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Phase Field Modelling of Dendritic Solidification Under Additive Manufacturing Conditions

  • High Temperature Alloys: Manufacturing, Processing, and Repair
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Abstract

Melting and solidification in metal-based additive manufacturing (AM) ultimately determine the crystallographic texture, cellular/columnar dendritic growth, solute segregation, and resultant materials properties. The microstructure of AM-built alloys is closely related to various physics during the printing process. In the present study, a multi-physics model was developed to simulate the evolution of grain and dendritic-scale microstructure during laser AM of a Ni-based alloy. Computational fluid dynamics was used to simulate the melt pool dynamics and temperature distribution for the laser powder bed fusion process. Using Ni-Nb as an analogue to Inconel 625, a phase field model was applied to predict the microstructural features within a two-dimensional solidified melt pool. The predicted results exhibit fair agreement with experimental characteristics in the literature, including melt pool profile, dendrite size, dendrite morphology, and crystallographic texture. The multi-physics model paves the way for computationally predicting the chemistry-process-structure relationship in AM-built alloys, which helps to understand the fundamental physics of AM solidification.

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Acknowledgements

The authors acknowledge the support by the National Research Foundation, Prime Minister’s Office, Singapore, under its Medium Sized centre funding scheme. The computational work for this article was partially performed on resources of the National Supercomputing Centre, Singapore (https://www.nscc.sg). Thanks are extended to Dr Patrick I. O’Toole and Dr. Milan J. Patel for the valuable discussions.

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Authors and Affiliations

  1. Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore, 639798, Singapore

    Chao Tang & Hejun Du

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  1. Chao Tang
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  2. Hejun Du
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Correspondence to Chao Tang or Hejun Du.

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Tang, C., Du, H. Phase Field Modelling of Dendritic Solidification Under Additive Manufacturing Conditions. JOM 74, 2996–3009 (2022). https://doi.org/10.1007/s11837-022-05310-3

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