Numerical Analysis of Stray Grain Formation during Laser Welding Nickel-Based Single-Crystal Superalloy Part III: Crystallography-Dependent Solidification Behavior

2021 ◽  
Vol 1033 ◽  
pp. 40-48
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Heat Input ◽  
Solidification Cracking ◽  
Growth Region ◽  
Solidification Temperature ◽  
Temperature Range ◽  
Grain Formation ◽  
Solidification Temperature Range ◽  
Stray Grain

The solidification temperature range was numerically analyzed to optimize nonequilibrium solidification behavior during ternary Ni-Cr-Al nickel-based single-crystal superalloy weld pool solidification with variation of laser welding conditions (either heat input or welding configuration). The distribution of solidification temperature range along the fusion boundary is beneficially symmetrical about the weld pool centerline in the (001)/[100] welding configuration. The distribution of solidification temperature range along the fusion boundary is detrimentally asymmetrical about the weld pool centerline in the (001)/[110] welding configuration. The stray grain formation and solidification cracking are preferentially confined to [100] dendrite growth region. [001] epitaxial growth region with columnar dendrite morphology is favored at the expense of undesirable [100] growth region with equiaxed dendrite morphology to facilitate essential single-crystal solidification with considerable reduction of heat input. The smaller heat input is used, the narrower solidification temperature range is thermodynamically promoted to reduce nucleation and growth of stray grain formation with decrease of constitutional undercooling ahead of dendrite tip and mitigate thermo-metallurgical factors for morphology instability and microstructure anomalies. Potential low heat input(both decreasing laser power and increasing welding speed) with (001)/[100] welding configuration decreases solidification temperature range to significantly minimize columnar/equiaxed transition (CET) and stray grain formation, and improve resistance to solidification cracking through microstructure control. On both sides of weld pool are imposed by the same heat input, while the solidification temperature range along the fusion boundary inside of [100] dendrite growth region on the right part of the weld pool is spontaneously wider than that of [010] dendrite growth region on the left part to increase solidification cracking susceptibility in the (001)/[110] welding configuration. Furthermore, another mechanism of solidification cracking as consequence of severe solidification behavior and anomalous microstructure with asymmetrical crystallographic orientation is therefore proposed. The theoretical predictions are well verified by experiment results. The useful and satisfactory numerical modeling is also available for other single-crystal superalloys during successful laser repair process without stray grain formation.

Numerical Analysis of Stray Grain Formation during Laser Welding Nickel-Based Single-Crystal Superalloy Part II: Multicomponent Dendrite Growth

2021 ◽  
Vol 1033 ◽  
pp. 31-39
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Heat Input ◽  
Dendrite Growth ◽  
Solidification Cracking ◽  
Growth Region ◽  
Dendrite Trunk ◽  
Solidification Interface ◽  
Grain Formation ◽  
Stray Grain

Multicomponent dendrite growth is theoretically predicted to optimize solidification cracking susceptibility during ternary Ni-Cr-Al nickel-based single-crystal superalloy weld pool solidification. The distribution of dendrite trunk spacing along the weld pool solidification interface is clearly symmetrical about the weld pool centerline in beneficial (001)/[100] welding configuration. The distribution of dendrite trunk spacing along the weld pool solidification interface is crystallography-dependent asymmetrical from bottom to top surface of the weld pool in detrimental (001)/[110] welding configuration. The smaller heat input is used, the finer dendrite trunk spacing is kinetically promoted by less solute enrichment and narrower constitutional undercooling ahead of solid/liquid interface with mitigation of metallurgical contributing factors for solidification cracking and vice versa. Vulnerable [100] dendrite growth region is predominantly suppressed and epitaxial [001] dendrite growth region is favored to spontaneously facilitate single-crystal columnar dendrite growth and reduce microstructure anomalies with further reduction of heat input. Optimum low heat input (both lower laser power and higher welding speed) with (001)/[100] welding configuration is the most favorable one to avoid nucleation and growth of stray grain formation, minimize both dendrite trunk spacing and solidification cracking susceptibility potential, improve resistance to solidification cracking, and ameliorate weldability and weld integrity through microstructure modification instead of inappropriate high heat input (both higher laser power and slower welding speed) with (001)/[110] welding configuration. The dendrite trunk spacing in the [100] dendrite growth region on the right side of the weld pool is considerably coarser and grows faster than that within the [010] dendrite growth region of the left side in the (001)/[110] welding configuration to deteriorate weldability, although the welding conditions are the same on the either side. Furthermore, the alternative mechanism of crystallography-dependent solidification cracking as consequence of asymmetrical microstructure development and diffusion-controlled dendrite growth of γ phase is therefore proposed. The theoretical predictions are comparable with experiment results. The reliable model is also useful for welding conditions optimization for crack-free laser processing.

