Anthony Rollett’s research focuses on microstructural evolution and microstructure-property relationships in 3D, using both experiments and simulations. Interests include 3D printing of metals, materials for energy conversion systems, strength of materials, constitutive relations, microstructure, texture, anisotropy, grain growth, recrystallization, formability and stereology. He is co-director of the Next Manufacturing Center on additive manufacturing and previously worked at the Los Alamos National Laboratory, where he was group leader of metallurgy and deputy division director of materials science and technology.
Areas of Expertise (7)
Manufacturing & Materials Microstructure
Computational Materials Science
Media Appearances (5)
NASA Aeronautics Selects Three University Teams for Research Help
The JHU-CMU partnership is led by the University’s Somnath Ghosh, Michael G. Callas chair professor in the Department of Civil and Systems Engineering and director of the Computational Mechanics Research Laboratory, and CMU’s Anthony Rollett, a professor in the Department of Materials Science and Engineering and co-director of the Next Manufacturing Center.
CMU To Lead NASA Space Technology Research Institute
Carnegie Mellon University online
"The STRI affords us an opportunity for a major collaboration through which we can construct the models that our partners at NASA very much need." — Tony Rollett
A route for avoiding defects during additive manufacturing
CMU Engineering News online
“The real practical value of this research is that we can be precise about controlling the machines to avoid this problem,” says Anthony Rollett, a professor of materials science and engineeringOpens in new window and a lead co-author of the paper.
Department of Energy Awards Rollett $2.4 Million To 3D-Print Heat Exchangers
Carnegie Mellon University online
The project, led by Anthony Rollett, a Carnegie Mellon University professor of materials science and engineering, is one of 18 projects being supported by the Department of Energy for high-temperature materials and is part of the High Intensity Thermal Exchange through Materials and Manufacturing Processes program.
Carnegie Mellon University and Argonne National Laboratory Unlock Keyhole Phenomenon in Metal 3D Printing
3D Printing Industry online
Anthony Rollett, a co-author of the paper and Professor of Materials Science and Engineering at Carnegie Mellon University, said, “The research in this paper will translate into better quality control and better control of working with the machines.”
Industry Expertise (1)
Chercheur d'Excellence (Outstanding Researcher). University of Lorraine (professional)
Brahm Prakash Professor at the Indian Institute of Science (Bangalore) (professional)
Member of Honor of the French Metallurgical Society (professional)
Fellow of TMS (professional)
Cyril Stanley Smith Award from TMS (professional)
Drexel University: Ph.D., Materials Engineering 1987
Cambridge University: M.A., Metallurgy & Materials Science 1976
Mapping nanocrystal orientations via scanning Laue diffraction microscopy for multi-peak Bragg coherent diffraction imagingJournal of Synchrotron Radiation
2023 The recent commissioning of a movable monochromator at the 34-ID-C endstation of the Advanced Photon Source has vastly simplified the collection of Bragg coherent diffraction imaging (BCDI) data from multiple Bragg peaks of sub-micrometre scale samples. Laue patterns arising from the scattering of a polychromatic beam by arbitrarily oriented nanocrystals permit their crystal orientations to be computed, which are then used for locating and collecting several non-co-linear Bragg reflections. The volumetric six-component strain tensor is then constructed by combining the projected displacement fields that are imaged using each of the measured reflections via iterative phase retrieval algorithms. Complications arise when the sample is heterogeneous in composition and/or when multiple grains of a given lattice structure are simultaneously illuminated by the polychromatic beam
Small dataset for hot cracking susceptibility of Al alloys and Ni alloys using dynamic X-ray radiography (DXR) techniqueData in Brief
2023 Hot cracking as the major concern in the manufacturing process of metal alloys is detrimental to part performance and can lead to catastrophic failure. However, current research in this field is restricted to the scarcity of the relevant hot cracking susceptibility data. Here, using the DXR technique provided at 32-ID-B beamline of Advanced Photon Source (APS) at Argonne National Laboratory, we characterized the hot cracking formation in Laser Powder Bed Fusion (L-PBF) process for ten commercial alloys (Al7075, Al6061, Al2024, Al5052, Haynes 230, Haynes 160, Haynes X, Haynes 120, Haynes 214, and Haynes 718). The extracted DXR images captured the post-solidification hot cracking distribution and allow the quantification of the hot cracking susceptibility of those alloys.
Variant selection in laser powder bed fusion of non-spherical Ti-6Al-4V powderJournal of Materials Science & Technology
2023 The presence of α/α′ on prior β/β grain boundaries directly impacts the final mechanical properties of the titanium alloys. The β/β grain boundary variant selection of titanium alloys has been assumed to be unlikely owing to the high cooling rates in laser powder bed fusion (L-PBF). However, we hypothesize that powder characteristics such as morphology (non-spherical) and particle size (50–120 µm) could affect the initial variant selection in L-PBF processed Ti-6Al-4V alloy by locally altering the cooling rates. Despite the high cooling rate found in L-PBF, results showed the presence of β/β grain boundary α′ lath growth inside two adjacent prior β grains.
Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powderMaterials Characterization
2023 Powder feedstock is a major cost driver in metal additive manufacturing (AM). Replacing the spherical powder with the cost-efficient non-spherical one can reduce the feedstock cost up to 50% and attract more interest to adopt AM in production and new alloy development. Here, a comprehensive study was conducted to understand process-microstructure-property relationships in laser powder bed fusion of hydride-dehydride Ti-6Al-4V powder. We demonstrated that variation of laser scan speed had a significant impact on the grain structure, pore evolution and properties compared to laser power. Dynamic X-ray radiography showed that with decreasing scan speed at a constant laser power, a transition from conduction to keyhole mode laser processing occurred, in which a deeper melt pool at lower scan speed intensified texture.
Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power3D Printing and Additive Manufacturing
2023 Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. The materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF.