Additive manufacturing (AM) comprises a group of transformative technologies that are likely to revolutionize manufacturing. In particular, laser-based metal AM techniques can not only fabricate parts with extreme complexity, but also provide innovative means for designing and processing new metallic systems. However, there are still several technical barriers that constrain metal AM. Overcoming these barriers requires a better understanding of the physics underlying the complex and dynamic laser–metal interaction at the heart of many AM processes. This article briefly describes the state of the art of in situ/operando synchrotron x-ray imaging and diffraction for studying metal AM, mostly the laser powder-bed fusion process. It highlights the immediate impact of operando synchrotron studies on the advancement of AM technologies, and presents future research challenges and opportunities.

Solidification processing offers the first opportunity to control microstructure, properties, and performance in metallic alloy components. Until recently, microstructural evaluations were limited to post-solidification characterization by destructive methods. We review the development of time-resolved, in situ imaging techniques capable of capturing solid–liquid interfacial evolution in metallic alloys with high spatial and temporal resolution under diverse solidification conditions relevant for applications ranging from conventional directional solidification, crystal growth, and casting, to welding and additive manufacturing. These experiments enable direct visualization of transient behaviors that would otherwise remain unknown, uniquely providing insights into the physics that impact microstructure and defect development, and strategies for microstructural control and defect mitigation. Understanding microstructural evolution and the characteristics that form under various solidification conditions is essential for the development of multiscale, experimentally informed predictive modeling. This is highlighted by solidification simulations that utilize in situ measurements of solidification dynamics from state-of-the-art experimental techniques.

The field of solidification has evolved from metallurgical alchemy to a predictive science over the past century. Our particular focus is on metals and their alloys, whose thermophysical properties tend to differ distinctively from that of organic systems. Rapid advances in modeling efforts and real-time experiments have yielded a wealth of new and quantitative information across relevant length- and time scales, thereby expanding our understanding of the liquid-to-solid phase transition. The articles in this issue highlight some important recent developments in the field, including solidification at extreme rates, as well as the state-of-the-art computational and experimental techniques that allow us to probe the otherwise improbable. In light of this progress, we identify critical issues and open questions that point to future research directions in solidification science.

Synchrotron x-rays are a powerful tool to probe real-time changes in the microstructure of materials as they respond to an external stimulus, such as phase transformations that take place in response to a change in temperature. X-ray imaging techniques include radiography and tomography, and have been steadily improved over the last decades so that they can now resolve micrometer-scale or even finer structural changes in bulk specimens over time scales of a second or less. Under certain conditions, these imaging approaches can also give spatially resolved chemical information. In this article, we focus on the liquid to solid transformation of metallic alloys and the temporal and spatial resolution of the accompanying segregation of alloying elements. The solidification of alloys provides an excellent case study for x-ray imaging because it is usually accompanied by the progressive, preferential segregation of one or more of the alloying elements to either the solid or the liquid, and gives rise to surprisingly complex chemical segregation patterns. We describe chemical mapping investigations of binary and quasi-binary alloys using radiography and tomography, and recent developments in x-ray fluorescence imaging that offer the prospect of a more general, multielement mapping technique. Future developments for synchrotron-based chemical mapping are also considered.

Rapid solidification gives rise to solute trapping, which decreases solute partitioning and alters equilibrium solidification velocity-undercooling relationships. These effects influence microsegregation, solidification morphology, and the emergent microstructure length scales. Here, we review solute trapping and solute drag in rapid solidification in terms of theory, simulation methods, and experimental techniques. The basic theory to describe solute trapping is contained in the continuous growth model. This model breaks down at high solidification velocities, where solidification transitions abruptly to complete trapping, a limit that can be captured with the local nonequilibrium model. Solute trapping theories contain unknown parameters. Their determination from atomistic simulations or pulsed laser melting experiments is discussed. Microstructural evolution in rapid solidification can be readily investigated with the phase-field method, various alternatives of which are presented here. Uncertainties related to kinetic parameters and heat transfer during rapid solidification can be studied by comparing phase-field simulations to dynamic transmission electron microscopy observations.