In situ observation of crystal rotation in Ni-based superalloy during additive manufacturing process.

Understanding the dynamic process of epitaxial microstructure forming in laser additive manufacturing is very important for achieving products with a single crystalline texture. Here, we perform in situ, real-time synchrotron Laue diffraction experiments to capture the microstructural evolution of nickel-based single-crystal superalloys during the rapid laser remelting process. In situ synchrotron radiation Laue diffraction characterises the crystal rotation behaviour and stray grain formation process. With a complementary thermomechanical coupled finite element simulation and molecular dynamics simulation, we identify that the crystal rotation is governed by the localised heating/cooling heterogeneity-induced deformation gradient and recognise that the sub-grain rotation caused by rapid dislocation movement could be the origin of granular stray grains at the bottom of the melt pool.