Investigation of temperature distribution and solidification morphology in multilayered directed energy deposition of Al-0.5Sc-0.5Si alloy

Singh, Amit Kumar; Mundada, Yasham; Bajaj, Priyanshu; Wilms, Markus Benjamin; Patil, Jeet; Mishra, Sushil Kumar; Jägle, Eric Aimé; Arora, Amit

doi:10.1016/j.ijheatmasstransfer.2021.122492

Cited by 20 publications

(11 citation statements)

References 48 publications

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“…where G is the temperature gradient, R is the solidification rate, N 0 is the number of available nucleation sites, and a and n are material-dependent constants that describe the relation between solidification rate and undercooling. The typical G and R for the DED process were reported to be in the ranges of 10 4 - 10 7 K/m and 10 −4 -10 −1 m/s, respectively [119][120][121][122]. Equation (5) indicates that the combination of low G and high R, together with the abundance of the nucleation sites, could promote the formation of randomly oriented equiaxed grains, which is illustrated by the solidification diagram displayed in Figure 4(b) [117].…”

Section: Grain Morphologymentioning

confidence: 98%

“…Aside from the residual stress-based studies, significant attention has been given to the numerical methods that provide the predictive capability of the microstructural evolution in AB DED samples, especially the grain morphologies [114,121,[327][328][329]. This is achieved through the coupling of temperature field evolution in the simulated melt pool to reliable criteria [118,123] on CET in metallic melts.…”

Section: Modelling and Simulation Studies On Dedmentioning

confidence: 99%

See 1 more Smart Citation

Directed energy deposition of metals: processing, microstructures, and mechanical properties

Kumar

Chandra

et al. 2022

International Materials Reviews

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Amongst the many additive manufacturing (AM) techniques, directed energy deposition (DED) is a prominent one, which can also be used for the repair of damaged components. In this paper, we provide an overview on it, with emphasis on the typical microstructures of DED alloys and discuss the processing-microstructure-mechanical property correlations. Comparison is made with those manufactured using the conventional techniques and those obtained with laser beam powder bed fusion (LB-PBF). The characteristic solidification rates and thermal histories in DED result in distinct micro-and meso-structural features and mechanical performance, which are succinctly summarized. The potential of DED for manufacturing graded materials and for component repair is elaborated while highlighting the key-associated challenges and possible solutions. Modelling and simulation studies that facilitate an in-depth understanding of the DED technique are summarized. Finally, some critical issues and research directions that would help develop DED further and extend its application potential are identified.

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Section: Grain Morphologymentioning

confidence: 98%

Section: Modelling and Simulation Studies On Dedmentioning

confidence: 99%

Directed energy deposition of metals: processing, microstructures, and mechanical properties

Kumar

Chandra

et al. 2022

International Materials Reviews

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“…A proposed fin modeling-based temperature distribution prediction developed by Basil J. Paudel et al [24] can anticipate the onset of the substrate-affected zone during the DED process. Amit Kumar Singh et al [25] and Claire Bruna-Rosso et al [26] computed the thermal cycle and melt pool size for different laser parameters and verified by experiment. Their model can fairly predict the transition in the melt pool with varying input parameters.…”

Section: Introductionmentioning

confidence: 96%

Numerical simulation on melt pool and solidification in the direct energy deposition process of GH3536 powder superalloy

Liu

Liu²,

Li³

et al. 2023

Preprint

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In the direct energy deposition (DED) process, the highly energetic laser, rapid melting, and solidification processes lead to complex heat transfer and flow phenomena. A three-dimensional finite element model (FEM) is established to study the effect of process parameters on the melt pool and solidification quality during the DED process. The heat transfer, fluid flow, and solidification in the DED process of the GH3536 superalloy are studied. By investigating the effects of laser power, scanning speed, and feed rate on the morphology of melt pool and interlayer fusion, the appropriate input parameters for GH3536 are obtained. Temperature gradient and solidification rate obtained in transient thermal distribution are applied to predict the quality and morphology of the solidified structure at the cut-off point. Results show that high laser power and low scanning speed or feed rate will enlarge the melt pool. Well-solidified microstructure frequently appears in the middle of the parameter set; focusing on the enlargement of the melt pool is not the best strategy. The correlation between feed rate and laser power is not obvious. The minimum threshold for scanning speed is found at a given feed rate. When the scanning rate is below the threshold, abnormal morphology of the melt pool and irregular solidification structures will occur. The laser power and scanning speed range suitable for the GH3536 superalloy are summarized, and the undesirable and possibly fluctuating parameters are marked. The middle part of the parameter set is recommended for the feed rate.

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“…Nevertheless, the poor printability of Al is related to the inherent characteristics of Al alloy and the LAM process (e.g. high thermal conductivity and high laser reflectivity, strong oxidizing sensitivity, high hydrophilicity, poor powder fluidity, high thermal expansivity and high cooling rate [31][32][33]). The near-eutectic Al-Si alloy is relatively mature and reliable for LAM processing due to its outstanding printability [34][35][36].…”

Section: Introductionmentioning

confidence: 99%

Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

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Investigation of temperature distribution and solidification morphology in multilayered directed energy deposition of Al-0.5Sc-0.5Si alloy

Cited by 20 publications

References 48 publications

Directed energy deposition of metals: processing, microstructures, and mechanical properties

Directed energy deposition of metals: processing, microstructures, and mechanical properties

Numerical simulation on melt pool and solidification in the direct energy deposition process of GH3536 powder superalloy

Review on laser directed energy deposited aluminum alloys

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