Finite Interface Dissipation Phase Field Modeling of Ni-Nb under Additive Manufacturing Conditions

Abstract

During the laser powder bed fusion (L-PBF) process, the built part undergoes multiple rapid heating-cooling cycles, leading to complex microstructures with nonuniform properties. In the present work, a computational framework, which weakly couples a finite element thermal model to a non-equilibrium PF model was developed to investigate the rapid solidification microstructure of a Ni-Nb alloy during L-PBF. The framework is utilized to predict the spatial variation of the morphology and size of cellular segregation structure as well as the microsegregation in single-track melt pool microstructures obtained under different process conditions. A solidification map demonstrating the variation of microstructural features as a function of the temperature gradient and growth rate is presented. A planar to cellular transition is predicted in the majority of keyhole mode melt pools, while a planar interface is predominant in conduction mode melt pools. The predicted morphology and size of the cellular segregation structure agrees well with experimental measurements.

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Cited by in corpus (10)

• Morphological stability of solid-liquid interfaces under additive manufacturing conditions
• Multiscale simulation of powder-bed fusion processing of metallic alloys
• Grain growth competition during melt pool solidification -- Comparing phase-field and cellular automaton models
• Uncertainty Propagation in a Multiscale CALPHAD-Reinforced Elastochemical Phase-field Model
• Tusas: A fully implicit parallel approach for coupled phase-field equations
• Orientation selection in alloy dendritic evolution during melt-pool solidification
• Phase-field modeling of microstructure evolution: Recent applications, perspectives and challenges
• Mapping of Microstructure Transitions during Rapid Alloy Solidification Using Bayesian-Guided Phase-Field Simulations
• 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