In-situ studies of 3D microstructure evolution and spectroscopic imaging during processing and manufacturing of advanced materials

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The development of novel materials concomitantly with the optimization of novel synthesis and manufacturing processes requires a complete understanding of microstructural details such as grain size distribution and crystallographic orientation, phase composition, element interdiffusion at heterogeneous interfaces, presence of pores, voids or microcracks, interfacial bonding, etc. Recent advances of X-Ray Microscopy (XRM) together with on-going efforts into fabricating spectroscopic detectors that allow a simultaneous detection of 3D microstructural maps and 3D chemical imaging open wholly new ways for a knowledge-based, concurrent development of materials and processes. The MAPEX Center for Materials and Processes of the University of Bremen plans to acquire, further develop and intensively use a new XRM facility, in a joint effort of seven institutes covering the fields of Materials Science, Engineering, Processing, Manufacturing, Modelling, Industrial Mathematics and Information Technology. Starting from a commercially available XRM instrument, on one side we will establish a correlated workflow with a SEM/FIB instrument augmented with micro X-Ray Fluorescence and Electron Dispersive X-ray Spectroscopy modules. On the other side we will expand the detecting capability of the XRM by means of a CdTe HEXITEC spectroscopic detector fabricated by our cooperation partners at the University of Manchester. Furthermore, a set of accessories to place materials samples under thermal, mechanical or chemical load in the XRM sample chamber shall be developed to enable in-situ studies of the effects of such loads on the materials microstructure and composition. The effect of harsh processing and manufacturing, such as sintering, welding or machining, will be investigated in-situ, as it will be the microstructural and compositional changes during additive manufacturing processes. Materials classes will comprise especially, but not exclusively, advanced metals, carbon-reinforced polymers, and porous ceramics, with a strong focus on heterogeneous interfaces, out-of-equilibrium alloys, complex architectures and sensor integration. The data collected from the measurements will be analyzed and visualized both using available software solutions and new software developed ad hoc. We will concentrate on aspects of usability and interactivity to guarantee an optimal interface between investigating scientist and investigated material. The large amount of collected material data will be stored in the form of a searchable database along with appropriately defined indexing metadata. Finally, the observed materials microstructures and process-induced changes will be rationalized by means of accurate simulations performed at all size scales, employing quantum mechanical, classical atomistic and coarse-grained as well as microstructure evolution simulation methods, alone or in mutual combinations, following an Integrated Computational Materials Engineering approach.