Numerical Analysis of Aerospace Nickel-Based Single-Crystal Superalloy Weldability Part II: Nonequilibrium Solidification Behavior

2021 ◽  
Vol 1018 ◽  
pp. 33-41
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Heat Input ◽  
Dendrite Growth ◽  
Solidification Cracking ◽  
Solidification Temperature ◽  
Temperature Range ◽  
Solidification Temperature Range ◽  
Solid Liquid Interface ◽  
Nonequilibrium Solidification

The thermal metallurgical modeling by coupling of heat transfer model, dendrite selection model, columnar/equiaxed transition (CET) model and nonequilibrium solidification model was further developed to numerically analyze stray grain formation and solidification temperature range on the basis of three criteria of constitutional undercooling, marginal stability of planar front and minimum growth velocity during multicomponent nickel-based single-crystal superalloy weld pool solidification. It is indicated that the primary γ gamma phase microstructure development and solidification cracking susceptibility along the solid/liquid interface are symmetrically distributed throughout the weld pool in (001) and [100] welding configuration. The microstructure development and solidification cracking susceptibility along the solid/liquid interface are asymmetrically distributed in (001) and [110] welding configuration. Appropriate low heat input (low laser power and high welding speed) simultaneously minimizes stray grain formation, grain boundary misorientation and solidification temperature range in the vulnerable [100] dendrite growth region and beneficially maintains single-crystal nature of the material in the [001] epitaxial dendrite growth region to improve the cracking resistance, while high heat input (high laser power and low welding speed) increases the solidification cracking susceptibility to deteriorate weldability and weld integrity. The solidification temperature range in (001) and [110] welding configuration is detrimentally wider than that of (001) and [100] welding configuration due to crystallographic orientation of dendrite growth regardless of heat input. The mechanism of asymmetrical crystallography-dependant solidification cracking because of nonequilibrium solidification behavior is proposed. The elliptical and shallow weld pool shape is less susceptible to solidification cracking for successful crack-free laser welding. Moreover, the promising theoretical predictions agree well with the experiment results. The useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties during laser welding or laser cladding.

Numerical Analysis of Aerospace Nickel-Based Single-Crystal Superalloy Weldability Part III: Solidification Cracking Susceptibility

2021 ◽  
Vol 1018 ◽  
pp. 23-32
Author(s):  
Zhi Guo Gao
Keyword(s):  
Laser Welding ◽  
Single Crystal ◽  
Welding Speed ◽  
Heat Input ◽  
Laser Power ◽  
Solidification Cracking ◽  
Solidification Behavior ◽  
Solidification Temperature ◽  
Temperature Range ◽  
Solidification Temperature Range

The thermal-metallurgical model of primary γ gamma phase through couple of heat transfer model, dendrite selection model, columnar/equiaxed transition (CET) model, multicomponent dendrite growth model and nonequilibrium solidification model is further developed on the basis of criteria of minimum growth velocity, constitutional undercooling and marginal stability of planar front during nickel-based single-crystal weld pool solidification. It is clearly indicated that crystallographic orientation plays more important role than heat input in microstructure development and solidification behavior. The dendrite trunk spacing and solidification temperature range along the solid/liquid interface are symmetrically distributed about the weld pool centerline in (001) and [100] welding configuration, while they are asymmetrically distributed in (001) and [110] welding configuration. The dendrite size and solidification temperature range are beneficially smaller in (001) and [100] welding configuration than that of (001) and [110] welding configuration regardless of heat input. The mechanism of asymmetrical solidification cracking because of crystallography-dependent growth kinetics and solidification behavior is proposed. Optimum low heat input (low laser power and high welding speed) refines dendrite size and suppresses the solidification temperature range to minimize the solidification cracking susceptibility and ameliorate the weldability through microstructure control, while high heat input (high laser power and low welding speed) deteriorates the weldability and weld integrity. It is therefore imperative to optimize the welding conditions for successful defect-free laser welding. Moreover, the promising theoretical predictions agree well with the experiment results. The useful model is also applicable to other single-crystal superalloys with similar metallurgical properties by laser welding or laser cladding, and provide a more accurate and reliable way of solidification cracking susceptibility evaluation.

