
Jonathan D. MadisonNational Science Foundation | NSF · Division of Materials Research (DMR)
Jonathan D. Madison
Ph.D., Materials Science & Engineering
About
46
Publications
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Introduction
Half of my research portfolio is fueled by my education as a metallurgist with a strong emphasis on solidification and 3D characterization of microstructure. The other half centers on developing microstructural evolution models to approximate a variety of materials phenomena using kinetic monte carlo approaches and appropriating experimental findings to further improve our models.
Additional affiliations
February 2018 - present
February 2010 - February 2018
Education
June 2003 - December 2009
June 2003 - August 2007
June 1998 - May 2003
Publications
Publications (46)
Additive manufacturing (AM) is of tremendous interest given its ability to realize complex, non-traditional geometries in engineered structural materials. However, microstructures generated from AM processes can be equally, if not more, complex than their conventionally processed counterparts. While some microstructural features observed in AM may...
Mechanical serial sectioning is a highly repetitive technique employed in metallography for the rendering of three-dimensional reconstructions of microstructure. While alternate techniques such as ultrasonic detection, micro-computed tomography and focused ion beam milling have progressed much in recent years, few alternatives provide equivalent op...
This study offers experimental observation of the effect of low strain conditions (e\10%) on abnormal
grain growth (AGG) in Nickel-200. At such conditions, stored mechanical energy is low within the microstructure
enabling one to observe the impact of increasing mechanical deformation on the early onset of AGG compared to a control, or nondeformed,...
Standing-edge joints made by a continuous-wave Nd:YAG laser are examined in 304L stainless steel to advance understanding of the linkage between processing and microstructure in high-rate solidification events. Microcomputed tomography combined with traditional metallography has provided qualitative and quantitative characterization of welds in thi...
304L stainless steel partial-penetration laser welds with varying penetration depths are needed for a variety of national security applications. Their mechanical performance depends on many parameters including weld schedule, penetration depth, and weld porosity. Unfortunately, these parameters are not easily divorced from one another as each has v...
Additively manufactured metals can show more than an order of magnitude increase in variability in mechanical properties compared to traditionally manufactured materials. This makes the qualification of additively manufactured parts difficult, especially in safety critical applications where unexpected material failure can be detrimental. Sandia ha...
Grain-scale microstructure evolution during additive manufacturing is a complex physical process. As with traditional solidification methods of material processing (e.g. casting and welding), microstructural properties are highly dependent on the solidification conditions involved. Additive manufacturing processes however, incorporate additional co...
Structural features, spatial locations, and morphological measures not readily attainable with 2D methods are now accessible using 3D microstructure characterization techniques.
The mechanical properties of additively manufactured metals tend to show high variability, due largely to the stochastic nature of defect formation during the printing process. This study seeks to understand how automated high throughput testing can be utilized to understand the variable nature of additively manufactured metals at different print c...
Porosity in additively manufactured metals can reduce material strength and is generally undesirable. Although studies have shown relationships between process parameters and porosity, monitoring strategies for defect detection and pore formation are still needed. In this paper, instantaneous anomalous conditions are detected in-situ via pyrometry...
The quality of metal objects fabricated via laser powder bed fusion are highly affected by process parameters, and their influence on final products is yet to be fully explored. In this work, pyrometry signals of the melt pool were collected from a set of stainless-steel samples during manufacturing and the effect of laser power on porosity and rou...
The third Sandia Fracture Challenge (SFC3) was a benchmark problem for comparing experimental and simulated ductile deformation and failure in an additively manufactured (AM) 316L stainless steel structure. One surprising observation from the SFC3 was the Challenge-geometry specimens had low variability in global load versus displacement behavior,...
The present invention relates to a metallographic system including a measurement module configured to provide precise differential measurements of a sample after serial sectioning, as well as methods of employing such a module. In particular example, the measurement module provides differential measurement(s) without contacting the surface of a sam...
Additive manufacturing (AM) processes for metals can yield as-built microstructures that vary significantly from their cast or wrought counterparts. These microstructural variations can in turn, have profound effects on the properties of a component. Here, a modeling methodology is presented to investigate microstructurally-influenced mechanical re...
Additive manufacturing enables the production of previously unachievable designs in conjunction with time and cost savings. However, spatially and temporally fluctuating thermal histories can lead to residual stress states and microstructural variations that challenge conventional assumptions used to predict part performance. Numerical simulations...
The intrinsic relation between structure and performance is a foundational tenant of most all materials science investigations. While the specific form of this relation is dictated by material system, processing route and performance metric of interest, it is widely agreed that appropriate characterization of a material allows for greater accuracy...
Grain boundary engineering (GBE) is a thermomechanical processing technique used to control the distribution, arrangement, and identity of grain boundary networks, thereby improving their mechanical properties. In both GBE and non-GBE metals, the phenomena of abnormal grain growth (AGG) and its contributing factors is still a subject of much intere...
