Abstract
Avoiding solidification cracks is one of the requirements to successfully manufacture high gamma prime superalloys by Additive Manufacturing (AM). In this research, an analytical model based on the classic Rappaz–Drezet–Gremaud (RDG) model coupled with thermal simulation was developed to predict the susceptibility of solidification cracks in Rene 80 in the directed energy deposition (DED) process. Taking into account the solidification path, local thermal history via the process model for DED, and thermal strain via finite element models, the analytical model shows a promising capability to estimate the crack formation in Rene 80. This predictive model was examined over selected print parameters, including laser power, speed, spot size, and feed rate, to account for different local cooling rates and thermal gradients. Thin wall samples of Rene 80 were fabricated to calibrate and validate the proposed model. This development provides a practical and physics-based method to evaluate the solidification cracking in additively manufactured alloys.
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Hosseinzadeh, H. et al. (2023). Prediction of Solidification Cracking in Rene 80 Superalloy During the Directed Energy Deposition Process. In: TMS 2023 152nd Annual Meeting & Exhibition Supplemental Proceedings. TMS 2023. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-031-22524-6_18
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