Numerical Analysis of Solidification Behavior during Laser Welding Nickel-Based Single-Crystal Superalloy Part I: Crystallography-Dependent Solid Aluminum Distribution

2021 ◽  
Vol 1020 ◽  
pp. 13-22
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Heat Input ◽  
Dendrite Growth ◽  
Solidification Cracking ◽  
Aluminum Concentration ◽  
Growth Region ◽  
Solid Aluminum ◽  
Solid Liquid Interface ◽  
Solid Liquid

The thermal metallurgical modeling of alloying aluminum redistribution was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrtie grwoth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification over a wide range of welding conditions (laser power, welding speed and welding configuration) to facilitate understanding of solidification cracking phenomena. It is indicated that the welding configuration plays more important role than heat input in aluminum redistribution. The bimodal distribution of solid aluminum concentration along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline for (001) and [100] welding configuration, while the distribution of solid aluminum concentration along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool for (001) and [110] welding configuration. The size of vulnerable [100] dendrite growth region is beneficially suppressed in favor of epitaxial [001] dendrite growth region through optimum low heat input (low laser power and high welding speed) to facilitate single-crystal dendrite growth for successful crack-free weld at the expense of shallow weld pool geometry. The overall aluminum concentration in (001) and [100] welding configuration is significantly smaller than that of (001) and [110] welding configuration regardless of heat input. Severe aluminum enrichment is confined to [100] dendrite growth region where is more susceptible to solidification cracking. Heat input and welding configuration are optimized in order to minimize the solidification cracking susceptibility and improve microstructure stability. The relationship between welding conditions and alloying aluminum redistribution are established for solidification cracking susceptibility evaluation. The higher heat input is used, the more aluminum enrichment is monotonically incurred by diffusion with considerable increase of metallurgical driving forces for morphology instability and microstructure anomalies to deteriorate weldability and vice versa. The mechanism of asymmetrical solidification cracking because of crystallography-dependent alloying redistribution is proposed. The theoretical predictions agree well with the experiment results. Moreover, the useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties during laser welding or laser cladding.

scholarly journals Numerical Analysis of Solidification Behavior during Laser Welding Nickel-based Single-crystal Superalloy Part III: Auspicious Control of Dendrite Tip Undercooling

2021 ◽  
Vol 1996 (1) ◽  
pp. 012003
Author(s):  
Zhiguo Gao
Keyword(s):  
Numerical Analysis ◽  
Single Crystal ◽  
Heat Input ◽  
Planar Interface ◽  
Microstructure Development ◽  
Solidification Behavior ◽  
Growth Region ◽  
Solidification Interface ◽  
Grain Formation ◽  
Stray Grain

