Somayeh Pasebani

Profile Information
Name
Dr. Somayeh Pasebani
Institution
Oregon State University
Position
Assistant Professor
Affiliation
Oregon State University
h-Index
ORCID
0000-0001-8744-6598
Expertise
Advanced Manufacturing, Oxide Dispersion-Strengthened Alloy (ODS)
Publications:
"A Preliminary Investigation of High Dose Ion Irradiation Response of a Lanthana-Bearing Nanostructured Ferritic Steel Processed via Spark Plasma Sintering" Somayeh Pasebani, Indrajit Charit, Ankan Guria, Yaqiao Wu, Jatuporn Burns, Darryl Butt, James Cole, Lin Shao, Journal of Nuclear Materials Vol. 495 2017 78-84 Link
A lanthana-containing nanostructured ferritic steel (NFS) was processed via mechanical alloying (MA) of Fe-14Cr-1Ti-0.3Mo-0.5La2O3 (wt.%) and consolidated via spark plasma sintering (SPS). In order to study the consolidation behavior via SPS, sintering temperature and dwell time were correlated with microstructure, density, microhardness and shear yield strength of the sintered specimens. A bimodal grain size distribution including both micron-sized and nano-sized grains was observed in the microstructure of specimens sintered at 850, 950 and 1050 oC for 45 min. Significant densification occurred at temperatures greater than 950 oC with a relative density higher than 98%. A variety of nanoparticles, some enriched in Fe and Cr oxides and copious nanoparticles smaller than 10 nm with faceted morphology and enriched in La and Ti oxides were observed. After SPS at 950 oC, the number density of Cr-Ti-La-O enriched nanoclusters with an average radius of 1.5 nm was estimated to be 1.2 ×10^24 m^-3 . The La + Ti : O ratio was close to 1 after SPS at 950 and 1050 C; however, the number density of nanoclusters decreased at 1050 C. With SPS above 950 C, the density improved but the microhardness and shear yield strength decreased due to partial coarsening of the grains and nanoparticles.
"A preliminary study on the development of La2O3-bearing nanostructured ferritic steels via high energy ball milling" Somayeh Pasebani, Indrajit Charit, Darryl Butt, James Cole, Journal of Nuclear Materials Vol. 434 2013 282-286 Link
Elemental powder mixture of Fe–Cr–Ti–Mo and La2O3 were ball milled for different milling times in a high energy shaker mill. Effects of ball milling time on crystallite size, particle size and hardness were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM) and microhardness tester. After 10 h of ball milling, the smallest crystallite size and highest hardness were ~24 nm and ~970 HV, respectively. Transmission electron microscopy (TEM) studies have revealed nanoscale features 2–5 nm in diameter present in the milled powder. Local atom probe tomography studies have shown that these nanoscale features were possibly nanoclusters enriched in La, TiO and O.
"Effect of alloying elements on the microstructure and mechanical properties of nanostructured ferritic steels produced by spark plasma sintering" Indrajit Charit, Somayeh Pasebani, Journal of Alloys and Compounds Vol. 599 2014 206-211 Link
Several Fe–14Cr based alloys with varying compositions were processed using a combined route of mechanical alloying and spark plasma sintering. Microstructural characteristics of the consolidated alloys were examined via transmission electron microscopy and atom probe tomography, and mechanical properties evaluated using microhardness testing. Lanthanum oxide (0.5 wt.%) was added to Fe–14Cr leading to improvement in microstructural stability and mechanical properties mainly due to a high number density of La–Cr–O-enriched nanoclusters. The combined addition of La, Ti (1 wt.%) and Mo (0.3 wt.%) to the Fe–14Cr base composition further enhanced the microstructural stability and mechanical properties. Nanoclusters enriched in Cr–Ti–La–O with a number density of 1.4 × 1024 m-3 were found in this alloy with a bimodal grain size distribution. After adding Y2O3 (0.3 wt.%) along with Ti and Mo to the Fe–14Cr matrix, a high number density (1.5 × 1024 m-3) of Cr–Ti–Y–O-enriched NCs was also detected. Formation mechanism of these nanoclusters can be explained through the concentrations and diffusion rates of the initial oxide species formed during the milling process and initial stages of sintering as well as the thermodynamic nucleation barrier and their enthalpy of formation.
"Effect of alloying elements on the microstructure and mechanical properties of nanostructured ferritic steels produced by spark plasma sintering" Somayeh Pasebani, Indrajit Charit, Journal of Alloys and Compounds Vol. 599 2014 206-214 Link
"Effect of laser power and deposition sequence on microstructure of GRCop42Inconel 625 joints fabricated using laser directed energy deposition" Yu Lu, Somayeh Pasebani, Jakub Pries, Zexiao Wang, Jana Howard, Nick Wannenmacher, Sheng Shen, Brian Paul, Vol. 2024 Link
"High Temperature Tensile Properties and Related Microstructural Evolution in Grade 92 Steel" SULTAN ALSAGABI, Indrajit Charit, Somayeh Pasebani, Mechanical and Creep Behavior of Advanced Materials, Part of the Minerals, Metals & Materials Series (MMMS) Vol. 2017 229-242 Link
Ferritic-martensitic steels with good high temperature mechanical properties have many promising applications in fossil and nuclear power plants. In this work, a F92 steel was tensile tested from room to elevated temperatures (up to 700 °C). This material exhibited higher strength than traditional P92 steels. The reasons for the observed changes in mechanical properties were investigated by studying the microstructural characteristics in undeformed and deformed specimens using transmission electron microscopy. The microstructural evolution accelerated significantly under loading as temperature increased. For instance, the deformed microstructure at 600 °C showed early stages of M23C6 precipitate formation under loading. The M23C6 precipitates exhibited more coarsening tendency whereas the MX-type precipitates retained their size. As coarsening of M23C6 precipitates progressed at elevated temperatures, the strength gradually decreased as the solid solution strengthening deteriorated by removing W and Mo from the solid solution matrix.
"Lanthana-bearing nanostructured ferritic steels via spark plasma sintering" SULTAN ALSAGABI, Darryl Butt, Indrajit Charit, James Cole, Somayeh Pasebani, Yaqiao Wu, Jatuporn Burns, Kerry Allahar, Journal of Nuclear Materials Vol. 470 2016 297-306 Link
A lanthana-containing nanostructured ferritic steel (NFS) was processed via mechanical alloying (MA) of Fe-14Cr-1Ti-0.3Mo-0.5La2O3 (wt.%) and consolidated via spark plasma sintering (SPS). In order to study the consolidation behavior via SPS, sintering temperature and dwell time were correlated with microstructure, density, microhardness and shear yield strength of the sintered specimens. A bimodal grain size distribution including both micron-sized and nano-sized grains was observed in the microstructure of specimens sintered at 850, 950 and1050 °C for 45 min. Significant densification occurred at temperatures greater than 950 °C with a relative density higher than 98%. A variety of nanoparticles, some enriched in Fe and Cr oxides and copious nanoparticles smaller than 10 nm with faceted morphology and enriched in La and Ti oxides were observed. After SPS at 950 °C, the number density of Cr–Ti–La–O-enriched nanoclusters with an average radius of 1.5 nm was estimated to be 1.2 × 1024 m−3. The La + Ti:O ratio was close to 1 after SPS at 950 and 1050 °C; however, the number density of nanoclusters decreased at 1050 °C. With SPS above 950 °C, the density improved but the microhardness and shear yield strength decreased due to partial coarsening of the grains and nanoparticles.
