Agency: European Research Council (ERC)
Instrument: Starting Grant 2020
GrantID: 946959
Institutions: École Polytechnique
PI: Manas V. Upadhyay
Core scientific team: N. Mohanan (Ph.D. student), G. D. Lima-Chaves (Ph.D. student), K. A. Abdesselam (Ph.D. student), S. Gaudez (Post-doc), J. G. Santos Macías (Post-doc), K. Chen (Post-doc)
Dates: March 2021 – February 2026
Funds: 1,499,877 €
Webpage: https://cordis.europa.eu/project/id/946959
Aim: To highlight the important role of solid-state thermal cycling (SSTC) on microstructure evolution during AM, and to show how SSTC can be harnessed to design microstructures with desired mechanical responses.
Objectives:
- Propose and perform experiments to quantify the microstructural changes brought about solely by SSTC, and to identify the underlying micro-mechanisms.
- Develop and validate theoretical and fast numerical models to gain deep insight on dynamics of micro-mechanisms and predict polycrystalline evolution due to SSTC.
- Use the novel models in synergy with experiments to tailor AM process parameters and suggest in-process/post-process thermo-mechanical treatments in order to guide the microstructure evolution in the solid-state and optimize material properties and performance.
Methods:
- Development of a miniature LMD machine for synchrotron X-ray experiments
- Designing a novel coupling between a continuous-wave laser and an SEM (CW Laser-SEM) to facilitate microstructure characterization inside an SEM without mechanical polishing by preventing oxidation
- SEM and TEM characterization using the same capabilities from project MiAM
- Theoretical development and numerical implementation of novel dislocation and polycrystalline thermomechanical models to study microstructure evolution during thermal cycling.
- Establishing novel experiment-modelling synergies extended to AM
Expected Impact and Output:
- Filling a significant knowledge gap in understanding role of thermal cycling on micromechanisms and microstructure evolution occurring during metal AM of steels and Ti-alloys.
- Proposed novel energy-efficient rapid in-process/post-process laser treatments to alter/fine tune mechanical performance of alloys.
- Directly inspired follow-on projects, GISTEAM3 (GIS HEAD), LaserSurf (CIEDS) and IMP3D (ANR), and preparation of an ERC Consolidator Grant proposal as well as Proof-of-concept proposal (2026).
- As of Sep 2025, delivered 19 journal publications, 2 patents, 3 keynote lectures, and 24 invited talks
Publication list:
- J. Dumbre, Z. Tong, Y. Chen, A. Rack, N. Isac, M. V. Upadhyay, M. Easton and D. Qiu
“Impact of build process on microstructural evolution in laser directed energy deposition of Ti-8.5Cu Alloy: An in situ synchrotron X-ray imaging and post-build electron microscopy study”
Additive Manufacturing, 109 (2025) 104841
DOI: 10.1016/j.addma.2025.104841
- K. A. Abdesselam, S. Gaudez, S. van Petegem, V. Honkimäki, S. Hallais, L. Cornet, M. Vallet and M. V. Upadhyay
“Altering microstructure and enhancing mechanical properties during direct energy deposition of Ti-6Al-4V via in-process laser heat treatments”
Materials & Design, 254 (2025) 113997
DOI: 10.1016/j.matdes.2025.113997
- J. G. Santos Macías, K. Chen, A. Tanguy, M. Vallet, L. Cornet, V. Michel and M. V. Upadhyay
“High-vacuum laser treatments enhance strength, ductility and fatigue limit of additively manufactured stainless steel”
Materials & Design, 254 (2025) 114064
DOI: 10.1016/j.matdes.2025.114064
- C. B. Larsen, S. Samothrakitis, R. Woracek, E. Polatidis, J. Čapek, M. V. Upadhyay, M. Tovar, S. Schmidt and M. Strobl
“Exploring Grain-Resolved Strain Tensors and Non-Uniform Lattice Deformations with Laue 3DNDT”
Acta Materialia, 289 (2025) 120869
DOI: 10.1016/j.actamat.2025.120869
- G. D. Lima Chaves, A. Acharya and M. V. Upadhyay
“A finite deformation theory of dislocation thermomechanics”
Journal of the Mechanics and Physics of Solids, 200 (2025) 106141
DOI: 10.1016/j.jmps.2025.106141
Preprint DOI: arXiv.2409.17194
- S. Gaudez, D. Weisz-Patrault, K. A. Abdesselam, H. Gharbi, V. Honkimäki, S. van Petegem and M. V. Upadhyay
