To push the limits of rapid solidification (RS) processing techniques like laser powder bed
fusion (LPBF), a greater understanding of how rapid solidification affects the microstructure and features is essential. Using Two-Piston Splat Quenching (SQ), small metallic samples are electromagnetically levitated and melted via induction heating before being released into free fall and crushed (splat) between two Cu platens which are driven together at a high rate of speed. We are able to study RS in various metallic systems like austenitic stainless steels and Titanium based alloys for application in additive manufacturing technologies. The entire splat event occurs in less than one milli-second and generates solidification rates estimated between 0.1-2.0 m/s for stainless steels.
This work was funded by the Department of Energy’s Kansas City National Security Campus which is operated and managed by Honeywell Federal Manufacturing Technologies, LLC under contract number DE-NA0002839.

Recent Publications:

• Z. Hasenbusch, A. Deal, B. Brown, D. Wilson, L. Nastac, L. N. Brewer, A comparison of solidification structures and sub-microscale cellular segregation in rapidly solidified stainless steels produced via two-piston splat quenching and laser powder bed fusion – In Progress, 2022
• Z. Hasenbusch, Use of two-piston splat quenching to investigate and characterize the impact of compositional variations on rapid solidification microstructures and sub-microscale features in stainless steel alloys, The University of Alabama, 2022, Doctorate
• J. M. Roze, Heat transfer aspects of two piston splat quenching, The University of Alabama, 2022, Masters
• S. M. Morales, Rapid solidification of austenitic stainless steels by splat quenching, The University of Alabama, 2020, Masters