"Mechanical Alloying of Lanthana-Bearing Nanostructured Ferritic Steels" Darryl Butt, James Cole, Somayeh Pasebani, Yaqiao Wu, Indrajit Charit, Acta Materialia Vol. 61 2013 5605-5617 Link
A novel nanostructured ferritic steel powder with the nominal composition Fe–14Cr–1Ti–0.3Mo–0.5La2O3 (wt.%) was developed via high energy ball milling. La2O3 was added to this alloy instead of the traditionally used Y2O3. The effects of varying the ball milling parameters, such as milling time, steel ball size and ball to powder ratio, on the mechanical properties and microstructural characteristics of the as-milled powder were investigated. Nanocrystallites of a body-centered cubic ferritic solid solution matrix with a mean size of approximately 20 nm were observed by transmission electron microscopy. Nanoscale characterization of the as-milled powder by local electrode atom probe tomography revealed the formation of Cr–Ti–La–O-enriched nanoclusters during mechanical alloying. The Cr:Ti:La:O ratio is considered “non-stoichiometric”. The average size (radius) of the nanoclusters was about 1 nm, with number density of 3.7x10^24 m^-3. The mechanism for formation of nanoclusters in the as-milled powder is discussed. La2O3 appears to be a promising alternative rare earth oxide for future nanostructured ferritic steels.
"Microstructural stability of a self-ion irradiated lanthana-bearing nanostructured ferritic steel" SULTAN ALSAGABI, Darryl Butt, Indrajit Charit, James Cole, Somayeh Pasebani, Lin Shao, Jatuporn Burns, Lloyd Price, Journal of Nuclear Materials Vol. 462 2015 191-204 Link
Thermally stable nanofeatures with high number density are expected to impart excellent high temperature strength and irradiation stability in nanostructured ferritic steels (NFSs) which have potential applications in advanced nuclear reactors. A lanthana-bearing NFS (14LMT) developed via mechanical alloying and spark plasma sintering was used in this study. The sintered samples were irradiated by Fe2+ ions to 10, 50 and 100 dpa at 30 °C and 500 °C. Microstructural and mechanical characteristics of the irradiated samples were studied using different microscopy techniques and nanoindentation, respectively. Overall morphology and number density of the nanofeatures remained unchanged after irradiation. Average radius of nanofeatures in the irradiated sample (100 dpa at 500 °C) was slightly reduced. A notable level of irradiation hardening and enhanced dislocation activity occurred after ion irradiation except at 30 °C and ⩾50 dpa. Other microstructural features like grain boundaries and high density of dislocations also provided defect sinks to assist in defect removal.
"Processing of a novel nanostructured ferritic steel via spark plasma sintering and investigation of its mechanical and microstructural characteristics" Darryl Butt, Indrajit Charit, James Cole, Somayeh Pasebani, Yaqiao Wu, Jatuporn Burns, Kerry Allahar, INIS Repository Vol. 46 2015 Link
Nano-structured ferritic steels (NFSs) with 12-14 wt% Cr have attracted widespread interest for potential high temperature structural and fuel cladding applications in advanced nuclear reactors. They have excellent high temperature mechanical properties and high resistance to radiation-induced damage. The properties of the NFSs depend on the composition that mainly consists of Cr, Ti, W or Mo, and Y2O3 as alloying constituents. In this study, a novel nano-structured ferritic steel (Fe-14Cr-1Ti-0.3Mo-0.5La2O3, wt%) termed as 14LMT was developed via high energy ball milling and spark plasma sintering. Vickers microhardness values were measured. Microstructural studies of the developed NFSs were performed by EBSD and TEM, which revealed a bimodal grain size distribution. A significant number density of nano-precipitates was observed in the microstructure. The diameter of the precipitates varied between 2-70 nm and the morphology from the spherical to faceted shape. The Cr-La-Ti-O-enriched nano-clusters were identified by APT studies.
"Sintering Behavior of Lanthana-Bearing Nanostructured Ferritic Steel Consolidated via Spark Plasma Sintering" Darryl Butt, Indrajit Charit, James Cole, Somayeh Pasebani, Yaqiao Wu, Jatuporn Burns, Advanced Engineering Materials Vol. 18 2015 324-332 Link
Elemental powder mixture of Fe–14Cr–1Ti–0.3Mo–0.5La2O3(wt%) composition is mechanicallyalloyed for different milling durations (5, 10 and 20 h) and subsequently consolidated via spark plasmasintering under vacuum at 950?C for 7 min. The effects of milling time on the densi?cation behaviorand density/microhardness are studied. The sintering activation energy is found to be close to that ofgrain boundary diffusion. The bimodal grain structure created in the milled and sintered material isfound to be a result of milling and not of sintering alone. The oxide particle diameter varies between2 and 70 nm. Faceted precipitates smaller than 10 nm in diameter are found to be mostly La–Ti–Cr-enriched complex oxides that restrict further recrystallization and related phenomena
"The Irradiation Performance and Microstructural Evolution in 9Cr-2W Steel Under Ion Irradiation" SULTAN ALSAGABI, Indrajit Charit, Somayeh Pasebani, Journal of Materials Engineering and Performance Vol. 25 2015 401-408 Link
Grade 92 steel (9Cr-2W) is a ferritic-martensitic steel with good mechanical and thermal properties. It is being considered for structural applications in Generation IV reactors. Still, the irradiation performance of this alloy needs more investigation as a result of the limited available data. The irradiation performance investigation of Grade 92 steel would contribute to the understanding of engineering aspects including feasibility of application, economy, and maintenance. In this study, Grade 92 steel was irradiated by iron ion beam to 10, 50, and 100 dpa at 30 and 500 °C. In general, the samples exhibited good radiation damage resistance at these testing parameters. The radiation-induced hardening was higher at 30 °C with higher dislocation density; however, the dislocation density was less pronounced at higher temperature. Moreover, the irradiated samples at 30 °C had defect clusters and their density increased at higher doses. On the other hand, dislocation loops were found in the irradiated sample at 50 dpa and 500 °C. Further, the irradiated samples did not show any bubble or void.
"Use of Bimodal Particle Size Distribution in Selective Laser Melting of 316L Stainless Steel" Somayeh Pasebani, Journal of Manufacturing and Materials Processing 4 (1), 8 (2020) 1-16. Vol. 8 2020 1-16
Presentations:
"Processing of a Novel Nanostructured Ferritic Steel via Spark Plasma Sintering and Investigation of Its Mechanical and Microstructural Characteristics" Darryl Butt, Indrajit Charit, James Cole, Somayeh Pasebani, Yaqiao Wu, SMINS-3 October 7-10, (2013)
Additional Publications:
"Joining Inconel 718 and GRCop42: A framework for developing transition compositions to avoid cracking and brittle phase formation" Stephanie B. Lawson, Nick Wannenmacher, Somayeh Pasebani, Jakub Preis, [2025] Materials & Design · DOI: 10.1016/j.matdes.2025.113733
"Multiscale Modeling of Nanoparticle Precipitation in Oxide Dispersion-Strengthened Steels Produced by Laser Powder Bed Fusion" Seongun Yang, Stephanie B. Lawson, Cheng-Hsiao Tsai, V. Vinay K. Doddapaneni, Marc Albert, Benjamin Sutton, Chih-Hung Chang, Somayeh Pasebani, Donghua Xu, Zhengming Wang, [2024] Materials · DOI: 10.3390/ma17225661

