An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition

Gao, Lin; Chuang, Andrew C.; Kenesei, Peter; Ren, Zhongshu; Balderson, Lilly; Sun, Tao

doi:10.1016/j.ijmachtools.2023.104089

An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition

Journal Article · Wed Nov 08 23:00:00 EST 2023 · International Journal of Machine Tools and Manufacture

DOI:https://doi.org/10.1016/j.ijmachtools.2023.104089· OSTI ID:2229540

^[1]; Chuang, Andrew C. ^[2]; Kenesei, Peter ^[2]; ^[3]; Balderson, Lilly ^[1]; ^[3]

University of Virginia, Charlottesville, VA (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)
University of Virginia, Charlottesville, VA (United States); Northwestern University, Evanston, IL (United States)

Directed energy deposition (DED) with a coaxial wire-laser configuration has gained significant attention in recent years for the production of large-scale metallic components because of its low directional dependence, fast deposition rate, high feedstock efficiency, and low manufacturing costs. This work studies the coaxial wire-laser DED process of Inconel 718 alloy under a stable deposition condition with a relatively low input volumetric energy density (55.5J/mm³). Post characterization reveals a cluster of refined grains at the center-bottom region of the as-printed track. Operando high-energy synchrotron X-ray experiments and multi-physics modeling are applied innovatively to study the fundamental mechanism responsible for the formation of this microstructure. The X-ray diffraction experiment provides direct evidence, which is supported by the simulation, that the feeding wire can reach the melt pool bottom and release solid particles (primarily carbides) near the mushy zone owing to insufficient melting. Consequently, these sub-micron sized particles suppress the growth of large columnar grains and cause the formation of unique microstructural heterogeneity. In conclusion, this discovery offers new opportunities for tailoring the solidification microstructure by controlling the melting state of the feedstock wire in DED process, in addition to commonly known factors such as the thermal gradient and solidification velocity.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2229540

Alternate ID(s):: OSTI ID: 2369127

Journal Information:: International Journal of Machine Tools and Manufacture, Journal Name: International Journal of Machine Tools and Manufacture Journal Issue: Part A Vol. 194; ISSN 0890-6955

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
Inconel 718
Solidification microstructure
Synchrotron X-ray diffraction
Wire-laser directed energy deposition

An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition

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