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Computational Tools for Additive Manufacture of Tailored Microstructure and Properties

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Abstract

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Currently, most additive builds use a single set of process parameters which results in a part with a homogenous microstructure that provides a singular performance level. To move beyond this state, a set of computational tools has been developed to track material evolution through each step of the additive process. Computational fluid dynamics and phase field models for microstructure evolution as a function of processing parameters and a crystal plasticity model coupling microstructure and mechanical properties for performance predictions are leveraged to establish a connection between additive parameters, the final microstructure, and mechanical performance. This framework was utilized to tailor spatially-varying mechanical properties in a part by controlling the microstructure evolution during the additive process. Specifically, a turbine blade was 3D-printed from nickel superalloy IN718 using laser powder bed fusion with coarse grains in the airfoil section and finer grains printed in the root of the blade. The benefit of being able to intentionally insert coarse grains in the high-temperature region of the blade was showcased with a microstructure-sensitive creep model that indicates longer creep life for coarser grains.

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Acknowledgements

This material is based upon work supported by the Department of Energy under Award Number(s) DE-FE0031642. Disclaimer: "This presentation was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof."

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Authors and Affiliations

  1. Collins Aerospace, One Hamilton Road, Windsor Locks, CT, 06096, USA

    R. Acharya

  2. Raytheon Technologies Research Center, 411 Silver Lane, East Hartford, CT, 06118, USA

    L. Borkowski, B. Fisher, J. Sharon, A. Staroselsky & A. Ventura

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  1. R. Acharya
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  2. L. Borkowski
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Correspondence to L. Borkowski.

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Acharya, R., Borkowski, L., Fisher, B. et al. Computational Tools for Additive Manufacture of Tailored Microstructure and Properties. Metallogr. Microstruct. Anal. 12, 906–923 (2023). https://doi.org/10.1007/s13632-023-01023-4

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