Laser Powder Bed Fusion (LPBF) enables the efficient production of near-net-shape oxide dispersion-strengthened (ODS) alloys, which possess superior mechanical properties due to oxide nanoparticles (e.g., yttrium oxide, Y-O, and yttrium-titanium oxide, Y-Ti-O) embedded in the alloy matrix. To better understand the precipitation mechanisms of the oxide nanoparticles and predict their size distribution under LPBF conditions, we developed an innovative physics-based multiscale modeling strategy that incorporates multiple computational approaches. These include a finite volume method model (Flow3D) to analyze the temperature field and cooling rate of the melt pool during the LPBF process, a density functional theory model to calculate the binding energy of Y-O particles and the temperature-dependent diffusivities of Y and O in molten 316L stainless steel (SS), and a cluster dynamics model to evaluate the kinetic evolution and size distribution of Y-O nanoparticles in as-fabricated 316L SS ODS alloys. The model-predicted particle sizes exhibit good agreement with experimental measurements across various LPBF process parameters, i.e., laser power (110–220 W) and scanning speed (150–900 mm/s), demonstrating the reliability and predictive power of the modeling approach. The multiscale approach can be used to guide the future design of experimental process parameters to control oxide nanoparticle characteristics in LPBF-manufactured ODS alloys. Additionally, our approach introduces a novel strategy for understanding and modeling the thermodynamics and kinetics of precipitation in high-temperature systems, particularly molten alloys.

