scholarly journals Kinetic interface condition phase diagram for the rapid solidification of multi-component alloys with an application to additive manufacturing

Calphad ◽  
2022 ◽  
Vol 76 ◽  
pp. 102365
Author(s):  
Qiang Du ◽  
Amin S. Azar ◽  
Mohammed M'Hamdi
Keyword(s):  
Phase Diagram ◽  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Interface Condition

scholarly journals Modelling of Microstructure Evolution during Laser Processing of Intermetallic Containing Ni-Al Alloys

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1051
Author(s):  
Mohammad Amin Jabbareh ◽  
Hamid Assadi
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Microstructure Evolution ◽  
Phase Field ◽  
Laser Processing ◽  
Field Model ◽  
Phase Field Model ◽  
Intermetallic Phases ◽  
Al Alloy ◽  
Kinetic Effects

There is a growing interest in laser melting processes, e.g., for metal additive manufacturing. Modelling and numerical simulation can help to understand and control microstructure evolution in these processes. However, standard methods of microstructure simulation are generally not suited to model the kinetic effects associated with rapid solidification in laser processing, especially for material systems that contain intermetallic phases. In this paper, we present and employ a tailored phase-field model to demonstrate unique features of microstructure evolution in such systems. Initially, the problem of anomalous partitioning during rapid solidification of intermetallics is revisited using the tailored phase-field model, and the model predictions are assessed against the existing experimental data for the B2 phase in the Ni-Al binary system. The model is subsequently combined with a Potts model of grain growth to simulate laser processing of polycrystalline alloys containing intermetallic phases. Examples of simulations are presented for laser processing of a nickel-rich Ni-Al alloy, to demonstrate the application of the method in studying the effect of processing conditions on various microstructural features, such as distribution of intermetallic phases in the melt pool and the heat-affected zone. The computational framework used in this study is envisaged to provide additional insight into the evolution of microstructure in laser processing of industrially relevant materials, e.g., in laser welding or additive manufacturing of Ni-based superalloys.

Review on Phase-Field Modeling of Microstructure Evolutions: Application to Electron Beam Additive Manufacturing

2014 ◽  
Author(s):  
Seshadev Sahoo ◽  
Kevin Chou
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Phase Field ◽  
Solidification Process ◽  
Materials Processing ◽  
Rapid Solidification Process ◽  
Phase Field Modeling ◽  
Diffuse Interfaces ◽  
Field Modeling

Powder-bed electron beam additive manufacturing (EBAM) is a relatively new technology to produce metallic parts in a layer by layer fashion by melting and fusing metallic powders. EBAM is a rapid solidification process and the properties of the parts depend on the solidification behavior as well as the microstructure of the build material. Thus, the prediction of part microstructures during the process may be an important factor for process optimization. Nowadays, the increase in computational power allows for direct simulations of microstructures during materials processing for specific manufacturing conditions. Among different methods, phase-field modeling (PFM) has recently emerged as a powerful computational technique for simulating microstructure evolutions at the mesoscale during a rapid solidification process. PFM describes microstructures using a set of conserved and non-conserved field variables and the evolution of the field variables are governed by Cahn-Hilliard and Allen-Cahn equations. By using the thermodynamics and kinetic parameters as input parameters in the model, PFM is able to simulate the evolution of complex microstructures during materials processing. The objective of this study is to achieve a thorough review of PFM techniques used in various processes, attempted for an application to microstructure evolutions during EBAM. The concept of diffuse interfaces, phase field variables, thermodynamic driving forces for microstructure evolutions and the kinetic phase-field equations are described in this paper.

scholarly journals In Situ and Ex Situ Characterization of the Microstructure Formation in Ni-Cr-Si Alloys during Rapid Solidification—Toward Alloy Design for Laser Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2192
Author(s):  
Xiaoshuang Li ◽  
Kai Zweiacker ◽  
Daniel Grolimund ◽  
Dario Ferreira Sanchez ◽  
Adriaan B. Spierings ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Chemical Composition ◽  
Laser Beam ◽  
Rapid Solidification ◽  
Liquid Droplet ◽  
Lamellar Microstructure ◽  
Ex Situ ◽  
X Ray Diffraction ◽  
X Ray

Laser beam-based deposition methods such as laser cladding or additive manufacturing of metals promises improved properties, performance, and reliability of the materials and therefore rely heavily on understanding the relationship between chemical composition, rapid solidification processing conditions, and resulting microstructural features. In this work, the phase formation of four Ni-Cr-Si alloys was studied as a function of cooling rate and chemical composition using a liquid droplet rapid solidification technique. Post mortem x-ray diffraction, scanning electron microscopy, and in situ synchrotron microbeam X-ray diffraction shows the present and evolution of the rapidly solidified microstructures. Furthermore, the obtained results were compared to standard laser deposition tests. In situ microbeam diffraction revealed that due to rapid cooling and an increasing amount of Cr and Si, metastable high-temperature silicides remain in the final microstructure. Due to more sluggish interface kinetics of intermetallic compounds than that of disorder solid solution, an anomalous eutectic structure becomes dominant over the regular lamellar microstructure at high cooling rates. The rapid solidification experiments produced a microstructure similar to the one generated in laser coating thus confirming that this rapid solidification test allows a rapid pre-screening of alloys suitable for laser beam-based processing techniques.

