Faculty DirectoryTao Sun

Associate Professor of Mechanical Engineering
Contact
2145 Sheridan RoadTech L288
Evanston, IL 60208-3109
847-467-2676Email Tao Sun
Departments
Education
PhD, Materials Science and Engineering, Northwestern University, Evanston, IL
MS, Materials Science and Engineering, Tsinghua University, Beijing, China
BS, Materials Science and Engineering, Tsinghua University, Beijing, China
Research Interests
- Additive manufacturing
- In situ/operando characterization and metrology
- Synchrotron x-ray imaging and scattering techniques
- Ultrafast dynamics in soft and hard condensed matters
- Machine design and process sensing
- Data analytics and machine learning
Significant Recognition
- TMS Young Innovator in the Materials Science of Additive Manufacturing Award
- TMS Structural Materials Division JOM Best Paper Award
Selected Publications
- Z. Ren, L. Gao, S. Clark, K. Fezzaa, P. Shevchenko, A. Choi, W. Everhart, A. Rollett, L. Chen, T. Sun, “Machine learning aided real-time detection of keyhole pore generation in laser powder bed fusion”, Science, 379, (2023) 89
- C. Zhao, N. Parab, X. Li, K. Fezzaa, W. Tan, A. Rollett, T. Sun, “Critical instability at moving keyhole tip generates porosity in laser melting”, Science, 370, (2020) 1080
- R. Cunningham*, C. Zhao*, N. Parab, K. Fezzaa, T. Sun, A. Rollett, “Keyhole Threshold and Morphology in Laser Melting Revealed by Ultrahigh-Speed X-ray Imaging”, Science, 363, (2019) 849 (*equal contribution)
- C. Zhao, Q. Guo, X. Li, N. Parab, K. Fezzaa, W. Tan, L. Chen, T. Sun, “Bulk explosion induced metal spattering during laser processing”, Physical Review X, 9, (2019) 021052
- C. Zhao, B. Shi, S. Chen, D. Du, T. Sun, B. Simonds, K. Fezzaa, A. Rollett, “Laser melting modes in metal powder bed fusion additive manufacturing”, Review of Modern Physics, 94, (2022) 045002
- S. Hojjatzadeh, N. Parab, W. Yan, Q. Guo, L. Xiong, C. Zhao, L. Escano, M. Qu, X. Xiao, K. Fezzaa, W. Everhart, T. Sun, L. Chen, “Mechanisms of pore elimination during 3D printing of metals”, Nature Communications, 10, (2019) 3088
- N. Parab*, C. Zhao*, R. Cunningham, L. Escano, K. Fezzaa, W. Everhart, A. Rollett, L. Chen, T. Sun, “Ultrafast X-ray Imaging of Laser Metal Additive Manufacturing Processes”, Journal of Synchrotron Radiation, 25, (2018) 1467 (*equal contribution, Top 10% most downloaded paper of JSR in 2018-2019)
- C. Zhao, K. Fezzaa, R. Cunningham, H. Wen, F. De Carlo, L. Chen, A. Rollett, T. Sun, “Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction”, Scientific Reports, 7, (2017) 3602 (Top 100 in Materials Science in Scientific Reports in 2017)
- N. Parab, J. Barnes, C. Zhao, R. Cunningham, K. Fezzaa, A. Rollett, T. Sun, “Real time observation of binder jetting printing process using high-speed X-ray imaging”, Scientific Reports, 9, (2019) 2499 (Top 100 Materials Science in Scientific Reports in 2019)
In The News
Machine Learning Approach Helps Hit 100% Prediction Rate
Researchers unveil new AI-driven method for improving additive manufacturing
Beautiful Physics Governs Complex Energy-matter Interactions
X-Ray Movie Reveals Origin of Metal Splashing
New research identifies causes for defects in 3D printing and paves way for better results
Adding It Up: Three Routes to Better 3-D Printing
X-ray vision accelerates 3-D printing journey