"A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing" Milad Ghayoor, V. Vinay K. Doddapaneni, Kenta Noma, Somayeh Pasebani, Chih-Hung Chang, Brian Fronk, Brian K. Paul, Kijoon Lee, [2024] Journal of Manufacturing Science and Engineering · DOI: 10.1115/1.4065820 · ISSN: 1087-1357
Abstract

This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

"A FeCrAl-Al2O3 Composite Produced Via Laser Powder Bed Fusion of a Mixed Powder for Porous Catalyst Scaffolds" Hsin-Mei Kao, Patrick McNeff, Seongun Yang, Nahal Ghanadi, Somayeh Pasebani, Chi-hung Chang, Brian K. Paul, Kwangtae Son, [2024] Journal of Micro and Nano Science and Engineering · DOI: 10.1115/1.4066114 · ISSN: 2994-7316
Abstract

This study proposes a novel approach for synthesizing and etching bicontinuous FeCrAl-Al2O3 composites as a means for replacing FeCrAl foams as catalyst scaffolds in biodriven alcohol reactors for jet-fuel production. Conventional FeCrAl foams suffer from poor availability and consequent high costs. New additive manufacturing techniques provide an opportunity to produce tailored foams at reasonable times and at acceptable costs. This research aimed to generate a porous FeCrAl structure by etching a bicontinuous FeCrAl-Al2O3 composite produced by laser powder bed fusion of amalgamated FeCrAl and Al2O3 powders. The composite powder for laser powder bed fusion is created by ball-milling FeCrAl and Al2O3 powders. This research focuses on achieving a bi-continuous FeCrAl-Al2O3 structure, essential for the selective removal of the ceramic phase. The influence of laser processing parameters on the microstructure was examined across a range of laser powers (60–120 W) and scan speeds (100–400 mm/s), showing that higher powers and speeds produce finer metal struts. A bi-continuous microstructure was consistently obtained, marking a key achievement. The Al2O3 removal process involved a two-step etching method using hydrochloric and phosphoric acids, tested across various etching times. The alumina phase was reduced from 36 vol% to 17 vol% (corresponding to an increase in porosity from 24 vol% to 43 vol%), showing the potential for use as a porous catalyst scaffold. This research demonstrates the potential for using additive manufacturing to produce porous FeCrAl structures capable of replacing hard-to-source FeCrAl foams.

"Effect of laser power and deposition sequence on microstructure of GRCop42 - Inconel 625 joints fabricated using laser directed energy deposition" Zexiao Wang, Jana Howard, Yu Lu, Nick Wannenmacher, Sheng Shen, Brian K. Paul, Somayeh Pasebani, Jakub Preis, [2024] Materials & Design · DOI: 10.1016/j.matdes.2024.112944
"A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths" Somayeh Pasebani, Nahal Ghanadi, [2024] Journal of Manufacturing and Materials Processing · DOI: 10.3390/jmmp8020084

Wire-laser directed energy deposition has emerged as a transformative technology in metal additive manufacturing, offering high material deposition efficiency and promoting a cleaner process environment compared to powder processes. This technique has gained attention across diverse industries due to its ability to expedite production and facilitate the repair or replication of valuable components. This work reviews the state-of-the-art in wire-laser directed energy deposition to gain a clear understanding of key process variables and identify challenges affecting process stability. Furthermore, this paper explores modeling and monitoring methods utilized in the literature to enhance the final quality of fabricated parts, thereby minimizing the need for repeated experiments, and reducing material waste. By reviewing existing literature, this paper contributes to advancing the current understanding of wire-laser directed energy deposition technology. It highlights the gaps in the literature while underscoring research needs in wire-laser directed energy deposition.

