The laser–matter interaction and solidification phenomena associated with laser additive manufacturing (LAM) remain unclear, slowing its process development and optimisation. Here, through in situ and operando high-speed synchrotron X-ray imaging, we reveal the underlying physical phenomena during the deposition of the first and second layer melt tracks. We show that the laser-induced gas/vapour jet promotes the formation of melt tracks and denuded zones via spattering (at a velocity of 1 m s−1). We also uncover mechanisms of pore migration by Marangoni-driven flow (recirculating at a velocity of 0.4 m s−1), pore dissolution and dispersion by laser re-melting. We develop a mechanism map for predicting the evolution of melt features, changes in melt track morphology from a continuous hemi-cylindrical track to disconnected beads with decreasing linear energy density and improved molten pool wetting with increasing laser power. Our results clarify aspects of the physics behind LAM, which are critical for its development.

I12 is the Joint Engineering, Environmental and Processing (JEEP) beamline, constructed during Phase II of the Diamond Light Source. I12 is located on a short (5 m) straight section of the Diamond storage ring and uses a 4.2 T superconducting wiggler to provide polychromatic and monochromatic X-rays in the energy range 50-150 keV. The beam energy enables good penetration through large or dense samples, combined with a large beam size (1 mrad horizontally  0.3 mrad vertically). The beam characteristics permit the study of materials and processes inside environmental chambers without unacceptable attenuation of the beam and without the need to use sample sizes which are atypically small for the process under study. X-ray techniques available to users are radiography, tomography, energy-dispersive diffraction, monochromatic and white-beam two-dimensional diffraction/scattering and small-angle X-ray scattering. Since commencing operations in November 2009, I12 has established a broad user community in materials science and processing, chemical processing, biomedical engineering, civil engineering, environmental science, palaeontology and physics.

SummaryWe utilized induced pluripotent stem cells (iPSCs) derived from Huntington’s disease (HD) patients as a human model of HD and determined that the disease phenotypes only manifest in the differentiated neural stem cell (NSC) stage, not in iPSCs. To understand the molecular basis for the CAG repeat expansion-dependent disease phenotypes in NSCs, we performed transcriptomic analysis of HD iPSCs and HD NSCs compared to isogenic controls. Differential gene expression and pathway analysis pointed to transforming growth factor β (TGF-β) and netrin-1 as the top dysregulated pathways. Using data-driven gene coexpression network analysis, we identified seven distinct coexpression modules and focused on two that were correlated with changes in gene expression due to the CAG expansion. Our HD NSC model revealed the dysregulation of genes involved in neuronal development and the formation of the dorsal striatum. The striatal and neuronal networks disrupted could be modulated to correct HD phenotypes and provide therapeutic targets.

a Lithium-ion batteries are being used in increasingly demanding applications where safety and reliability are of utmost importance. Thermal runaway presents the greatest safety hazard, and needs to be fully understood in order to progress towards safer cell and battery designs. Here, we demonstrate the application of an internal short circuiting device for controlled, on-demand, initiation of thermal runaway. Through its use, the location and timing of thermal runaway initiation is pre-determined, allowing analysis of the nucleation and propagation of failure within 18 650 cells through the use of high-speed X-ray imaging at 2000 frames per second. The cause of unfavourable occurrences such as sidewall rupture, cell bursting, and cell-to-cell propagation within modules is elucidated, and steps towards improved safety of 18 650 cells and batteries are discussed. Broader contextFrom portable electronics to grid-scale storage, high energy density Li-ion batteries are ubiquitous in today's society. Such cells can and do fail, sometimes catastrophically, releasing large amounts of energy. To facilitate safer and more reliable cell designs, the importance of understanding failure mechanisms of Li-ion cells is widely recognised. Here, we demonstrate the application of a novel device that is capable of generating an internal short circuit within commercial cell designs, on-demand, and at a predetermined location. This enables us to test more effectively the ability of safety devices of cells and modules to withstand 'worst-case' failure scenarios. By combining the use of this device with high-speed X-ray imaging at 2000 frames per second, we characterise for the first time the initiation and propagation of thermal runaway from a known location within a Li-ion cell. The insights achieved in this study are expected to guide the design and development of safer and more reliable Li-ion cells.

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Understanding defect formation during laser additive manufacturing (LAM) of virgin, stored, and reused powders is crucial for the production of high quality additively manufactured parts. We investigate the effects of powder oxidation on the molten pool dynamics and defect formation during LAM. We compare virgin and oxidised Invar 36 powder under overhang and layer-by-layer build conditions using in situ and operando X-ray Imaging. The oxygen content of the oxidised powder was found to be ca. 6 times greater (0.343 wt.%) than the virgin powder (0.057 wt.%). During LAM, the powder oxide is entrained into the molten pool, altering the Marangoni convection from an inward centrifugal to an outward centripetal flow. We hypothesise that the oxide promotes pore nucleation, stabilisation, and growth. We observe that spatter occurs more frequently under overhang conditions compared to layer-by-layer conditions. Droplet spatter can be formed by indirect laser-driven gas expansion and by the laser-induced metal vapour at the melt surface. In layer-by-layer build conditions, laser re-melting reduces the pore size distribution and number density either by promoting gas release from keyholing or by inducing liquid flow, partially or completely filling pre-existing pores. We also observe that pores residing at the track surface can burst during laser re-melting, resulting in either 2 formation of droplet spatter and an open pore or healing of the pore via Marangoni flow. This study confirms that excessive oxygen in the powder feedstock may cause defect formation in LAM.

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