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Grain Structure Evolution in Fe-6Si During Directed Energy Deposition

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Abstract

The purpose of this study is to explore the effect of additive manufacturing (AM) process variables on the grain structure of Fe-6Si, a soft-magnetic alloy used in electrical machine and grid applications. Samples were fabricated with laser engineered net shaping (LENS) with varying inter-pass timing and numbers of unidirectional passes. The results show that the grain structure was affected by both solidification and solid-state grain growth mechanisms. A model of the LENS process suggests that, although shorter inter-pass times encourage greater nucleation of new grains and therefore grain refinement during solidification, these conditions also help maintain high solid-state temperatures that allow for grain boundary motion to keep pace with the build rate. Grains formed under these conditions may span multiple layers, and the high-temperature gradient promotes directional growth. This new understanding of these microstructure evolution mechanisms will aid in using process conditions to control the competition between solidification and solid-state grain growth to create grain structures that may not be possible with conventional processing.

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Acknowledgements

The authors would like to acknowledge Sarah Graham and Andres Marquez Rossy for sample preparation and electron microscopy, respectively. Sandia National Laboratories is a multi-mission laboratory managed and operated by National Technology and Engineering Solutions of Sandia LLC, a wholly owned subsidiary of Honeywell International Inc. for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. This paper describes objective technical results and analysis. Any subjective views or opinions that might be expressed in the paper do not necessarily represent the views of the U.S. Department of Energy or the United States Government.

Funding

Research was sponsored the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technology Office. Support from the Sandia National Laboratories Laboratory Directed Research and Development (LDRD) program is acknowledged.

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Authors and Affiliations

  1. Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USA

    A. Plotkowski & C. M. Fancher

  2. Computational Sciences and Engineering Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USA

    J. Coleman

  3. University of Tennessee-Knoxville, Knoxville, TN, 37916, USA

    M. P. Haines

  4. Material, Physical, and Chemical Sciences Center, Sandia National Laboratories, Albuquerque, NM, 87185, USA

    S. R. Whetten & A. B. Kustas

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Plotkowski, A., Coleman, J., Fancher, C.M. et al. Grain Structure Evolution in Fe-6Si During Directed Energy Deposition. JOM 76, 1031–1043 (2024). https://doi.org/10.1007/s11837-023-06279-3

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