Research

ADDITIVE MANUFACTURING (3D PRINTING):

We used advanced electron microscopy and computational analyses to reveal the underlying mechanism responsible for the microstructure development and mechanical performance in 3D printing of alloys. Our recent study is a highly cited paper and featured in Nature Communications's Metallurgy Collection.

Selected references:

  1. Alloy design against the solidification cracking in fusion additive manufacturing: an application to a FeCrAl alloy, Materials Research Letters (2021), 9 (8), 350-357, B. Dovgyy, M Simonelli, M.S. Pham,

  2. Micro-cracking, microstructure and mechanical properties of Hastelloy-X alloy printed by laser powder bed fusion: as-built, annealed and hot-isostatic pressed, Additive Manufacturing, 101853 (2021), H Wang, L Chen, B Dovgyy, W Xu, A Sha, X Li, H Tang, Y Liu, H Wu, M.S. Pham

  3. Creep deformation and failure properties of 316L stainless steel manufactured by laser powder bed fusion under multiaxial loading conditions, Additive Manufacturing, 101706 (2020), R. Williams, J. Al-Lami, P.A. Hooper, M.S. Pham,C.M. Davies,

  4. The role of side-branching in microstructure development in laser powder-bed fusion, MS Pham, B Dovgyy, P Hooper, C. Gourlay, A. Piglione, Nature Communications 11, 749, 2020.

  5. Damage-tolerant architected materials inspired by crystal microstructure, M.S. Pham, C. Liu, I. Todd, J. Lerttharnasarn, Nature, 565, 305-311 (2019)

  6. Cyclic plasticity and fatigue damage of CrMnFeCoNi high entropy alloy fabricated by laser powder-bed fusion, Additive Manufacturing, 36, 101584 (2020), M.S. Jin, A. Piglione, B. Dovgyy, E. Hosseini, P. A. Hooper, S. R. Holdsworth, M. S. Pham

  7. Comprehensive assessment of the printability of CoNiCrFeMn in Laser Powder Bed Fusion, Materials & Design, 194, 108845 (2020), B Dovgyy, A. Piglione, P Hooper, M.S. Pham,

  8. Printability and microstructure of the CoCrFeMnNi high-entropy alloy fabricated by laser powder bed fusion, A.Piglione, B.Dovgyy, C.Liu, C.M.Gourlay, P.A.Hooper, M.S.Pham, Materials Letters, 2018

Image: https://onlinelibrary.wiley.com/doi/full/10.1016/j.joa.2017.08.001

META-MATERIALS & PROGRAMMABLE MATERIALS:

Our groundbreaking study "Damage-tolerant architected materials inspired by crystal microstructure, Nature, 565, 305-311 (2019)" presents a transformative approach to combine the science of metals with 3D printing to generate extraordinarily tough and lightweight meta-materials with desired properties, holding great potential for a variety of applications.

The study has been highlighted by > 15 media channels (in English, Dutch, Korean): Imperial College's webpage, Physics World, Chemical & Engineering News, Dutch Newspaper NRC, Science News, EurekAlert, Nature Korea, University of Sheffield, Reuter's most innovative universities & many more


We currently work with leading experts in aerospace and personal protection and with medical doctors and surgeons to design novel meta-materials for medical treatments such as atrial fibrillation treatment.

References:

  1. Damage-tolerant architected materials inspired by crystal microstructure, Nature, 565, 305-311 (2019), M.S. Pham, C. Liu, I. Todd, J. Lerttharnasarn

  2. The origin of the boundary strengthening in polycrystal-like architected materials, Nature Communications, (2021), C. Liu, J. Lertthernasarn, M.S. Pham,

  3. Synergistic effects of crystalline microstructure, architected mesostructure, and processing defects on the mechanical behaviour of Ti6Al4V meta-crystals, MSE A (2021), 141436, J. Lertthernasarn, C. Liu, M.S. Pham,

AEROSPACE:

We work with world-leading industry in aerospace to understand the creep and fatigue damage of Ti and Ni superalloys to help ensure the safety and performance of aero-engines - the hearts of every aeroplanes.