"Multi-metal additive manufacturing of selectively doped 316 L stainless steel-copper composite using hybrid laser powder bed fusion" V. Vinay K. Doddapaneni, Saereh Mirzababaei, Somayeh Pasebani, Chih-Hung Chang, Brian K. Paul, Kijoon Lee, [2024] Additive Manufacturing · DOI: 10.1016/j.addma.2024.104202 · ISSN: 2214-8604
"Atomic Diffusivities of Yttrium, Titanium and Oxygen Calculated by Ab Initio Molecular Dynamics in Molten 316L Oxide-Dispersion-Strengthened Steel Fabricated via Additive Manufacturing" Seongun Yang, Stephanie B. Lawson, V. Vinay K. Doddapaneni, Marc Albert, Benjamin Sutton, Chih-Hung Chang, Somayeh Pasebani, Donghua Xu, Zhengming Wang, [2024] Materials · DOI: 10.3390/ma17071543

Oxide-dispersion-strengthened (ODS) steels have long been viewed as a prime solution for harsh environments. However, conventional manufacturing of ODS steels limits the final product geometry, is difficult to scale up to large components, and is expensive due to multiple highly involved, solid-state processing steps required. Additive manufacturing (AM) can directly incorporate dispersion elements (e.g., Y, Ti and O) during component fabrication, thus bypassing the need for an ODS steel supply chain, the scale-up challenges of powder processing routes, the buoyancy challenges associated with casting ODS steels, and the joining issues for net-shape component fabrication. In the AM process, the diffusion of the dispersion elements in the molten steel plays a key role in the precipitation of the oxide particles, thereby influencing the microstructure, thermal stability and high-temperature mechanical properties of the resulting ODS steels. In this work, the atomic diffusivities of Y, Ti, and O in molten 316L stainless steel (SS) as functions of temperature are determined by ab initio molecular dynamics simulations. The latest Vienna Ab initio Simulation Package (VASP) package that incorporates an on-the-fly machine learning force field for accelerated computation is used. At a constant temperature, the time-dependent coordinates of the target atoms in the molten 316L SS were analyzed in the form of mean square displacement in order to obtain diffusivity. The values of the diffusivity at multiple temperatures are then fitted to the Arrhenius form to determine the activation energy and the pre-exponential factor. Given the challenges in experimental measurement of atomic diffusivity at such high temperatures and correspondingly the lack of experimental data, this study provides important physical parameters for future modeling of the oxide precipitation kinetics during AM process.

"Effect of Liquid Miscibility Gap on Defects in Inconel 625–GRCop42 Joints through Analysis of Gradient Composition Microstructure" Donghua Xu, Brian K. Paul, Peter A. Eschbach, Somayeh Pasebani, Jakub Preis, [2024] Journal of Manufacturing and Materials Processing · DOI: 10.3390/jmmp8010042

Joining of Cu-based dispersion-strengthened alloys to Ni-based superalloys has garnered increased attention for liquid rocket engine applications due to the high thermal conductivity of Cu-based alloys and high temperature tensile strength of Ni-based superalloys. However, such joints can suffer from cracking when joined via liquid state processes, leading to part failure. In this work, compositions of 15–95 wt.% GRCop42 are alloyed with Inconel 625 and characterized to better understand the root cause of cracking. Results indicate a lack of miscibility between Cu-deprived and Cu-rich liquids in compositions corresponding to 30–95 wt.% GRCop42. Two distinct morphologies are observed and explained by use of CALPHAD; Cu-deprived dendrites with Cu-rich interdendritic zones at 30–50 wt.% GRCop42 and Cu-deprived spheres surrounded by a Cu-rich matrix at 60–95 wt.% GRCop42. Phase analysis reveals brittle intermetallic phases precipitate in the 60–95 wt.% GRCop42 Cu-deprived region. Three cracking mechanisms are proposed herein that provide guidance on the avoidance of defects Ni-based superalloy to Cu-based dispersion strengthened alloy joints.

"A Review on Progress, Challenges, and Prospects of Material Jetting of Copper and Tungsten" Kijoon Lee, Havva Eda Aysal, Brian K. Paul, Somayeh Pasebani, Konstantinos A. Sierros, Chinedum E. Okwudire, Chih-hung Chang, V. Vinay K. Doddapaneni, [2023] Nanomaterials · DOI: 10.3390/nano13162303

Copper (Cu) and tungsten (W) possess exceptional electrical and thermal conductivity properties, making them suitable candidates for applications such as interconnects and thermal conductivity enhancements. Solution-based additive manufacturing (SBAM) offers unique advantages, including patterning capabilities, cost-effectiveness, and scalability among the various methods for manufacturing Cu and W-based films and structures. In particular, SBAM material jetting techniques, such as inkjet printing (IJP), direct ink writing (DIW), and aerosol jet printing (AJP), present a promising approach for design freedom, low material wastes, and versatility as either stand-alone printers or integrated with powder bed-based metal additive manufacturing (MAM). Thus, this review summarizes recent advancements in solution-processed Cu and W, focusing on IJP, DIW, and AJP techniques. The discussion encompasses general aspects, current status, challenges, and recent research highlights. Furthermore, this paper addresses integrating material jetting techniques with powder bed-based MAM to fabricate functional alloys and multi-material structures. Finally, the factors influencing large-scale fabrication and potential prospects in this area are explored.

"Remarkable enhancement in thermal conductivity of stainless-steel leveraging metal composite via laser powder bed fusion: 316L-Cu composite" V. Vinay.K. Doddapaneni, Kijoon Lee, Gabrielle E. Paul, Hadi Pirgazi, Kim-Seah Tan, Osman Ertorer, Chih-hung Chang, Brian K. Paul, Somayeh Pasebani, Saereh Mirzababaei, [2023] Additive Manufacturing · DOI: 10.1016/j.addma.2023.103576
"Thermal Profile Modeling and Microstructural Evolution in Laser Processing of Inconel 625 Plates" Milad Ghayoor, Ali Tabei, Somayeh Pasebani, Stephanie Lawson, [2023] · DOI: 10.21203/rs.3.rs-2743943/v1
Abstract

Thermal modeling is used in additive manufacturing laser processes to predict microstructural evolution of the materials under specified process conditions and parameters. The objective of this study was to develop, analyze and compare two predictive models: an analytical model and a numerical model for laser processing of materials of Inconel 625. These models were compared with experimental results for thermal profiling, and the effect of thermal profiles on microstructure of the experimental samples was explored. The three approaches; analytical modeling, numerical modeling, and experimental results were evaluated against thermal profile histories and correlated to microstructural evolution in laser processing. Maximum temperatures in the thermal profile of both models were shown in good agreement when compared to the experimental results. Cooling curves were also correlated with microstructure in terms of grain size, morphology, orientation, and texture evolution, with findings that match previously reported results. This research validates the proposed numerical model for examining optimal laser processing conditions for IN625 through both thermal history and microstructure comparison with experimental results using literature derived thermo-physical material properties.

"Electrochemical behavior of alloy 22 processed by laser powder bed fusion (L-PBF) in simulated seawater and acidic aqueous environments" Dongqing Yan, Gabrielle E. Paul, Hamidreza Torbati-Sarraf, Behrang Poorganji, Osman Ertorer, Kim-Seah Tan, Somayeh Pasebani, S. Alireza Torbati-Sarraf, O. Burkan Isgor, Kai Coldsnow, [2022] Electrochimica Acta · DOI: 10.1016/j.electacta.2022.140519
"A Scalable Solution Route to Porous Networks of Nanostructured Black Tungsten" Kijoon Lee, Tyler T. Colbert, Saereh Mirzababaei, Brian K. Paul, Somayeh Pasebani, Chih-Hung Chang, V. Vinay K. Doddapaneni, [2021] Nanomaterials · DOI: 10.3390/nano11092304

This paper studied the feasibility of a new solution-processed method to manufacture black tungsten nanostructures by laser conversion of tungsten hexacarbonyl precursor on the Inconel 625 substrate under argon atmosphere at ambient pressure. The results show that sublimation of the precursor can be prevented if the decomposition temperature (>170 °C) is achieved using the laser heating method. Three different laser powers from 60–400 W were used to investigate the role of laser parameters on the conversion. It was found that lower laser power of 60 W resulted in a mixture of unconverted precursor and converted tungsten. Higher laser powers >200 W resulted in α-W (BCC) in one step without further heat treatment. Different oxygen concentrations from 0.5 ppm to 21 vol% were used in the laser canister to investigate the effect of oxygen concentration on the conversion. It was found that the hard vacuum (>10−4 torr) or hydrogen is not necessary to obtain α-W (BCC). The solar absorptance varied from 63–97%, depending on the amount of precursor deposited on the substrate and oxygen content in the laser canister. This solution-based laser conversion of tungsten precursor is a scalable method to manufacture tungsten coatings for high-temperature applications.

