New 3D model for accurate prediction of thermal and microstructure evolution of laser powder cladding of Ti6Al4V alloy

Youssef, Doaa; Hassab-Elnaby, Salah; Al-Sayed, Samar Reda

doi:10.1016/j.aej.2021.09.014

Cited by 25 publications

(7 citation statements)

References 40 publications

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“…The difference between parallel and perpendicular grain orientation is reported in prior work [51], [53][54][55]. This can explain why the perpendicular scan direction exhibits long columnar grains extending to the surface, while the parallel scan direction results in equiaxed at the surface with columnar grains beneath as each pass of the laser advances at 20 µm hatch spacing with each line scan.…”

Section: Statements and Declarationsmentioning

confidence: 73%

“…This model led to the conclusion that increasing the parameters of laser power and scan speed increases the heating and cooling rates. According to Youseff et al [55], laser power contributed most to the peak melt-pool and heat affected zone temperatures when compared to experimental results, and the quick movement of the scanning laser beam leads to the scan speed having more effect on cooling rate than power. Laser remelting has also been investigated as a means to understand the thermal impact on microstructure [53].…”

Section: Et Al [1] Incorporatesmentioning

confidence: 97%

“…Thermal history and microstructural evolution (grain morphology, grain size, and texture) considering time history of material phase transformation and fluid dynamics with materials have rarely been studied [22][23]. Youseff et al [55] developed a three-dimensional finite-difference analysis model to predict thermal and clad layer morphology and geometry evolution of laser powder cladding of Ti6Al4V alloy. This model led to the conclusion that increasing the parameters of laser power and scan speed increases the heating and cooling rates.…”

Section: Et Al [1] Incorporatesmentioning

confidence: 99%

See 2 more Smart Citations

Thermal Profile Modeling and Microstructural Evolution in Laser Processing of Inconel 625 Plates

Lawson¹,

Ghayoor²,

Tabei³

et al. 2023

Preprint

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Thermal modeling is used in additive manufacturing laser processes to predict microstructural evolution of the materials under specified process conditions and parameters. The objective of this study was to develop, analyze and compare two predictive models: an analytical model and a numerical model for laser processing of materials of Inconel 625. These models were compared with experimental results for thermal profiling, and the effect of thermal profiles on microstructure of the experimental samples was explored. The three approaches; analytical modeling, numerical modeling, and experimental results were evaluated against thermal profile histories and correlated to microstructural evolution in laser processing. Maximum temperatures in the thermal profile of both models were shown in good agreement when compared to the experimental results. Cooling curves were also correlated with microstructure in terms of grain size, morphology, orientation, and texture evolution, with findings that match previously reported results. This research validates the proposed numerical model for examining optimal laser processing conditions for IN625 through both thermal history and microstructure comparison with experimental results using literature derived thermo-physical material properties.

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Section: Statements and Declarationsmentioning

confidence: 73%

Section: Et Al [1] Incorporatesmentioning

confidence: 97%

Section: Et Al [1] Incorporatesmentioning

confidence: 99%

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Thermal Profile Modeling and Microstructural Evolution in Laser Processing of Inconel 625 Plates

Lawson¹,

Ghayoor²,

Tabei³

et al. 2023

Preprint

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“…New clad phases were formed depending on the diffusion rates, chemical reactions, growth properties and nucleation between the reacting species as well as the thermophysical properties of the different elements. [48] According to the literature, [6] the quality and performance of the products such as their hardness and wear resistance are dependent on the element distribution of the coated surface and the homogeneity of the formed phases inside the matrix. The SEM micrograph presented in Figure 2 illustrates the whole clad layer of a sample processed at 20 g min À1 that constitutes two zones, clad zone (CZ), and interface zone (IZ).…”

Section: A Clad Layer Characterizationmentioning

confidence: 99%

Novel Surface Topography and Microhardness Characterization of Laser Clad Layer on TC4 Titanium Alloy Using Laser-Induced Breakdown Spectroscopy and Machine Learning