Additive manufacturing enables the rapid, cost effective production of customized structural components. To fully capitalize on the agility of additive manufacturing, it is necessary to develop complementary high-throughput materials evaluation techniques. In this study, over 1000 nominally identical tensile tests are used to explore the effect of...
A novel data science workflow is developed and demonstrated to extract process-structure linkages (i.e., reduced-order model) for microstructure evolution problems when the final microstructure depends on (simulation or experimental) processing parameters. This workflow consists of four main steps: data pre-processing, microstructure quantification...
An adage within the Additive Manufacturing (AM) community is that “complexity is free”. Complicated geometric features that normally drive manufacturing cost and limit design options are not typically problematic in AM. While geometric complexity is usually viewed from the perspective of part design, this advantage of AM also opens up new options i...
Integrated Computational Materials Engineering (ICME) is a relatively new methodology full of tremendous potential to revolutionize in which science, engineering and manufacturing work together. ICME was motivated by the desire to derive greater understanding throughout each portion of the development life cycle of materials, while simultaneously r...
Using the kinetic Monte Carlo simulator, Stochastic Parallel PARticle Kinetic Simulator, from Sandia National Laboratories, a user routine has been developed to simulate mesoscale predictions of a grain structure near a moving heat source. Here, we demonstrate the use of this user routine to produce voxelized, synthetic, three-dimensional microstru...
This book presents a collection of papers presented at the 3rd World Congress on Integrated Computational Materials Engineering (ICME), a specialty conference organized by The Minerals, Metals & Materials Society (TMS). This meeting convened ICME stakeholders to examine topics relevant to the global advancement of ICME as an engineering discipline....
Abstract to accompany poster and presentation
This report covers the modeling of seven directionally solidified samples, five under normal gravitational conditions and two in microgravity. A model is presented to predict macrosegregation during the melting phases of samples solidified under microgravitational conditions. The results of this model are compared against two samples processed in m...
Porosity in linear autogenous laser welds of 304L stainless steel has been investigated using micro computed tomography to reveal defect content in fifty-four welds made with varying delivered power, travel speed and focal lens. Trends associated with porosity size and frequencies are shown and interfacial measures are employed to provide quantitat...
Porosity resulting from linear autogenous laser-welds of 304L stainless steel are non-destructively examined and digitally reproduced by means of micro-computed tomography. These digitized microstructures are then imported into a finite element framework in which the pores are surrounded by an idealized, homogenized geometry, and exposed to a plast...
Most materials microstructural evolution processes progress with multiple processes occurring simultaneously. In this work, we have concentrated on the processes that are active in nuclear materials, in particular, nuclear fuels. These processes are coarsening, nucleation, differential diffusion, phase transformation, radiation-induced defect forma...
High burn-up, rim structures within uranium dioxide (UO2) light water reactor fuels exhibit marked differences in microstructure that are attributed to dynamic recrystallization. The recrystallization process has three distinct, interacting components: damage accumulation, nucleation and growth of damage-free regions, and subsequent evolution of re...
A variety of edge joints utilizing a continuous wave Nd:YAG laser have been produced and examined in a 304-L stainless steel to advance fundamental understanding of the linkage between processing and resultant microstructure in high-rate solidification events. Acquisition of three-dimensional reconstructions via micro-computed tomography combined w...
Fluid flow within the dendritic structure at the solid–liquid interface in nickel-based superalloys has been studied in two
directionally solidified alloy systems. Millimeter-scale, three-dimensional (3D) datasets of dendritic structure have been
collected by serial sectioning, and the reconstructed mushy zones have been used as domains for fluid-f...
Convection during directional solidification can cause defects such as freckles and misoriented grains. To gain a better understanding of conditions associated with the onset of convective instabilities, flow was investigated using three-dimensional (3D) computational fluid dynamics simulations in an experimentally obtained dendritic network. A ser...
Convective flow within the mushy zone of directionally solidified superalloys can result in the formation of freckles and misoriented grains. These defects signal not only a disruption in the columnar or single crystal nature of the component but also a tendency toward reduction in life and performance. Approximations of the onset of convective flo...
During solidification, solute-induced convective instabilities at the solid - liquid interface can result in the formation of defects such as freckles and misoriented grains in superalloy single crystals. These defects can be particularly detrimental to the properties of single crystal nickel-base superalloys. Unfortunately, detailed understanding...
Directional solidification of nickel-based single crystals requires control of the heat transfer, fluid flow, and phase transformations
at the solid-liquid interface during withdrawal in the Bridgman process. While the morphological details of the dendritic
structure at the solid-liquid interface influence defect formation processes, there is an in...
Use of difference in image quality ("pattern quality" term used in paper) to differentiate martensite and ferrite phases in dual-phase material. Where the two phases are present in large contiguous areas, the image quality distribution is bimodal and a threshold can be set to identify martensite. Good agreement with optical point-counting. However,...