electron microscopy and electron backscatter diffraction (EBSD) were used in conjunction with image analysis tools to quantify the grain interface areas of the as‐atomized samples and estimate cooling rates during solidification. Cooling rates were found to vary with particle size within a range of roughly 22000 to 164000 K s−1. Results from both XRD analysis and metallography were used to predict average misorientation angles between grains; the predicted angles range from roughly 0.68° to 0.83°. EBSD was utilized to quantify average misorientation angles and compare them with the predicted values. The EBSD measured angles ranged from roughly 0.74° to 0.95° and followed the same trend as the predictions, linking the dislocation density to the cooling rate and solidification history of the powder. Quantifying the dislocation density and average misorientation angle provides a deeper understanding of the microstructure produced during rapid solidification. These results establish a physical relationship between particle size, cooling rate, dislocation density and grain misorientation during rapid solidification of Al2024 powder. This relationship is relevant to the study of solidification and to applications where gas‐atomized powder is utilized without necessarily being fully remelted. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Journal of Applied Crystallography is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1107/S1600576726006758 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 9 StartPage: 1384 Subjects: – SubjectFull: Dislocation density Type: general – SubjectFull: Solidification Type: general – SubjectFull: Aluminum powder Type: general – SubjectFull: Rapid solidification processing of metals Type: general – SubjectFull: Powder bed fusion Type: general – SubjectFull: Heat treatment Type: general – SubjectFull: Electron backscattering Type: general – SubjectFull: Particle size determination Type: general Titles: – TitleFull: Influence of solidification history and particle size on defect evolution in Al2024 alloy additive manufacturing powder. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Azersky, Colby – PersonEntity: Name: NameFull: Jeon, Sangho – PersonEntity: Name: NameFull: Kolbe, Matthias – PersonEntity: Name: NameFull: Walde, Caitlin – PersonEntity: Name: NameFull: Matson, Douglas IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 10 Text: Oct2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 00218898 Numbering: – Type: volume Value: 59 – Type: issue Value: 5 Titles: – TitleFull: Journal of Applied Crystallography Type: main |
| ResultId | 1 |