Abstract Location-dependent dendrite tip undercooling is numerically elucidated to predict crystallography-assisted resistance to centerline grain boundary formation and morphology transition of stray grain formation ahead of dendrite tip in the ternary Nickel-Chromium-Aluminum molten pool during course of nonequilibrium solidification for explanation arduous solidification behavior control of microstructure melioration. Heat input is not so salient as welding configuration for auspicious solidification behavior and beneficial microstructure development. Advantageous symmetry of welding configuration efficiently lessens dendrite tip undercooling for prevalent dendrite morphology stability of planar interface with alleviation of columnar/equiaxed transition (CET) phenomenon. The bimodal distribution of undercooling ahead of dendrite tip is symmetrically dominant for (001)/[100] growth crystallography with capability of increasing morphology of interface kinetics for epitaxial growth and guarantees single-crystal potential. Alternatively, the distribution of undercooling ahead of dendrite tip is asymmetrically prevalent for (001)/[110] growth crystallography with inefficiency of nonhomologous solidification behavior for discontinuous intersection of solidification interface. Undercooling ahead of dendrite tip inside [010] growth region is not so wide as inside [100] growth region, where thermometallurgically initiates unstable solidification interface and inferior solidification behavior, with unfavorable crystallography in the case of asymmetrical (001)/[110] welding configuration. The smaller heat input is applied, the narrower undercooling ahead of dendrite tip is acquired to significantly mitigate microstructure anomalies with favorable solidification conditions, meliorate metallurgical properties and potentially improve weldability with viability of epitaxial columnar morphology and vice versa. Optimum heat input, especially low laser power and high welding speed together, is a viable and robust way to limit plethora of undercooling and easily decrease solidification behavior anomalies. When low laser power or rapid welding speed is chosen, low heat input not only lessens [100] dendrite growth region, where is spontaneously vulnerable to columnar/equiaxed transition, as ramification of prominent dendrite tip undercooling, but also metallurgically ameliorates [001] dendrite growth region, where morphologically aids epitaxial growth and activates stable planar interface, with achievable diminution of dendrite tip undercooling. Symmetrical (001)/[100] welding configuration, in which undercooling ahead of dendrite tip is preferably narrower than asymmetrical (001)/[110] welding configuration, is one of the most important ingredient for auspicious control of dendrite tip undercooling, once other welding conditions are similar. The main reason, why welding conditions (both low heat input and (001)/[100] welding configuration) is quite superior to welding conditions (both high heat input and (001)/[110] welding configuration), is attributable to favorable crystallography-dependent thermometallurgical factors to suppress inhomogeneous microstructure as long as solidification conditions within marginal stability range. Satisfying crack-free microstructure development is strongly interdependent on kinetics-related solidification behavior through scrupulous control of dendrite tip undercooling to balance between microstructure amelioration and weld depth requirement. The mechanism of columnar/equiaxed transition elimination, by which kinetic driving forces of abnormal microstructure development within high-undercooling region on either left or right side of weld pool is diminished through challenging method of crystallography-dependent dendrite tip undercooling control, is therefore proposed. Finally, there is reasonable consensus between numerical analysis results and experiment results. The numerical analysis provides credible insight into where is liable to microstructure anomalies and why dendrite tip undercooling suppresses stray grain formation for successful laser surface modification of Ni-based single-crystal superalloy.

Numerical Analysis of Aerospace Nickel-Based Single-Crystal Superalloy Weldability Part I: Crystallography-Dependent Dendrite Growth

2021 ◽  
Vol 1018 ◽  
pp. 3-12
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Dendrite Growth ◽  
Liquid Interface ◽  
Solidification Cracking ◽  
Microstructure Development ◽  
Growth Region ◽  
The Right ◽  
Solid Liquid Interface ◽  
Solid Liquid

The thermal-metallurgical modeling of microstructure development was further advanced during single-crystal superalloy weld pool solidification by coupling of heat transfer model, columnar/equiaxed transition (CET) model and multicomponent dendrite growth model on the basis criteria of minimum dendrite velocity, constitutional undercooling and marginal stability of planar front. It is clearly indicated that heat input (laser power and welding speed) and welding configuration simultaneously influence the stray grain formation, columnar/equiaxed transition and dendrite growth. For beneficial (001) and [100] welding configuration, the microstructure development along the solid/liquid interface is symmetrically distributed about the weld pool centerline throughout the weld pool. Finer columnar in [001] epitaxial dendrite growth region is kinetically favored at the bottom of the weld pool. For detrimental (001) and [110] welding configuration, the microstructure development along the solid/liquid interface is asymmetrically distributed. The dendrite trunk spacing along the solid/liquid interface from the beginning to end of solidification morphologically increases on the left side of the weld pool, while it spontaneously decreases on the right side. The vulnerable location of solidification cracking is confined in the [100] dendrite growth region on the right side of the weld pool because of increasing metallurgical contributing factors of severe stray grain formation, centerline grain boundary formation and coarse dendrite size. The mechanism of crystallography-dependent asymmetrical solidification cracking due to microstructure anomalies is proposed. It is crystallographically favorable for predominant morphology instability to deteriorate weldability. Active [100] dendrite growth region is diminished in the shallow elliptical weld pool by optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration to essentially facilitate single-crystal solidification conditions and provide enough resistant to solidification cracking. Moreover, the theoretical predictions agree well with the experiment results. The reliable weldability maps are therefore established to determine the prerequisite for successful crack-free laser welding or cladding. The useful model is also applicable for other single-crystal superalloys with similar metallurgical properties.