References:

  1. Micro-cracking, microstructure and mechanical properties of Hastelloy-X alloy printed by laser powder bed fusion: as-built, annealed and hot-isostatic pressed, Additive Manufacturing, 101853 (2021), H Wang, L Chen, B Dovgyy, W Xu, A Sha, X Li, H Tang, Y Liu, H Wu, M.S. Pham

  2. Micro-mechanisms of Cyclic Plasticity at Stress Concentrations in a Ni-Based Single-Crystal Superalloy, Superalloys 2020, 333-340, A Piglione, J Yu, J Zhao, C Xiao, F Dunne, MS Pham

  3. Crystal plasticity analysis of deformation anisotropy of lamellar TiAl alloy: 3D microstructure-based modelling and in-situ micro-compression, L Chen, TEJ Edwards, F Di Gioacchino, WJ Clegg, FPE Dunne, MS Pham, Int. Journal of Plasticity 119, 344-360

  4. Creep deformation mechanisms and CPFE modelling of a nickel-based superalloy, M.Z. Li, M.S. Pham, Z. Peng, G. Tian, B.A. Shollock, MSE A, 2018

Image source: CCFE

ENERGY (INCLUDING FUSION)

We have studied the mechanical integrity of structures and components in power plants. We currently work with experts in UK Atomic Energy Authority - Culham Centre for Fusion Energy to study the fatigue-creep interaction of critical components, helping to realise future power plants powered by green energy source - fusion.

References:

  1. Evolution of dislocation microstructures and internal stresses of AISI 316L during cyclic loading at 293 and 573K, M.S. Pham, S.R. Holdsworth, Metal. and Mat. Trans. A 45 (2014), 2, pp. 738-751, Springer.

  2. Cyclic deformation response of AISI 316L at room temperature: mechanical behaviour, microstructural evolution, physically-based evolutionary constitutive modelling, M.S. Pham, S.R. Holdsworth, K.G.F. Janssens, E. Mazza, Int. J. of Plasticity 47 (2013) 143-164.

  3. Role of microstructural condition on fatigue damage development of AISI 316L at 20 and 300°C, M.S. Pham & S.R. Holdsworth, Int. J. Fatigue 51 (2013) 36-48.

  4. Dynamic strain ageing of AISI 316L during cyclic loading at 300°C: Mechanism, evolution, and its effects, M.S. Pham & S.R. Holdsworth, MSE A 556 (2012) 122–133.

  5. Dislocation structures evolution and its effect on cyclic deformation behavior of AISI 316L steel, M.S. Pham, C. Solenthaler, K.G.F. Janssens & S.R. Holdsworth, MSE A 528 (2011) 3261-3269, Elsevier.

https://www.carbodydesign.com/gallery/2018/02/the-new-volvo-v60/13/)

MULTIAXIAL FORMING FOR CAR BODY COMPONENTS

We collaborate with experts at NIST-NCAL automotive consortium that consists of major car manufacturers and materials providers in USA including General Motors and Ford to support automotive industry in its efforts in reducing the weight of vehicles, hence reducing carbon emissions. Materials in car body in white (image source: https://www.carbodydesign.com/gallery/2018/02/the-new-volvo-v60/13/)

References:

  1. Roles of texture and latent hardening on plastic anisotropy of face-centered-cubic materials during multi-axial loading, M.S. Pham, A. Creuziger, M. Iadicola, T. Foecke, A.D. Rollett (Journal of Mechanics and Physics of Solids)

  2. Forming limit prediction using a self-consistent crystal plasticity framework: a casestudy for body-centered cubic materials (Modelling and Simulation in MSE, 5, Vol 24, 2016), 2016, Y.G. Jeong, M.S. Pham, M. Iadicola, A. Creuziger. T. Foecke

  3. Thermally-activated constitutive model includingdislocation interactions, aging and recovery for strain path dependence of solidsolution strengthened alloys: Application to AA5754, M.S. Pham,M. Iadicola, A. Creuziger, L. Hu and A. D. Rollett, Int. J. Plasticity, December (2015), 75, pp. 226-243.

  4. Constitutive Modeling based on Evolutionary Multi-junctionsof Dislocations, M.S. Pham, Anthony D. Rollett, Adam Crueziger,Mark A. Iadicola and Timothy Foecke, Key Engineering Materials, 2014, Vol 611, p1771-1776.

Experimental facilities

Metal printers: Concept Laser, Reninshaw AM250

Stereolithography printer: Form2

Fused deposition modelling: multiple Ultimaker2 printers

Metallographic facilities: Mounting, Cutting, Polishing, Etching, Tension/Compression test rigs, Heat-treatment

Electron Microscopy Suite at Imperial: TEM, SEM, EBSD, EDX, XRD

Softwares/Codes

Abaqus,

ThermoCalc including databases of high entropy alloys, Ti alloys, Mg alloys and Steels,

Matlab-based subroutines that integrates Thermocalc into machine learning platform

CAD software: Rhinoceros, Element for lattice design.

Acknowledgements:

  1. EPSRC

  2. Current industrial sponsors: CCFE, BIAM, AWE, BP, Cross Manufacturing

  3. Imperial College London, UK

  4. Materials Genome Initiative-USA

  5. NCAL-National Institute of Standards and Technology/Center for Automotive Lightweighting, USA

  6. Support for Dr. Pham's PhD study at ETHZ in Switzerland: CCMX-Swiss Competence Center in Materials Science and Technology, Swissnuclear, ABB, Alstom, Switzerland