Abstract
The mechanical properties of metal components are determined by the solidification behaviour and microstructure. A quantitative phase field model is used to investigate the microstructure evolution of fused-coating additive manufacturing, by which to improve the quality of deposition. During the fused-coating process, the molten metal in a crucible flows out of a nozzle and then reaches the substrate. The solidification happens at the moment when the molten metal comes into contact with substrate moving in three-dimensional space. The macroscopic heat transfer model of fused-coating is established to get the temperature field considered as the initial temperature boundary conditions in the phase field model. The numerical and experimental results show that the morphology of grains varies with different solidification environments. Columnar grains are observed during the early period at the bottom of fused-coating layer and the equiaxed grains appear subsequently ahead of the columnar grains. Columnar dendrites phase field simulations about the grains morphology and solute distribution are conducted considering the solidification environments. The simulation results are in good agreement with experimental results.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Wang Huaming. Materials' fundamental issues of laser additive manufacturing for high-performance large metallic components. Acta Aeronautica et Astronautica Sinica, 2014, 35(10): 2690–2698. (In Chinese)
Arcella F G, Froes F H. Producing titanium aerospace components from powder using laser forming. JOM, 2000, 52(5): 28–30.
Gong Shuili, Suo Hongbo, Li Xuehuai. Development and Application of Metal Additive Manufacturing Technology. Aeronautical Manufacturing Technology, 2013, 13: 66. (In Chinese)
Wilkes J, Hagedorn Y C, Meiners W. Additive manufacturing of ZrO2-Al2O3 ceramic components by selective laser melting. Rapid Prototyping Journal, 2013, 19(1): 51–57.
Heinl P, Rottmair A, Korner C. Cellular titanium by selective electron beam melting. Advanced Engineering Materials, 2007, 9(5): 360–364.
Yan Yongnian, Qi Haibo, Lin Feng, et al. Produced Threedimensional Metal Parts by Electron Beam Selective Melting. Chinses Journal of Mechanical Engineering, 2007, 43(6): 87. (In Chinese)
Brandl E, Heckenberger U, Holzinger V, et al. Additive manufactured AlSi10Mg samples using Selective Laser Melting (SLM): Microstructure, high cycle fatigue, and fracture behavior. Materials & Design, 2012, 34: 159–169.
Fallah V, Corbin S F, Khajepour A. Process optimization of Ti–Nb alloy coatings on a Ti-6Al-4V plate using a fiber laser and blended elemental powders. Journal of Materials Processing Technology, 2010, 210(14): 2081–2087.
Chao Yanpu, Qi Lehua, Zuo Hansong, et al. Remelting and bonding of deposited aluminum alloy droplets under different droplet and substrate temperatures in metal droplet deposition manufacture. International Journal of Machine Tools & Manufacture, 2013, 69(3): 38–47.
Lin Xin, Yang Haiou, Chen Jing, et al. Microstructure Evolution of 316L Stainless Steel During Laser Rapid Forming. Acta Metallurgica Sinica, 2006, 42(4): 361–368.
Fallah V, Amoorezaei M, Provatas N, et al. Phase-field simulation of solidification morphology in laser powder deposition of Ti-Nb alloys. Acta Materialia, 2012, 60(4):1633–1646.
Fallah V, Corbin S F, Khajepour A. Process optimization of Ti-Nb alloy coatings on a Ti-6Al-4V plate using a fiber laser and blended elemental powders. Journal of Materials Processing Technology, 2010, 210(14): 2081–2087.
Fallah V, Alimardani M, Corbin S F, et al. Temporal development of melt-pool morphology and clad geometry in laser powder deposition. Computational Materials Science, 2011, 50(7): 2124–2134.
Xie Yu, Dong Hongbiao, Liu Jun, et al. A Multi-Scale Approach to Simulate Solidification Structure Evolution and Solute Segregation in a Weld Pool. Journal of Algorithms & Computational Technology, 2013, 7(4): 489–508.
Kundin J, Mushongera L, Emmerich H. Phase-field modeling of microstructure formation during rapid solidification in Inconel 718 superalloy. Acta Materialia, 2015, 95:343-356.
Kouchair S. Weld Metal Chemical Inhomogeneities. Welding Metallurgy, Second Edition. John Wiley & Sons, Inc. 2003, Chapter 10: 243–262.
Poorhaydari K, Patchett B M, Ivey D G. Estimation of cooling rate in the welding of plates with intermediate thickness. Welding Journal, 2005, 84(10): 149s–155s.
Jun Du, Zhengying Wei, Xin Wang, et al. A novel high-efficiency methodology for metal additive. Appl. Phys. A, 2016, 122(11): 945.
Ramirez J C, Beckermann C, Karma A, et al. Phase-field modeling of binary alloy solidification with coupled heat and solute diffusion. Physical Review E Statistical Nonlinear & Soft Matter Physics, 2004, 69(1): 051607.
Karma A. Phase-field formulation for quantitative modeling of alloy solidification. Physical Review Letters, 2001, 87(11):115701.
Echebarria B, Folch R, Karma A, et al. Quantitative phasefield model of alloy solidification. Physical Review E Statistical Nonlinear & Soft Matter Physics, 2004, 70(1): 061604.
Echebarria B, Folch R, Karma A, et al. Quantitative phasefield model of alloy solidification. Physical Review E Statistical Nonlinear & Soft Matter Physics, 2004, 70(1): 061604.
Karma A, Rappel W J. Quantitative phase-field modeling of dendritic growth in two and three dimensions. Physical Review E, 1998, 57(4): 4323–4349.
Zimmermann M, Carrard M, Kurz W. Rapid solidification of Al-Cu eutectic alloy by laser remelting. Acta Metallurgica, 1989, 37(12): 3305–3313.
Author information
Authors and Affiliations
Corresponding author
Additional information
*Zheng-ying Wei Female, born in 1967, Ph.D., processor. Her research interests mainly focus on additive manufacturing. She has so far published over 70 papers in national and international journals.
This work was financially supported by the National Key R&D Program (2016YFB1100400) and the Ministry of Education, China (6141A02022109).
Rights and permissions
About this article
Cite this article
Geng, Rw., Du, J., Wei, Zy. et al. Simulation of microstructure evolution in fused-coating additive manufacturing based on phase field approach. China Foundry 14, 346–352 (2017). https://doi.org/10.1007/s41230-017-7124-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s41230-017-7124-9