Application of Finite Element, Phase-field, and CALPHAD-based Methods to Additive Manufacturing of Ni-based Superalloys
arXiv:1705.02016 · doi:10.1016/j.actamat.2017.05.003
Abstract
Numerical simulations are used in this work to investigate aspects of microstructure and microsegregation during rapid solidification of a Ni-based superalloy in a laser powder bed fusion additive manufacturing process. Thermal modeling by finite element analysis simulates the laser melt pool, with surface temperatures in agreement with in situ thermographic measurements on Inconel 625. Geometric and thermal features of the simulated melt pools are extracted and used in subsequent mesoscale simulations. Solidification in the melt pool is simulated on two length scales. For the multicomponent alloy Inconel 625, microsegregation between dendrite arms is calculated using the Scheil-Gulliver solidification model and DICTRA software. Phase-field simulations, using Ni-Nb as a binary analogue to Inconel 625, produced microstructures with primary cellular/dendritic arm spacings in agreement with measured spacings in experimentally observed microstructures and a lesser extent of microsegregation than predicted by DICTRA simulations. The composition profiles are used to compare thermodynamic driving forces for nucleation against experimentally observed precipitates identified by electron and X-ray diffraction analyses. Our analysis lists the precipitates that may form from FCC phase of enriched interdendritic compositions and compares these against experimentally observed phases from 1 h heat treatments at two temperatures: stress relief at 1143 K (870°C) or homogenization at 1423 K (1150°C).
Accepted for publication in Acta Materialia on May 1, 2017
References in corpus (3)
Cited by in corpus (25)
- Finite Interface Dissipation Phase Field Modeling of Ni-Nb under Additive Manufacturing Conditions
- Towards Stacking Fault Energy Engineering in FCC High Entropy Alloys
- On the primary spacing and microsegregation of cellular dendrites in laser deposited Ni-Nb alloys
- Three-dimensional non-isothermal phase-field modeling of microstructure evolution during selective laser sintering
- Single-Track Melt-Pool Measurements and Microstructures in Inconel 625
- Six-sigma Quality Management of Additive Manufacturing
- Scheil-Gulliver simulations for the design of functionally graded alloys by additive manufacturing using pycalphad
- A scalable parallel finite element framework for growing geometries. Application to metal additive manufacturing
- Simulation and analysis of -Ni cellular growth during laser powder deposition of Ni-based superalloys
- Multiscale simulation of powder-bed fusion processing of metallic alloys
- Strongly out-of-equilibrium columnar solidification during the Laser Powder-Bed Fusion additive manufacturing process
- Predictive modeling of solidification during laser additive manufacturing of nickel superalloys: Recent developments, future directions
- Formation of Nb-rich droplets in laser deposited Ni-matrix microstructures
- Computational study on microstructure evolution and magnetic property of laser additively manufactured magnetic materials
- Uncertainty Analysis of Microsegregation during Laser Powder Bed Fusion
- Simulation of temperature, stress and microstructure fields during laser deposition of Ti-6Al-4V
- Multiscale analysis of crystal defect formation in rapid solidification of pure aluminium and aluminium-copper alloys
- Tusas: A fully implicit parallel approach for coupled phase-field equations
- Extension of a phase-field KKS model to predict the microstructure evolution in LPBF AlSi10Mg alloy submitted to non isothermal processes
- Demonstration of a laser powder bed fusion combinatorial sample for high-throughput microstructure and indentation characterization
- Orientation selection in alloy dendritic evolution during melt-pool solidification
- MEMS-based in situ electron-microscopy investigation of rapid solidification and heat treatment on eutectic Al-Cu
- Exploring large language models for microstructure evolution in materials
- Effects of isotherm patterns on cellular interface morphologies of melt pool origin
- An efficient and energy stable framework for phase field simulations of grain growth in additive manufacturing