“Estimating elastic and thermal contributions to lattice strains from operando X-ray diffraction measurements using fast simulations”
Additive Manufacturing, 101 (2025) 104674
DOI: 10.1016/j.addma.2025.104674
- A. F. Chadwick, J. G. Santos Macías, A. Samaei, G. Wagner, M. V. Upadhyay and P. W. Voorhees
“On microstructure development during laser melting and resolidification: An experimentally validated simulation study”
Acta Materialia, 282 (2025) 120482
DOI: 10.1016/j.actamat.2024.120482
- M. V. Upadhyay, S. Gaudez and W. Pantleon
“Dislocation structure evolution during metal additive manufacturing”
IOP Conference Series: Materials Science and Engineering, 44th Risø International Symposium on Materials Science (RISO 2024) 02/09/2024 – 06/09/2024 Roskilde, Denmark, 1310 (2024) 012012
DOI: 10.1088/1757-899X/1310/1/012012
- K. Chen, J. G. Santos Macías, N. Isac, M. Vallet, L. Cornet and M. V. Upadhyay
“Silicon mediated twin formation in laser direct energy deposited 316L stainless steel”
Scripta Materialia, 253 (2024) 116257
DOI: 10.1016/j.scriptamat.2024.116257
- M. V. Upadhyay and J. Viñals
“Coupling Phase Field Crystal and Field Dislocation Mechanics for a consistent description of dislocation structure and elasticity”
European Journal of Mechanics-A/Solids, 108 (2024) 105419
DOI: 10.1016/j.euromechsol.2024.105419
- N. Mohanan, J. G. Santos Macías, J. Bleyer, T. Helfer, M. V. Upadhyay
“Intergranular stress and plastic strain formation during laser scanning of additively manufactured stainless steel: An experimentally-driven thermomechanical simulation study”
Materialia, 34 (2024) 102082
DOI: 10.1016/j.mtla.2024.102082
- G. D. Lima-Chaves and M. V. Upadhyay
“Finite element implementation of the thermal field dislocation mechanics model: study of temperature evolution due to dislocation activity”
Computer Methods in Applied Mechanics and Engineering, 421 (2024) 116763
DOI: 10.1016/j.cma.2024.116763
- S. Gaudez, M. Ben Haj Slama, E. Héripré, L. Yedra, M. Scheel, S. Hallais and M. V. Upadhyay
“A synchrotron transmission X-ray microscopy study on precipitate evolution during solid-state thermal cycling of a stainless steel”
Additive Manufacturing, 73 (2023) 103692
Preprint DOI: 10.2139/ssrn.4379782
DOI: 10.1016/j.addma.2023.103692
- S. Gaudez, K. A. Abdesselam, H. Gharbi, Z. Hegedüs, U. Lienert, W. Pantleon and M. V. Upadhyay
“High resolution reciprocal space mapping reveals dislocation structure evolution during 3D printing”
Additive Manufacturing, 71 (2023) 103602
Preprint DOI: 10.2139/ssrn.4367212
DOI: 10.1016/j.addma.2023.103602
- S. Gaudez, M. Ben Haj Slama, A. Kaestner and M. V. Upadhyay
“3D deep convolutional neural network segmentation model for precipitates and porosities identification in synchrotron X-ray tomograms”
Journal of Synchrotron Radiation, 29 (2022) 1232 – 1240
DOI: 10.1107/S1600577522006816
- M. Ben Haj Slama, L. Yedra, E. Héripré and M. V. Upadhyay
“Insight on precipitate evolution during additive manufacturing of stainless steels via in-situ heating-cooling experiments in a transmission electron microscope”
Materialia, 21 (2022) 101368
DOI: 10.1016/j.mtla.2022.101368
HAL (preprint): hal-03570116
- Invited Contribution: M. V. Upadhyay and J. Bleyer
“Dislocation transport using a time-explicit Runge-Kutta discontinuous Galerkin finite element approach”
Special Issue: “Emerging Leaders 2021”
Modelling and Simulation in Materials Science and Engineering, 30 (2022) 034002
DOI: 10.1088/1361-651X/ac44a7
HAL (preprint): hal-03466796
- Review article: S. Lucarini, M. V. Upadhyay and J. Segurado
“FFT based approaches in micromechanics: fundamentals, methods and applications”
Modelling and Simulation in Materials Science and Engineering, 30 (2022) 023002
DOI: 10.1088/1361-651X/ac34e1
- M. V. Upadhyay, M. Ben Haj Slama, S. Gaudez, N. Mohanan, L. Yedra, S. Hallais, E. Héripré and A. Tanguy
“Non-oxide precipitates in additively manufactured austenitic stainless steel”
Scientific Reports, 11 (2021) 10393
DOI: 10.1038/s41598-021-89873-2