Multiscale simulation of rapid solidification of an aluminium–silicon alloy under additive manufacturing conditions

2021 ◽  
Vol 48 ◽  
pp. 102353
Author(s):  
Patrick I. O’Toole ◽  
Milan J. Patel ◽  
Chao Tang ◽  
Dayalan Gunasegaram ◽  
Anthony B. Murphy ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Multiscale Simulation ◽  
Silicon Alloy

Experimental Study of Disruption of Columnar Grains During Rapid Solidification in Additive Manufacturing

JOM ◽  
2016 ◽  
Vol 68 (3) ◽  
pp. 842-849 ◽  
Author(s):  
Guha Manogharan ◽  
Bharat Yelamanchi ◽  
Ronald Aman ◽  
Zaynab Mahbooba
Keyword(s):  
Experimental Study ◽  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Columnar Grains

scholarly journals Understanding Hot Cracking of Steels during Rapid Solidification: An ICME Approach

2021 ◽  
Vol 3 (1) ◽  
pp. 30
Author(s):  
Fuyao Yan ◽  
Jiayi Yan ◽  
David Linder
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Solid Phase ◽  
Hot Cracking ◽  
Materials Engineering ◽  
Integrated Computational Materials Engineering ◽  
Δ Ferrite ◽  
Quantitative Understanding ◽  
Computational Materials ◽  
Kinetics Of

Cracking is a major problem for several types of steels during additive manufacturing. Non-equilibrium kinetics of rapid solidification and solid–solid phase transformations are critical in determining the cracking susceptibility. Previous studies correlate the hot cracking susceptibility to the solidification sequence, and therefore composition, empirically. In this study, an Integrated Computational Materials Engineering (ICME) approach is used to provide a more mechanistic and quantitative understanding of the hot cracking susceptibility of a number of steels in relation to the peritectic reaction and evolution of δ-ferrite during solidification. The application of ICME and hot cracking susceptibility predictions to alloy design for additive manufacturing is discussed.

Icosahedral phase formation in rapidly quenched aluminum-ruthenium alloys

1988 ◽  
Vol 3 (3) ◽  
pp. 421-425 ◽  
Author(s):  
Steven M. Anlage ◽  
Brent Fultz ◽  
Kannan M. Krishnan
Keyword(s):  
Electron Microscopy ◽  
Phase Diagram ◽  
Rapid Solidification ◽  
Phase Formation ◽  
Metastable Phase ◽  
Icosahedral Phase ◽  
Rapid Quenching ◽  
Metastable Phase Diagram ◽  
X Ray Diffraction ◽  
X Ray

Systematic rapid quenching experiments on the icosahedral phase-forming system Al1 − xRux were performed for × < 20 at. %. The solidified alloys have been studied by electron microscopy and x-ray diffraction to determine their composition, constituent phases, and phase morphology. It has been determined that the icosahedral phase must form directly from the liquid and, at these quench rates, is always found in the presence of second or third phases. The results have been summarized in a metastable phase diagram appropriate for rapid solidification of Al1 − xRux at piston and anvil quench rates. This metastable phase diagram describes the results for Ru concentrations less than 14 at. %.

Laser additive manufacturing of copper– chromium–niobium alloys using gas atomized powder

2020 ◽  
Vol 111 (7) ◽  
pp. 587-593
Author(s):  
Dora Maischner ◽  
Udo Fritsching ◽  
Anoop Kini ◽  
Andreas Weisheit ◽  
Volker Uhlenwinkel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Elevated Temperatures ◽  
High Strength ◽  
Copper Matrix ◽  
Metal Deposition ◽  
Raw Material ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Niobium Alloys

Abstract Copper-chrome-niobium alloys exhibit excellent thermal and electrical properties combined with high strength at elevated temperatures. Additive manufacturing techniques such as laser metal deposition using powder as raw material offer the potential for rapid solidification as well as a high freedom of design to manufacture parts layer by layer. Powder samples of copper- chrome-niobium alloys were produced by gas atomization. Via laser metal deposition, bulk volumes without cracks and with a very low porosity can be built up. Rapid solidification leads to the formation of fine precipitates which are likely to be (Cr,Fe)2Nb. The precipitates are distributed homogeneously in the copper matrix. The copper crystals grow across the layers due to epitaxial nucleation on the preceding layer.

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