Faculty Directory
Tao Sun

Associate Professor of Mechanical Engineering

Contact

2145 Sheridan Road
Tech L288
Evanston, IL 60208-3109

847-467-2676 Email Tao Sun

Website

FAST-AM Lab

Departments

Mechanical Engineering

Download CV

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, J. Shao, H. Liu, S. Clark, L. Gao, L. Balderson, K. Mumm, K. Fezzaa, A. Rollett, L. Kara and T. Sun, “Sub-millisecond keyhole pore detection in laser powder bed fusion using sound and light sensors and machine learning”, Materials Futures, 3 (2024) 045001
L. Gao, A. Chuang, P. Kenesei, Z. Ren, L. Balderson, T. Sun, “An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition”, International Journal of Machine Tools and Manufacture, 194 (2024) 104089
L. Gao, J. Bhattacharyya, W. Lin, Z. Ren, A. Chuang, P. Shevchenko, V. Nikitin, J. Ma, S. Agnew, T. Sun, “Tailoring material microstructure and property in wire-laser directed energy deposition through a wiggle deposition strategy”, Additive Manufacturing, 77, (2023) 103801
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
T. Sun, W. Tan, L. Chen, A. Rollett, “In situ/operando synchrotron x-ray studies of metal additive manufacturing”, MRS Bulletin, 45, (2020) 927
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
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)
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