Determination of Location-Specific Solidification Cracking Susceptibility for a Mixed Dissimilar Alloy Processed by Wire-Arc Additive Manufacturing

Sridar, Soumya; Sargent, Noah; Wang, Xin; Klecka, Michael A.; Xiong, Wei

doi:10.3390/met12020284

Determination of Location-Specific Solidification Cracking Susceptibility for a Mixed Dissimilar Alloy Processed by Wire-Arc Additive Manufacturing

Journal Article · Sat Feb 05 00:00:00 EST 2022 · Metals

DOI:https://doi.org/10.3390/met12020284· OSTI ID:1843876

Sridar, Soumya; Sargent, Noah; Wang, Xin; Klecka, Michael A.;

Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy mixture of 26 wt.% P91 and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks in the FCC matrix, which increased in length along with the enrichment of Nb (~27 to 56 wt.%) and Cu (~87 wt.%) in the middle and top regions. DICTRA simulations to model location-specific solidification cracking susceptibility showed that the top region with the highest cooling rate (270 K/s) has the highest solidification cracking susceptibility in comparison with the middle and bottom regions. This is in good agreement with the experimentally observed varying crack length. From Scheil simulations, it was deduced that enrichment of Nb and Cu affected the solidification range as high as ~77%, in comparison with the matrix composition. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.

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Research Organization:: Univ. of Pittsburgh, PA (United States)

Sponsoring Organization:: USDOE; USDOE Office of Fossil Energy (FE)

Grant/Contract Number:: FE0031637

OSTI ID:: 1843876

Alternate ID(s):: OSTI ID: 1842654

Journal Information:: Metals, Journal Name: Metals Journal Issue: 2 Vol. 12; ISSN MBSEC7; ISSN 2075-4701

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

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