Multi-scale simulation of dendrite growth for direct energy deposition of nickel-based superalloys

Xiao, Wenjia; Li, Simeng; Wang, Cunshan; Shi, Yan; Mazumder, J.; Xing, Hui; Song, Lijun

doi:10.1016/j.matdes.2018.107553

Cited by 60 publications

(15 citation statements)

References 45 publications

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“…According to the traditional cast iron theory, graphitic phases could be obtained under near-equilibrium cooling conditions (relatively low cooling rate 45 ). However, this is not the case in the laser cladding process, where the ultrahigh cooling happens (≥10 3 k·s –1 46 ). As the spherical or nearly spherical graphitic phases composed of graphene-like few-layer microstructures are found to contribute significantly to the coatings’ antifriction behavior, their formation mechanism is studied comprehensively.…”

Section: Resultsmentioning

confidence: 98%

Laser Cladding Induced Spherical Graphitic Phases by Super-Assembly of Graphene-Like Microstructures and the Antifriction Behavior

Weng

Zhang

et al. 2020

ACS Cent. Sci.

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Laser cladding coatings with excellent wear resistance behaviors are prepared on a titanium alloy substrate with a new precursor material system comprising nanoscale B 4 C and Ni60A self-fluxing alloy powder. Structural analysis reveals the existence of micron-size spherical or nearly spherical graphitic phases in the prepared coatings, which are composed of graphene-like microstructures closely associated with other reinforcement phases of high hardness such as TiC and CrB. The formation mechanism of these graphitic phases involves in situ superassembly of uncombined C atoms via repeated growth and reorientation of the graphene-like microstructures and is closely related to the laser processing parameters as well as the precursor compositions. The coexistence of these heterogeneous phases enable the obtained coatings with high wear resistance and low friction coefficient. It was found that the wear resistance of the coating has a remarkable 43.67 times enhancement than that of the titanium alloy while simultaneously showing a low friction coefficient (∼0.35). The understanding of the formation mechanism on the graphene-related novel microstructures with significantly improved mechanical properties is expected to lay the foundation for future developments and applications of graphene and its related carbon materials, such as large-scale production and further incorporation into composite materials with desired local structures.

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Section: Resultsmentioning

confidence: 98%

Laser Cladding Induced Spherical Graphitic Phases by Super-Assembly of Graphene-Like Microstructures and the Antifriction Behavior

Weng

Zhang

et al. 2020

ACS Cent. Sci.

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“…The simulated columnar dendrite arm spacing is consistent with the experimental results. Xiao et al (2019) also combined the finite element model with the PFM to establish a multi-scale model to analyze the solidification behavior and dendrite growth during the direct energy deposition process of Inconel 718 alloy. The predicted results of columnar dendrite morphology and dendrite arm spacing provided a good fit to experimental results.…”

Section: ; Dementioning

confidence: 99%

Phase field simulation of microstructure evolution and process optimization during homogenization of additively manufactured Inconel 718 alloy

Chen

Shi

et al. 2022

Front. Mater.

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An in-depth and integral understanding of the microstructural evolution during thermomechanical process (TMP) is of great significance to optimize the manufactural process for high-quality components via additive manufacturing. The solidified microstructure model of Inconel 718 alloy fabricated via laser powder bed fusion (L-PBF) is established by multiphase field model firstly. Furthermore, the microstructural evolution during homogenization process is simulated and optimized in this study. Phase field simulation results show that the concentration gradient of Nb along the radius of the cellular substructure decreases from the initial 1.217 wt% to 0.001 wt%, and 67% area fraction of the Laves phase dissolves at the homogenization time of 0.5 h, which have achieved the homogenization purpose. The experimental results show that the average grain size decreases from 9.4 μm to 5.9 μm at the homogenization time from 1.5 h (the standard AMS 5383) to 0.5 h, which resulted in the increase of yield strength and tensile strength of the aged alloy by 14% and 6%, respectively. This research can provide guidance and reference for the microstructural control as well as the TMP parameters design of the additive manufactured alloys.

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“…Note that the temperature gradient and cooling rate are constant in the dendrite growth model. Since Nb is one of the most important segregation elements in Inconel 718, and the Nb-rich precipitates in the inter-dendritic regions significantly affect the mechanical performance of the as-built products, the material is treated as Ni-Nb binary alloy following [22,37,38]. The concentration of Nb is 5 wt.%.…”

Section: Dendrite Growth In Additive Manufacturingmentioning

confidence: 99%

A multi-grid Cellular Automaton model for simulating dendrite growth and its application in additive manufacturing

Yu¹,

Li²,

Yan³

et al. 2021

Preprint

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The dendrite growth in casting and additive manufacturing is rather important and related to the formation of some defects. However, quantitatively simulating the growth of dendrites with arbitrary crystallographic orientations in 3-dimension(3D) is still very challenging. In the present work, we develop a multi-grid Cellular Automaton (CA) model for the dendrite growth. In this model, the interfacial area is further discretized into a child grid, on which the decentered octahedron growth algorithm is performed. The model is comprehensively and quantitatively verified by comparing with the prediction of analytical models and a published x-ray imaging observation result, proving that the model is quantitatively and morphologically accurate. After that, with the temperature gradient and cooling rate extracted from a finitevolume-method(FVM)-based thermal-fluid model, the model was applied in reproducing the dendrite growth process of nickel-based superalloy during a single-track electron beam melting process. The simulation results agree fairly well with the experimental observation, demonstrating the feasibility and effectiveness of using the model in additive manufacturing.

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Multi-scale simulation of dendrite growth for direct energy deposition of nickel-based superalloys

Cited by 60 publications

References 45 publications

Laser Cladding Induced Spherical Graphitic Phases by Super-Assembly of Graphene-Like Microstructures and the Antifriction Behavior

Laser Cladding Induced Spherical Graphitic Phases by Super-Assembly of Graphene-Like Microstructures and the Antifriction Behavior

Phase field simulation of microstructure evolution and process optimization during homogenization of additively manufactured Inconel 718 alloy

A multi-grid Cellular Automaton model for simulating dendrite growth and its application in additive manufacturing

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