Directed Energy Deposition (DED) is a metal 3D printing process. In this process, small metal powders are blown through a nozzle onto a block of metal and melted with a high-powered laser to form new, solid metal. An object is made by creating many layers of new metal from the powders. DED is very popular for making complex or customizable parts, such as car engine blocks or hip implants. However, very small pores are commonly left in the part. These pores can cause catastrophic failures, meaning the object that was just made can suddenly break in half or have a large crack in it when it is being used. Therefore, it is important to understand how pores form and how to get rid of them. The powerful x-ray beam used to capture this image can show what is happening inside the metal as it is melted, such as pore formation or how powder is incorporated into the melt pool.

Samantha Webster

Department of Theoretical and Applied Mecanics 

Tools & Techniques: Advanced Photon Source, Beamline 32-ID