"Passivation and Chloride-Induced Depassivation of Additively Manufactured Duplex Stainless Steel Clads in Simulated Concrete Pore Solution" Kai Coldsnow, Melissa McAlexander, Hunter M. Rada, Somayeh Pasebani, O. Burkan Isgor, Pratik Murkute, [2021] Journal of Materials in Civil Engineering · DOI: 10.1061/(asce)mt.1943-5533.0003833
"Fast Predictive Model of Crystallographic Texture Evolution in Metal Additive Manufacturing" Milad Ghayoor, Somayeh Pasebani, Ali Tabei, Yucong Lei, [2021] Crystals · DOI: 10.3390/cryst11050482

This communication introduces a fast material- and process-agnostic modeling approach, not reported in the open literature, that is calibrated for predicting the evolution of texture in metal additive manufacturing of stainless steel 304L as a function of a process parameter, namely the laser scanning speed. The outputs of the model are compared against independent validation experiments for the same material system and show excellent consistency. The model also predicts a trend in the change of texture intensity as a function of the process parameter. The major novelty and strength of this work is the model’s speed and extremely light computational load. The model’s calibrations and predictions were carried out in 9.2 s on a typical desktop computer.

"The effect of annealing on the selective laser melting of 2205 duplex stainless steel: Microstructure, grain orientation, and manufacturing challenges" O. Burkan Isgor, Somayeh Pasebani, Greg N. Nigon, [2021] Optics & Laser Technology · DOI: 10.1016/j.optlastec.2020.106643
"Effect of Build Orientation and Annealing on Corrosion Resistance of Additively Manufactured Duplex Stainless Steel in 3.5% NaCl" O. Burkan Isgor, Somayeh Pasebani, Greg N. Nigon, [2020] Journal of The Electrochemical Society · DOI: 10.1149/1945-7111/abc5dd
"Metal Powder Recyclability in Binder Jet Additive Manufacturing" Brian K. Paul, Somayeh Pasebani, Saereh Mirzababaei, [2020] JOM · DOI: 10.1007/s11837-020-04258-6
"Use of Bimodal Particle Size Distribution in Selective Laser Melting of 316L Stainless Steel" Somayeh Pasebani, Hannah G. Coe, [2020] Journal of Manufacturing and Materials Processing · DOI: 10.3390/jmmp4010008

Spherical powders with single-mode (D50 = 36.31 µm), and bimodal (D50,L = 36.31 µm, D50,s = 5.52 µm) particle size distribution were used in selective laser melting of 316L stainless steel in nitrogen atmosphere at volumetric energy densities ranging from 35.7–116.0 J/mm3. Bimodal particle size distribution could provide up to 2% greater tap density than single-mode powder. For low laser power (107–178 W), where relative density was <99%, bimodal feedstock resulted in higher density than single-mode feedstock. However, at higher power (>203 W), the density of bimodal-fed components decreased as the energy density increased due to vaporizing of the fine powder in bimodal distributions. Size of intergranular cell regions did not appear to vary significantly between single-mode and bimodal specimens (0.394–0.531 µm2 at 81–116 J/mm3). Despite higher packing densities in powder feedstock with bimodal particle size distribution, the results of this study suggest that differences in conduction melting and vaporization points between the two primary particle sizes would limit the maximum achievable density of additively manufactured components produced from bimodal powder size distribution.

"A Review on Binder Jet Additive Manufacturing of 316L Stainless Steel" Somayeh Pasebani, Saereh Mirzababaei, [2019] Journal of Manufacturing and Materials Processing · DOI: 10.3390/jmmp3030082

Binder jet additive manufacturing enables the production of complex components for numerous applications. Binder jetting is the only powder bed additive manufacturing process that is not fusion-based, thus manufactured parts have no residual stresses as opposed to laser-based additive manufacturing processes. Binder jet technology can be adopted for the production of various small and large metallic parts for specific applications, including in the biomedical and energy sectors, at a lower cost and shorter lead time. One of the most well-known types of stainless steels for various industries is 316L, which has been extensively manufactured using binder jet technology. Binder jet manufactured 316L parts have obtained near full density and, in some cases, similar mechanical properties compared to conventionally manufactured parts. This article introduces methods, principles, and applications of binder jetting of SS 316L. Details of binder jetting processes, including powder characteristics (shape and size), binder properties (binder chemistry and droplet formation mechanism), printing process parameters (such as layer thickness, binder saturation, drying time), and post-processing sintering mechanism and densification processes, are carefully reviewed. Furthermore, critical factors in the selection of feedstock, printing parameters, sintering temperature, time, atmosphere, and heating rate of 316L binder jet manufactured parts are highlighted and summarized. Finally, the above-mentioned processing parameters are correlated with final density and mechanical properties of 316L components to establish a guideline on feedstock selection and process parameters optimization to achieve desired density, structure and properties for various applications.