Al-Sayed

Samad²,

Mohamed³

et al. 2022

Metall Mater Trans A

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This study was performed to characterize surface topography and microhardness of 40 wt pct NiCrBSiC-60 wt pct WC hard coating on TC4 titanium after coaxial laser cladding via Laser Induced Breakdown Spectroscopy (LIBS) and machine learning. The high content of the hard WC particles is accomplished to enhance the abrasion wear resistance of such alloy. Various powder feeding rates were carried out during laser cladding process. The energy-dispersive X-ray analysis assured that W content in the metal matrix notably increased from 26.19 to 53.49 pct while the Ti content decreased from about 15.16 to 0.46 pct for the clad layer processed at 20 and 60 g min−1, respectively. The LIBS measurements successfully estimated such elements’ concentration as well as the clad layers' topography indicating that the effect of material matrix is a crucial challenge. Therefore, canonical correlation analysis and Belsley collinearity diagnostics were established to identify the essential emission lines from the whole spectra. Then, an optimized adaptive boosted random forest classifier was developed for microhardness investigation, with accuracy, sensitivity, and F1 score values of 0.9667. The results, confirmed by the metallurgical study, clarified that most of the titanium and tungsten emission lines have a significant impact on the surface topography as well as the microhardness values. The misclassification was attributed to the matrix effect such that the samples processed at 40 and 60 g min−1 were comparable in microstructure and chemical characterization unlike the one processed at 20 g min−1. Vickers microhardness of the metal matrix coating increased with the increase in the powder feeding rate, which is assured by the quantitative classification model. Graphical Abstract

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“…Owing to ductility as well as the high toughness of Co-based alloy and TC21 substrate, residual stresses may not be capable of causing cracks. However, during rapid heating as well as cooling of the deposition process, and the different thermal expansion coefficients of WC particles and Stellite-6 Co-based alloy powder, a large temperature differential would generate thermal stresses in WC particles [25].…”

Section: The Powder Feed Rate Of 60 ɡ Min −1mentioning

confidence: 99%

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

Elshaer

Elshazli

Al-Shatri

et al. 2022

Int J Adv Manuf Technol

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In the present study, layers consisting of 40% Stellite-6 and 60% WC were deposited on Ti-6Al-3Mo-2Sn-2Zr-2Nb-1.5Cr-0.1Si (TC21) alloy by means of direct energy deposition (DED) technology aiming to improve the microstructure and microhardness. Five powder feeding rates ranging from 20 to 100 ɡ min−1 were applied using CW fiber-coupled diode laser with 4 kW output power. The deposited layers were analyzed via scanning electron microscopy (SEM), energy-dispersive X-ray analysis (EDX), and X-ray diffractometry (XRD). The results show that WC particles are dispersed in a heterogeneous manner in the deposition zone, especially at the rates 20, 40, and 60 ɡ min−1. In addition, microcracks appeared in the interface zone particularly at 100 ɡ min−1 due to the higher induced residual stresses caused by the difference in the coefficient of thermal expansion between Stellite-6, WC particles, and TC21 substrate alloy. Several complex carbides and intermetallic compounds such as W2C, TiC, Cr7C3, Co3W3C, and Co25Cr25W8C2 were detected in the deposited layers depending on the powder feeding rate. With further increase in the powder feeding rate, the fractions of W2C and the bulk (unmelted) WC particles were increased and that of the TiC particle was reduced correspondingly due to the thermal diffusion. The layer thickness increased from 1.3 to 2.7 mm when the powder feeding rate increased from 40 to 100 ɡ min−1, while the dilution ratio decreased from 23 to 5.3% as a result of the thermal diffusion of the laser energy. The microhardness of the composite was found to be three times higher than that recorded for the TC21 substrate (1020 vs. 340 HV0.05). The results revealed that the best homogeneous microstructure with the highest microhardness was achieved at the powder feeding rate of 100 ɡ min−1 whereas microcracks free layers were accomplished at 40 ɡ min−1.

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New 3D model for accurate prediction of thermal and microstructure evolution of laser powder cladding of Ti6Al4V alloy

Cited by 25 publications

References 40 publications

Thermal Profile Modeling and Microstructural Evolution in Laser Processing of Inconel 625 Plates

Thermal Profile Modeling and Microstructural Evolution in Laser Processing of Inconel 625 Plates

Novel Surface Topography and Microhardness Characterization of Laser Clad Layer on TC4 Titanium Alloy Using Laser-Induced Breakdown Spectroscopy and Machine Learning

Impact of laser process parameters in direct energy deposition on microstructure, layer characteristics, and microhardness of TC21 alloy

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