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Uncovering 3D microstructural and crystallographic texture evolution in additively manufactured alloys

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Laser powder bed fusion (LPBF) of metals produces hierarchical microstructures—melt pools, grains, dendrites, and dislocations—driven by high cooling rates and thermal gradients. These features lead to complex solidification dynamics and strong textures via epitaxial grain growth. Using fully automated large-volume 3D electron backscatter diffraction (EBSD), we reveal how grains evolve across melt pools, often extending through the build with notable lattice rotations. Our findings highlight mechanisms of grain orientation selection and point toward the design of programmable microstructures on-demand in metal additive manufacturing.

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