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INTRODUCTION

POWDER-BASED additive manufacturing has become an increasingly attractive fabrication method in the aerospace and other industries because of the ability L.M. SOCHALSKI-KOLBUS, is with the Chemical and Engineering Materials Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6475, Oak Ridge, TN 37830-6475, and also with the Materials Science and Technology Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, Oak Ridge, TN 37830-6430. Contact e-mail: [email protected] E.A PAYZANT, Engineering Materials Group Leader, is with the Chemical and Engineering Materials Division, Oak Ridge National Laboratory. P.A. CORNWELL, Scientific Associate, and T.R. WATKINS, Scattering and Thermal Properties Group Leader, are with the Materials Science and Technology Division, Oak Ridge National Laboratory. S.S. BABU, Governoro´s Chair in Advanced Manufacturing, is with the Manufacturing Demonstration Facility, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6479, Oak Ridge, TN 37830-6479, and also with the Department of Aerospace and Biomedical Engineering, University of Tennessee, Knoxville. R.R. DEHOFF, Staff Scientist, and C. DUTY, Senior Staff Scientist, are with the Materials Science and Technology Division, Oak Ridge National Laboratory, and also with the Manufacturing Demonstration Facility, Oak Ridge National Laboratory. M. LORENZ, Scientist, is with the Chemical Sciences Division, Oak Ridge National Laboratory, One Bethel Valley Rd., P.O. Box 2008, MS 6131, Oak Ridge, TN 37830-6131, and also with the National Physics Laboratory, Teddington, U.K. O. OVCHINNIKOVA, Staff Scientist, is with the Chemical Sciences Division, Oak Ridge National Laboratory. Notice: This manuscript has been authored by UT-Battelle, LLC, under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. Manuscript submitted June 11, 2014. METALLURGICAL AND MATERIALS TRANSACTIONS A

to fabricate components heretofore unobtainable with subtractive manufacturing and to reduce the manufacturing time and cost. The ability to fabricate parts from computer-aided design drawings layer by layer opens new avenues to engineering design of components. While process control of the various additive manufacturing methods is evolving (e.g., electron beam melting (EBM) and welding,[1,2] laser metal sintering/melting,[3,4] laser cladding[5]), the main control parameters are typically beam power, speed, material feed rate scanning paths, and preheat temperature. Unfortunately, process control is hindered by indirect parameters within proprietary ‘‘black-box’’ interfaces, which typically require the user to accept limited processing parameter cond