"Effects of particle characteristics on the microstructure and mechanical properties of 17-4 PH stainless steel fabricated by laser-powder bed fusion" John Samuel Dilip Jangam, Somayeh Pasebani, Sunil Badwe, Jason Stitzel, Kunal Kate, Ozkan Gulsoy, Sundar V. Atre, Harish Irrinki, [2018] Powder Technology · DOI: 10.1016/j.powtec.2018.03.025
"Effects of Powder Attributes and Laser Powder Bed Fusion (L-PBF) Process Conditions on the Densification and Mechanical Properties of 17-4 PH Stainless Steel" Michael Dexter, Brenton Barmore, Ravi Enneti, Somayeh Pasebani, Sunil Badwe, Jason Stitzel, Rajiv Malhotra, Sundar V. Atre, Harish Irrinki, [2016] JOM · DOI: 10.1007/s11837-015-1770-4 · EID: 2-s2.0-84959161309
"Lanthana-bearing nanostructured ferritic steels via spark plasma sintering" Indrajit Charit, Yaqiao Wu, Jatuporn Burns, Kerry N. Allahar, Darryl P. Butt, James I. Cole, Sultan F. Alsagabi, Somayeh Pasebani, [2016] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2015.12.035 · EID: 2-s2.0-84953706400
"On the creep behavior of dual-scale particle strengthened nickel based alloy" Somayeh Pasebani, Indrajit Charit, Rajiv S. Mishra, Aniket K. Dutt, [2016] Materials Science and Engineering A · DOI: 10.1016/j.msea.2016.09.008 · EID: 2-s2.0-84989864749
"Sintering Behavior of Lanthana-Bearing Nanostructured Ferritic Steel Consolidated via Spark Plasma Sintering" Indrajit Charit, Darryl P. Butt, James I. Cole, Yaqiao Wu, Jatuporn Burns, Somayeh Pasebani, [2016] Advanced Engineering Materials · DOI: 10.1002/adem.201500294 · EID: 2-s2.0-84958914999
"The Irradiation Performance and Microstructural Evolution in 9Cr-2W Steel Under Ion Irradiation" Indrajit Charit, Somayeh Pasebani, Sultan Alsagabi, [2016] Journal of Materials Engineering and Performance · DOI: 10.1007/s11665-015-1841-2 · EID: 2-s2.0-84957432244
"Effect of tool rotation rate on constituent particles in a friction stir processed 2024Al alloy" Indrajit Charit, Rajiv S. Mishra, Somayeh Pasebani, [2015] Materials Letters · DOI: 10.1016/j.matlet.2015.07.074 · EID: 2-s2.0-84937927474
"Microstructural stability of a self-ion irradiated lanthana-bearing nanostructured ferritic steel" Indrajit Charit, Jatuporn Burns, Sultan Alsagabi, Darryl P. Butt, James I. Cole, Lloyd M. Price, Lin Shao, Somayeh Pasebani, [2015] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2015.03.040 · EID: 2-s2.0-84953860379
"Oxide dispersion strengthened nickel based alloys via spark plasma sintering" Aniket K. Dutt, Jatuporn Burns, Indrajit Charit, Rajiv S. Mishra, Somayeh Pasebani, [2015] Materials Science and Engineering A · DOI: 10.1016/j.msea.2015.01.066 · EID: 2-s2.0-84924208404
"Effect of alloying elements on the microstructure and mechanical properties of nanostructured ferritic steels produced by spark plasma sintering" Indrajit Charit, Somayeh Pasebani, [2014] Journal of Alloys and Compounds · DOI: 10.1016/j.jallcom.2014.01.243 · EID: 2-s2.0-84896127150
"Nickel-chromium alloys: Engineered microstructure via spark plasma sintering" [2014] Materials Science Forum · EID: 2-s2.0-84904571197
"A preliminary study on the development of La2O 3-bearing nanostructured ferritic steels via high energy ball milling" Indrajit Charit, Darryl P. Butt, James I. Cole, Somayeh Pasebani, [2013] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2012.11.020 · EID: 2-s2.0-84871799178
"Mechanical alloying of lanthana-bearing nanostructured ferritic steels" I. Charit, Y.Q. Wu, D.P. Butt, J.I. Cole, S. Pasebani, [2013] Acta Materialia · DOI: 10.1016/j.actamat.2013.06.002 · EID: 2-s2.0-84881479727
"Nano-grained 70/30 brass strip produced by accumulative roll-bonding (ARB) process" Mohammad Reza Toroghinejad, Somayeh Pasebani, [2010] Materials Science and Engineering A · DOI: 10.1016/j.msea.2009.09.029 · EID: 2-s2.0-71849092752
"Textural evolution of nano-grained 70/30 brass produced by accumulative roll-bonding" Mohammad Reza Toroghinejad, Majid Hosseini, Jerzy Szpunar, Somayeh Pasebani, [2010] Materials Science and Engineering A · DOI: 10.1016/j.msea.2010.01.005 · EID: 2-s2.0-75849163036
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