Numerical simulations are used in this work to investigate aspects of microstructure and microseg-regation during rapid solidification of a Ni-based superalloy in a laser powder bed fusion additive manufacturing process. Thermal modeling by finite element analysis simulates the laser melt pool, with surface temperatures in agreement with in situ thermographic measurements on Inconel 625. Geometric and thermal features of the simulated melt pools are extracted and used in subsequent mesoscale simulations. Solidification in the melt pool is simulated on two length scales. For the multicomponent alloy Inconel 625, microsegregation between dendrite arms is calculated using the Scheil-Gulliver solidification model and DICTRA software. Phase-field simulations, using Ni–Nb as a binary analogue to Inconel 625, produced microstructures with primary cellular/dendritic arm spacings in agreement with measured spacings in experimentally observed microstructures and a lesser extent of microsegregation than predicted by DICTRA simulations. The composition profiles are used to compare thermodynamic driving forces for nucleation against experimentally observed precipitates identified by electron and X-ray diffraction analyses. Our analysis lists the precipitates that may form from FCC phase of enriched interdendritic compositions and compares these against experimentally observed phases from 1 h heat treatments at two temperatures: stress relief at 1143 K (870 °C) or homogenization at 1423 K (1150 °C).

Objectives The aim of this study was to test the hypothesis that monolithic lithium disilicate glass-ceramic occlusal onlay can exhibit a load-bearing capacity that approaches monolithic zirconia, due to a smaller elastic modulus mismatch between the lithium disilicate and its supporting tooth structure relative to zirconia. Methods Ceramic occlusal onlays of various thicknesses cemented to either enamel or dentin were considered. Occlusal load was applied through an enamel-like deformable indenter or a control rigid indenter. Flexural tensile stress at the ceramic intaglio (cementation) surface—a cause for bulk fracture of occlusal onlays—was rigorously analyzed using finite element analysis and classical plate-on-foundation theory. Results When bonded to enamel (supported by dentin), the load-bearing capacity of lithium disilicate can approach 75% of that of zirconia, despite the flexural strength of lithium disilicate (400 MPa) being merely 40% of zirconia (1000 MPa). When bonded to dentin (with the enamel completely removed), the load-bearing capacity of lithium disilicate is about 57% of zirconia, still significantly higher than the anticipated value based on its strength. Both ceramics show slightly higher load-bearing capacity when loaded with a deformable indenter (enamel, glass-ceramic, or porcelain) rather than a rigid indenter. Significance When supported by enamel, the load-bearing property of minimally invasive lithium disilicate occlusal onlays (0.6 to 1.4 mm thick) can exceed 70% of that of zircona. Additionally, a relatively weak dependence of fracture load on restoration thickness indicates that a 1.2 mm thin lithium disilicate onlay can be as fracture resistant as its 1.6 mm counterpart.

We present a new concept for strengthening ceamics by utilizing a graded structure with a low elastic modulus at both top and bottom surfaces sandwiching a high-modulus interior. Closed-form equations have been developed for stress analysis of simply supported graded sandwich beams subject to transverse center loads. Theory predicts that suitable modulus gradients at the ceramic surface can effectively reduce and spread the maximum bending stress from the surface into the interior. The magnitude of such stress dissipation is governed by the thickness ratio of the beam to the graded layers. We test our concept by infiltrating both top and bottom surfaces of a strong class of zirconia ceramic with an in-house prepared glass of similar coefficient of thermal expansion and Poisson's ratio to zirconia, producing a controlled modulus gradient at the surface without significant long-range residual stresses. The resultant graded glass/zirconia/glass composite exhibits significantly higher load-bearing capacity than homogeneous zirconia.