Influence of alloy solidification path on melt pool behavior in additive manufacturing

Wells, Scott; Plotkowski, Alexander J.; Coleman, John; Krane, Matthew J. M.

doi:10.1016/j.ijheatmasstransfer.2024.125632

Influence of alloy solidification path on melt pool behavior in additive manufacturing

Journal Article · Wed May 22 00:00:00 EDT 2024 · International Journal of Heat and Mass Transfer

DOI:https://doi.org/10.1016/j.ijheatmasstransfer.2024.125632· OSTI ID:2373015

Wells, Scott ^[1]; ^[2]; ^[2]; Krane, Matthew J. M. ^[3]

Purdue Univ., West Lafayette, IN (United States). Purdue Center of Metal Casting Research; Excet, Springfield, VA (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Purdue Univ., West Lafayette, IN (United States). Purdue Center of Metal Casting Research

Numerical models used to study transport phenomena in laser-powder bed fusion processes often rely on assumptions and simplifications to reduce their computational expense. One common simplification is in the description of latent heat evolution during the solid-liquid phase change (i.e., the solidification pathway), justified by the fact that the mushy zone thickness is similar to the numerical grid spacing used for continuum transport models. The lack of resolution of transport phenomena in the mushy zone motivates the use of computationally convenient solidification paths such as linear or sigmoidal relationships over pathways derived from fundamental solidification theory such as equilibrium or Scheil models. In the present work, an uncertainty quantification (UQ) framework is used to analyze the influence of solidification pathway selection on the solidification dynamics and melt pool geometries in laser based additive manufacturing (AM) of IN625. Results show the solidification pathway has a quantifiable influence on the cooling rate at the liquidus isotherm, mushy zone thickness, and solidification time. Due to similarities in the latent heat evolution at the beginning of solidification, the equilibrium and Scheil models predict similar cooling rates near the liquidus isotherm, however the wider freezing range of Scheil leads to a wider mushy zone compared to equilibrium. The non-physical latent heat release profiles of sigmoidal and linear paths lead to significant overpredictions of cooling rates at the liquidus isotherm compared to equilibrium and Scheil. Finally, these results indicate that careful consideration should be given to the choice of solidification pathway to ensure reliable model predictions.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Science (SC)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2373015

Journal Information:: International Journal of Heat and Mass Transfer, Journal Name: International Journal of Heat and Mass Transfer Vol. 229; ISSN 0017-9310

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Additive manufacturing
Computational modeling
Heat transfer
Laser powder bed fusion
Solidification Pathways

Influence of alloy solidification path on melt pool behavior in additive manufacturing

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