High-throughput material characterization using laser deposition additive manufacturing combined with high-flux in situ X-Ray analysis enhanced by further instrumentation

对材料科学、工程和生产技术的研究人员来说，批量材料筛选仍然是一个挑战。传统上，对于金属合金设计，小钢锭被浇注、热处理，并通过光学显微镜和机械测试等传统技术进行表征。在并行模拟中，例如基于热力学考虑，辅助合金设计。在塑料技术中，设计新材料的过程链是复合、造粒和注射成型，然后是常规分析。按照这些既定的程序，所有的实验步骤都非常耗时。此外，由于添加制造材料的微观结构和相关性能(至少对于金属而言)远未达到平衡，因此采用这些方法很难确定添加制造(AM)材料的特性。因此，必须实现允许批量快速筛选合金的新设施，同时考虑到相关的材料条件(AM)。激光沉积，结合使用高通量X射线衍射源的现场X射线分析，将能够解决这一领域的普遍空白。原则上，该系统的灵感来自于金属领域中用于合金筛选的两种最先进的方法：沉积薄膜材料库，然后高通量表征，以及通过同步辐射原位分析微观结构演变。值得注意的是，这两种方法都有其固有的缺陷。薄膜不能捕捉快速凝固(AM)材料的微观结构，并且薄膜的特性可能与其块体对应物不同。原位同步加速器分析是一个非常强大的工具；然而，束流时间受到严格的限制。所提出的系统可以克服这些问题，从而能够在高可用性下高通量地表征复杂的AM大宗材料库。使用不同的线材和粉末的激光沉积将允许制造大块样品，其中化学成分可以逐个样品和/或逐层变化。因此，可以考虑以金属、陶瓷和聚合物(基本材料和/或预合金)为基础的整体材料以及复合材料和材料复合材料。原位X射线衍射和X射线照相术将能够实时分析熔池动力学和内部缺陷的演变以及晶相的深入表征。此外，将在提案中进一步详细说明的其他仪器将有助于实时筛选显微结构和相关性能。首席调查人员将涵盖实现和有效使用拟议系统的所有相关方面(从激光加工到最后的性能评估，包括测量和控制、数据分析和在许多领域的应用)。

Material screening in bulk is still a challenge for researchers in materials science and engineering and production technology. Traditionally, for metal alloy design small ingots are cast, heattreated and characterized by conventional techniques, such as optical microscopy and mechanical testing. In parallel simulations, e.g. based on thermodynamic considerations, assist alloy design. In plastics technology the process chain for design of novel materials is compounding, granulating and injection molding followed by subsequent conventional analysis. Following these established procedures, all experimental steps are highly time consuming. Furthermore, characteristics for materials processed by additive manufacturing (AM) can hardly be established following these approaches, since microstructures and related properties of AM materials, at least for metals, are far from equilibrium.Thus, novel facilities allowing for rapid alloy screening in bulk have to be realized, taking into account the relevant material conditions (AM). Laser deposition, combined with in situ X-Ray analysis using a high-flux XRD source will allow for tackling prevailing gaps in this field. In principle, the proposed system is inspired by two state-of-the-art approaches used for alloy screening in the field of metals: deposition of thin-film materials libraries followed by high-throughput characterization, and in situ analysis of microstructure evolution by means of synchrotron radiation. It is important to note that both approaches have inherent drawbacks. Thin films are not able to capture microstructures of rapidly solidified (AM) materials and properties of thin films can differ from those of their bulk counterparts. In situ synchrotron analysis is a very powerful tool; however, beam time is strictly limited.The proposed system allows overcoming these issues and, thus, enables high-throughput characterization of complex AM bulk materials libraries at high availability. Laser deposition using different wires and powders will allow for manufacturing bulk samples, where chemical composition can vary sample by sample and/or layer by layer, respectively. Thereby, monolithic materials as well as composite materials and materials composites can be considered using metals, ceramics and polymers as basis (elementary materials and/or pre-alloys). In situ X-Ray diffraction and X-Ray radiography will allow for analysis of melt pool dynamics and evolution of internal defects as well as in-depth characterization of crystalline phases in real-time. Furthermore, additional instrumentation, which will be further detailed in the proposal, will assist screening of microstructures and related properties in real time. The principal investigators will cover all relevant aspects (from laser-based processing to final property evaluation including measurement and control, data analysis and application in numerous fields) for realization and efficient use of the proposed system.