Numerical Analysis of Solidification Behavior during Laser Welding Nickel-Based Single-Crystal Superalloy Part: II Crystallography-Dependent Supersaturation of Liquid Aluminum

2021 ◽  
Vol 1018 ◽  
pp. 13-22
Author(s):  
Zhi Guo Gao
Keyword(s):  
Laser Welding ◽  
Single Crystal ◽  
Weld Pool ◽  
Welding Speed ◽  
Heat Input ◽  
Laser Power ◽  
Liquid Aluminum ◽  
Dendrite Growth ◽  
Solidification Cracking ◽  
Solid Liquid Interface

The thermal metallurgical modeling of liquid aluminum supersaturation was further developed through couple of heat transfer model, dendrite selection model, multicomponent dendrite growth model and nonequilibrium solidification model during three-dimensional nickel-based single-crystal superalloy weld pool solidification. The welding configuration plays more important role in supersaturation of liquid aluminum, morphology instability and nonequilibrium partition behavior. The bimodal distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically symmetrical about the weld pool centerline in (001) and [100] welding configuration. The distribution of liquid aluminum supersaturation along the solid/liquid interface is crystallographically asymmetrical throughout the weld pool in (001) and [110] welding configuration. Optimum low heat input (low laser power and high welding speed) with (001) and [100] welding configuration is more favored to predominantly promote epitaxial [001] dendrite growth to reduce the metallurgical factors for solidification cracking than that of high heat input (high laser power and slow welding speed) with (001) and [110] welding configuration. The lower the heat input is used, the lower supersaturation of liquid aluminum is imposed, and the smaller size of vulnerable [100] dendrite growth region is incurred to ameliorate solidification cracking susceptibility and vice versa. The overall supersaturation of liquid aluminum in (001) and [100] welding configuration is beneficially smaller than that of (001) and [110] welding configuration regardless of heat input, and is not thermodynamically relieved by gamma prime γˊ phase. (001) and [110] welding configuration is detrimental to weldability and deteriorates the solidification cracking susceptibility because of unfavorable crystallographic orientations and alloying aluminum enrichment. The mechanism of asymmetrical solidification cracking because of crystallography-dependent supersaturation of liquid aluminum is proposed. The eligible solidification cracking location is particularly confined in [100] dendrite growth region. Moreover, the theoretical predictions agree well with the experiment results. The useful modeling is also applicable to other single-crystal superalloys with similar metallurgical properties for laser welding or laser cladding. The thorough numerical analyses facilitate the understanding of weld pool solidification behavior, microstructure development and solidification cracking phenomena in the primary γ phase, and thereby optimize the welding conditions (laser power, welding speed and welding configuration) for successful crack-free laser welding.

Numerical Analysis of Microstructure Anomalies during Laser Welding Nickel-Based Single-Crystal Superalloy Part III: Amelioration of Solidification Behavior

2021 ◽  
Vol 1041 ◽  
pp. 47-56
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Welding Speed ◽  
Heat Input ◽  
Laser Power ◽  
Liquid Aluminum ◽  
High Heat ◽  
Solidification Cracking ◽  
Microstructure Development ◽  
High Heat Input ◽  
Stray Grain

