Publications

For a complete list of publications, please see Prof. Sun’s google scholar page

Sub-millisecond keyhole pore detection in laser powder bed fusion using sound and light sensors and machine learning

Zhongshu Ren*, Jiayun Shao*, Haolin Liu, Samuel J Clark, Lin Gao, Lilly Balderson, Kyle Mumm, Kamel Fezzaa, Anthony D Rollett, Levent Burak Kara, Tao Sun

Materials Futures, 3, (2024) 045001 (*equal contribution)

Abstract

An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition

Lin Gao, Andrew C Chuang, Peter Kenesei, Zhongshu Ren, Lilly Balderson, Tao Sun

International Journal of Machine Tools and Manufacture, 194, (2024) 104089

Abstract

Tailoring material microstructure and property in wire-laser directed energy deposition through a wiggle deposition strategy

Lin Gao, Jishnu Bhattacharyya, Wenhao Lin, Zhongshu Ren, Andrew C Chuang, Pavel D Shevchenko, Viktor Nikitin, Ji Ma, Sean R Agnew, Tao Sun
Additive Manufacturing, 77, (2023) 103801

Abstract

Machine learning–aided real-time detection of keyhole pore generation in laser powder bed fusion

Zhongshu Ren, Lin Gao, Samuel J Clark, Kamel Fezzaa, Pavel Shevchenko, Ann Choi, Wes Everhart, Anthony D Rollett, Lianyi Chen, Tao Sun

Science, 379, (2023) 89

Abstract

Critical instability at moving keyhole tip generates porosity in laser melting

Cang Zhao, Niranjan D Parab, Xuxiao Li, Kamel Fezzaa, Wenda Tan, Anthony D Rollett, Tao Sun

Science, 370, (2020) 1080

Abstract

Keyhole Threshold and Morphology in Laser Melting Revealed by Ultrahigh-Speed X-ray Imaging

R. Cunningham*, C. Zhao*, N. Parab, K. Fezzaa, T. Sun, A. Rollett

Science, 363, (2019) 849 (*equal contribution)

Abstract

Bulk explosion induced metal spattering during laser processing

C. Zhao, Q. Guo, X. Li, N. Parab, K. Fezzaa, W. Tan, L. Chen, T. Sun

Physical Review X, 9, (2019) 021052

Abstract

Ultrafast X-ray Imaging of Laser Metal Additive Manufacturing Processes

N. Parab*, C. Zhao*, R. Cunningham, L. Escano, K. Fezzaa, W. Everhart, A. Rollett, L. Chen, T. Sun 

Journal of Synchrotron Radiation, 25, (2018) 1467 (*equal contribution)

Abstract

Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Cang Zhao, Kamel Fezzaa, Ross W Cunningham, Haidan Wen, Francesco De Carlo, Lianyi Chen, Anthony D Rollett, Tao Sun
Scientific Reports, 7, (2017) 3602

Abstract

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Last Updated: March 13, 2025
Contact

Prof. Tao Sun
Department of Mechanical Engineering
2145 Sheridan Rd, Evanston, IL, 60208
taosun@northwestern.edu
1-847-467-2676