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With one type of X-ray light, they create micron-resolution images of what happens as the layers of metal build up.

SLAC researchers use two X-ray methods to see what happens during metal 3D printing. X-rays, however, proved to be an excellent way to see and record what’s happening inside parts as they’re being built. They tried using IR imaging on the layers, but this did not give them much information on what was causing weak spots. But they couldn’t see below the surface of the metal, so it was impossible to tell how deeply the laser was melting the layers as each one was applied. Until recently, researchers watched from above as layers were created and added to form parts.

They want to find the best combination of these parameters for eliminating pits, controlling the microstructure, and manufacturing strong metal parts. In the SLAC X-ray experiments, scientists are analyzing every aspect of the printing process, including the kinds of metal used, the laser’s heat level, and the speed at which the metal heats and cools. (Dawn Harmer/SLAC)ģD printing metal often results in pits or weak spots when the metal cools and hardens unevenly while building up the layers. SLAC staff scientist Johanna Nelson Weker, front, leads a study on metal 3D printing at SLAC’s Stanford Synchrotron Radiation Lightsource with researchers Andrew Kiss and Nick Calta, rear. If 3D printing were better understood and could reliably prints flawless parts, the need for qualification testing would diminish and manufacturing costs could come down. We still need to figure out all of the parameters involved in making solid, strong parts.”Ĭurrently, companies such as General Electric and Boeing build metal parts with 3D printing, but each part and 3D printer must pass vigorous qualifications. “Theoretically, 3D printing can be a quick turnaround, simply design, send, print from a remote location,” says SLAC staff scientist Johanna Nelson Weker, who is leading the project. The aim is to help manufacturers build more reliable parts whether in a factory, on a ship or plane, or even remotely in space, and do it more efficiently.

Scientists at the Department of Energy’s SLAC National Accelerator Laboratory are using X-ray light to observe and understand why the process of 3D printing metal parts leaves flaws in finished parts and how those flaws can be avoided.