Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing.

Residual stresses affect the performance and reliability of most manufactured goods and are prevalent in casting, welding, and additive manufacturing (AM, 3D printing). Residual stresses are associated with plastic strain gradients accrued due to transient thermal stress. Complex thermal conditions in AM produce similarly complex residual stress patterns. However, measuring real-time effects of processing on stress evolution is not possible with conventional techniques. Here we use operando neutron diffraction to characterize transient phase transformations and lattice strain evolution during AM of a low-temperature transformation steel. Combining diffraction, infrared and simulation data reveals that elastic and plastic strain distributions are controlled by motion of the face-centered cubic and body-centered cubic phase boundary. Our results provide a new pathway to design residual stress states and property distributions within additively manufactured components. These findings will enable control of residual stress distributions for advantages such as improved fatigue life or resistance to stress-corrosion cracking.

The high intensity diffractometer for residual stress analysis (HIDRA), a third generation residual stress mapping neutron diffractometer at the high flux isotope reactor.

This paper describes the hardware and software upgrades, operation, and performance of the high intensity diffractometer for residual stress analysis (HIDRA) instrument, a residual stress mapping neutron diffractometer located at the High Flux Isotope Reactor at Oak Ridge National Laboratory in Oak Ridge Tennessee, USA. Following a major upgrade in 2018, the new instrument has a single 3He multiwire 2D 30 × 30 cm2 position sensitive detector, yielding a field of view of 17° 2θ. The increase in the field of view (from 4° 2θ) from the previous model instrument has contributed to the tremendous improvement in the out of plane solid angle such that the 3D count rate could be obtained easily. Accordingly, the hardware, software, Data Acquisition System (DAS), and so on have also been updated. Finally, all these enhanced features of HIDRA have been ably demonstrated by conducting multi directional diffraction measurements in the quenched 750-T74 aluminum, and the evolved and improved strain/stress mappings are presented.

Probing orientation information using 3-dimensional reciprocal space volume analysis.

The crystallographic texture of polycrystalline materials is the result of how these materials are processed and what external forces materials have experienced. Neutron and X-ray diffraction are standard methods to characterize global crystallographic textures. However, conventional neutron and X-ray texture analyses rely on pole figure inversion routines derived from intensity analysis of individual reflections or powder Rietveld analysis to reconstruct and model the orientation distribution from slices through reciprocal space. In this work, we describe an original approach to directly probe the crystallographic texture information of rolled aluminum from the intensity distribution in 3-dimensional reciprocal space volumes measured simultaneously. Using the TOPAZ time-of-flight Laue neutron diffractometer, reciprocal space analysis allowed determination of "pole spheres" with <1° angular resolution. These pole spheres are compared with reconstructed pole figures from classic texture analysis.

Current capabilities of the residual stress diffractometer at the high flux isotope reactor.

The engineering diffractometer 2nd Generation Neutron Residual Stress Facility (NRSF2) at the Oak Ridge National Laboratory's High Flux Isotope Reactor was built specifically for the mapping of residual strains. NRSF2 is optimized to investigate a wide range of engineering materials by providing the user a selection of monochromatic neutron wavelengths to maintain the selected Bragg reflection near 2θ = 90°, which is the optimal scattering geometry for strain mapping. Details of the instrument configuration and operation are presented, and considerations for experimental planning are also discussed. Selected examples of recent residual stress work completed with NRSF2 are presented to highlight capabilities.

Time filtering of event based neutron scattering data: A pathway to study the dynamic structural responses of materials.

Time-resolved diffraction has become a vital tool for probing dynamic responses to an applied stimulus. Such experiments traditionally use hardware solutions to histogram measured data into their respective bin. We will show that a major advantage of event-based data acquisition, which time-stamps measured diffraction data with 100 ns accuracy, is much preferred over hardware histogramming of the data by enabling postprocessing for advanced custom binning using a software solution. This approach is made even more powerful by coupling measured diffraction data with metadata about the applied stimuli and material response. In this work, we present a time-filter approach that leverages the power of event-based diffraction collection to reduce stroboscopic data measured over many hours into equally weighted segments that represent subsets of the response to a single cycle of the applied stimulus. We demonstrate this approach by observing ferroelectric/ferroelastic domain wall motion during electric field cycling of BaTiO3. The developed approach can readily be expanded to investigate other dynamic phenomena using complex sample environments.