The contribution of crystallography-dependent metallurgical factors, such as supersaturation of liquid aluminum and minimum dendrite tip undercooling, to solidification behavior and microstructure development is numerically analyzed during Ni-Cr-Al ternary single-crystal superalloy molten pool solidification to better understand thermodynamic and kinetic driving forces behind solidification cracking resistance. The variation of supersaturation of liquid aluminum and minimum dendrite tip undercooling with location of solid/liquid interface is symmetrically consistent in (001)/[100] welding configuration. By comparison, the variation is asymmetrically consistent in (001)/[110] welding configuration. The different distribution is attributed to growth crystallography and dendrite selection. Significant increase of supersaturation of liquid aluminum and dendrite tip undercooling from [010] dendrite growth region to [100] dendrite growth region preferentially aggravates microstructure development as result of nucleation and growth of stray grain formation with the same heat input on each half of the weld pool in (001)/[110] welding configuration. High heat input (both increasing laser power and decreasing welding speed) exacerbates supersaturation of liquid aluminum and dendrite tip undercooling by faster diffusion to incur stray grain formation with severity of contributing thermometallurgical factors for susceptibility to solidification cracking, while low heat input (both decreasing laser power and increasing welding speed) ameliorates microstructure development and increases resistance to solidification cracking. Weld microstructure of optimum welding conditions, such as combination of low heat input and (001)/[100] welding configuration, is less susceptible to solidification cracking to suppress asymmetrical microstructure development and improve weld integrity potential rather than insidious welding conditions, such as combination of high heat input and (001)/[110] welding configuration. Severer supersaturation of liquid aluminum and wider dendrite tip undercooling occur in the [100] dendrite region as consequence of alloying enrichment, while smaller supersaturation of liquid aluminum and narrower dendrite tip undercooling occur in the [001] dendrite region as consequence of alloying depletion to spontaneously facilitate epitaxial growth of single-crystal essential. Symmetrical (001)/[100] welding configuration decreases growth kinetics of dendrite tip with smaller overall supersaturation of liquid aluminum and dendrite tip undercooling than that of asymmetrical (001)/[110] welding configuration regardless of combination of laser power and welding speed. Mitigation of supersaturation of liquid aluminum and dendrite tip undercooling simultaneously alleviate crack-susceptible microstructure development and solidification cracking. Additionally, the appropriate mechanism of solidification cracking resistance improvement through modification of crystallography-dependent supersaturation and undercooling of dendrite tip is proposed. Calculation analyses are sufficiently explained by experiment results in a reasonable way. The additional purpose of this theoretical analysis is to evaluate solidification cracking susceptibility of similar nickel-based or iron-based single-crystal superalloys.

Numerical Analysis of Microstructure Development during Laser Welding Nickel-Based Single-Crystal Superalloy Part I: Stray Grain Formation

2021 ◽  
Vol 1020 ◽  
pp. 23-31
Author(s):  
Zhi Guo Gao
Keyword(s):  
Single Crystal ◽  
Weld Pool ◽  
Welding Speed ◽  
Laser Power ◽  
Microstructure Development ◽  
Grain Formation ◽  
Microstructure Morphology ◽  
Solid Liquid Interface ◽  
Solid Liquid ◽  
Stray Grain

The mathematical modeling of microstructure development is further extended through coupling of heat transfer model and columnar/equiaxed transition (CET) model during nickel-based single-crystal superalloy weld pool solidification with different welding conditions (laser power, welding speed and welding configuration). It is indicated that crystallographic orientation plays an important role in stray grain formation ahead of the solid/liquid interface on the basis of constitutional undercooling mechanism. (001) and [100] welding configuration promotes symmetrical distribution of microstructure morphology about the weld pool centerline that is favored for reduction of stray grain formation, while detrimental (001) and [110] welding configuration induces asymmetrical distribution of microstructure morphology with more stray grain formation and deteriorates the weldability. The mechanism of increasing stray grain formation due to misorientation of dendrite growth crystallography is proposed. Appropriate low heat inputs (low laser power or high welding speed) of solidification conditions prevents stray grain formation and vice versa, and suppress the size of vulnerable [100] dendrite growth region. Weld pool geometry, θ-φ of solid/liquid interface, morphology transition and stray grain formation on either side of weld are closely correlated. In order to eliminate stray grain formation through microstructure control, it is imperative to optimize the welding configurations for defect-free weld through useful welding configuration-microstructure map. The theoretical predictions are verified by the experiment results in a consistent way. In addition, the model is also applicable to other single-crystal superalloys with similar metallurgical properties by feasible laser welding or laser cladding.

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