Modeling of rapid solidification in Laser Powder Bed Fusion processes

This paper addresses a numerical framework for modeling site-specific microstructure evolution in Laser Powder Bed Fusion (LPBF), where rapid solidification significantly influences the microstructure and properties of manufactured components. The fine microstructure and rapid solidification can enhance mechanical properties in final parts, yet pose challenges in controlling microstructure and addressing potential defects. In this study, an in-house developed free surface thermo-fluidic Computational Fluid Dynamics (CFD) model is coupled with a binary alloy phase-field model characterized by rapid solidification kinetics. The CFD model considers complex fluid flows related to Marangoni and recoil pressure, laser-material interactions, and rapid melting and solidification of the melt pool. A convergence study for the phase-field model is conducted, comparing simulated partition coefficients with the Continuous Growth Model (CGM) theory. The study investigates the individual effects of temperature gradients and solidification rates on simulated microstructure. Results indicate that, for the same order of magnitude change, the solidification rate has a more pronounced effect on microstructure than temperature gradients. The paper concludes with the simulation of site-specific microstructure evolution within the melt pool, comparing the results with experiments conducted at varied scanning speeds. The predicted microstructure aligns well with experimental measurements, suggesting the potential utility of the developed phase-field model in quantitative microstructural modeling. Overall, this work contributes to understanding microstructure evolution under rapid solidification conditions, providing a fundamental basis for optimizing the LPBF process.