Faculty DirectoryTao Sun

Associate Professor of Mechanical Engineering
Contact
2145 Sheridan RoadTech L288
Evanston, IL 60208-3109
847-467-2676Email Tao Sun
Website
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, 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
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