Development of a rapid solidification model for additive manufacturing process and application to Al-Si alloy
Source abstract
Abstract
Accurate prediction of the solidification microstructure produced by additive manufacturing (AM) process is indispensable for the precise manufacturing process control. In the present study, a simple solidification model that can be applied to the powder bed fusion – laser beam (PBF-LB) process has been developed by integrating conventional and rapid solidification theories in literature. Based on the solidification parameters calculated by Rosenthal equation, the present solidification model can predict the primary dendrite arm spacing (PDAS), primary cell fraction, and solute profile using solute trapping, dendrite tip undercooling, and eutectic undercooling. Single track experiments for Al-12Si binary alloy were also performed to validate the accuracy of the model.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Solidification and crystal growth phenomena · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (47)
Show source-provided references
1. Selective laser melting of aluminum alloys10.1557/mrs.2017.63 ↗
2. Rapid solidification as non-ergodic phenomenon10.1016/j.physrep.2019.06.002 ↗
3. Laser powder-bed fusion additive manufacturing: physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones10.1016/j.actamat.2016.02.014 ↗
4. Theory of microstructural development during rapid solidification10.1016/0001-6160(86)90056-8 ↗
5. Solute trapping and diffusionless solidification in a binary system10.1103/PhysRevE.76.031606 ↗
6. A new microsegregation model for rapid solidification multicomponent alloys and its application to single-crystal nickel-base superalloys of laser rapid directional solidification10.1016/j.actamat.2016.07.008 ↗
7. A comparative study of analytical rosenthal, finite element, and experimental approaches in laser welding of aa5456 alloy10.3390/met10040436 ↗
8. Solidification cracking susceptibility in pulsed laser welding of Al–Mg alloys10.1016/j.mtla.2019.100417 ↗
9. Rapid solidification: selective laser melting of AlSi10Mg10.1007/s11837-015-1763-3 ↗
10. On the primary spacing and microsegregation of cellular dendrites in laser deposited Ni–Nb alloys10.1088/1361-651X/aa7369 ↗
11. Investigation on microsegregation of IN718 alloy during additive manufacturing via integrated phase-field and finite-element modeling10.1007/s11665-018-3620-3 ↗
12. Quantitative phase-field modeling of solute trapping in rapid solidification10.1016/j.actamat.2020.116562 ↗
13. Phase field modeling of rapid resolidification of Al-Cu thin films10.1016/j.jcrysgro.2019.125418 ↗
14. Quantitative phase field modeling of solute trapping and continuous growth kinetics in quasi-rapid solidification10.1016/j.actamat.2019.02.009 ↗
15. Cellular automaton modeling for dendritic growth during laser beam welding solidification process10.2351/1.5040605 ↗
16. Mathematical theory of heat distribution during welding and cutting
17. Stability of cellular microstructure in laser powder bed fusion of 316L stainless steel10.1016/j.msea.2018.10.051 ↗
18. A comprehensive comparison of the analytical and numerical prediction of the thermal history and solidification microstructure of Inconel 718 products made by laser powder-bed fusion10.1016/J.ENG.2017.05.023 ↗
19. The coupled zone of rapidly solidified Al-Si alloys in laser treatment10.1016/0956-7151(92)90106-O ↗
20. On the formation of AlSi10Mg single tracks and layers in selective laser melting: microstructure and nano-mechanical properties10.1016/j.jmatprotec.2015.11.016 ↗
21. Melt pool characterization for selective laser melting of Ti-6Al-4V pre-alloyed powder
22. Tang · 2017
23. Heat and fluid flow in additive manufacturing–Part II: powder bed fusion of stainless steel, and titanium, nickel and aluminum base alloys10.1016/j.commatsci.2018.04.027 ↗
24. Understanding the laser powder bed fusion of AlSi10Mg alloy10.1007/s13632-020-00659-w ↗
25. Solidification modes during additive manufacturing of steel revealed by high-speed X-ray diffraction10.1016/j.actamat.2023.118713 ↗
26. W. Kurz, D.J. Fisher, Fundamentals of solidification, 1984.
27. Unravelling the multi-scale structure–property relationship of laser powder bed fusion processed and heat-treated AlSi10Mg10.1038/s41598-021-85047-2 ↗
28. Eutectic growth under rapid solidification conditions10.1007/BF02650266 ↗
29. Microstructural evolution in Mg–Zn alloys during solidification: an experimental and simulation study10.1016/j.jcrysgro.2014.02.010 ↗
30. The marangoni convection effect on melt pool formation during selective laser melting process, defect and diffusion forum
31. A model of microsegregation during binary alloy solidification10.1016/S0017-9310(99)00268-9 ↗
32. Effect of silicon content on densification, mechanical and thermal properties of Al-xSi binary alloys fabricated using selective laser melting10.1016/j.msea.2016.11.059 ↗
33. The effect of solidification rate on microsegregation10.1007/BF02645003 ↗
34. Narra · 2017
35. Reprint of: factSage thermochemical software and databases, 2010–201610.1016/j.calphad.2016.07.004 ↗
36. Thermal and electrical conductivity in Al–Si/Cu/Fe/Mg binary and ternary Al alloys10.1007/s10853-015-9115-9 ↗
37. Diffusion coefficients of some solutes in fcc and liquid Al: critical evaluation and correlation10.1016/S0921-5093(03)00624-5 ↗
38. The application of computational thermodynamics and a numerical model for the determination of surface tension and Gibbs–Thomson coefficient of aluminum based alloys10.1016/j.tca.2011.05.015 ↗
39. Computational thermodynamic calculations: factSage from CALPHAD thermodynamic database to virtual process simulation10.1007/s11663-020-01908-7 ↗
40. Modeling of thermal behavior and microstructure evolution during laser cladding of AlSi10Mg alloys10.1016/j.optlastec.2019.105926 ↗
41. Dendritic growth in Al–Si alloys during brazing. Part 2: computational modeling10.1016/j.ijheatmasstransfer.2005.01.036 ↗
42. The effect of cooling rate on the dendrite spacing in splat-cooled aluminium alloys
43. Nucleation mechanism of the eutectic phases in aluminum–silicon hypoeutectic alloys10.1016/j.actamat.2004.05.045 ↗
44. Nucleation behaviour and microstructure of single Al-Si12 powder particles rapidly solidified in a fast scanning calorimeter10.1007/s10853-021-06096-6 ↗
45. Fast scanning calorimetry study of Al alloy powder for understanding microstructural development in laser powder bed fusion10.1016/j.matdes.2022.110830 ↗
46. Rapid solidification and non-equilibrium phase constitution in laser powder bed fusion (LPBF) of AlSi10Mg alloy: analysis of nano-precipitates, eutectic phases, and hardness evolution10.1007/s11661-019-05505-5 ↗
47. An extended rosenthal weld model