A Multi‐Scale Multi‐Physics Approach to Modelling of Additive Manufacturing in Nickel‐Based Superalloys

Panwisawas, Chinnapat; Sovani, Yogesh; Anderson, Magnus; Turner, Richard; Palumbo, Nunzio; Saunders, Benjamin; Choquet, Isabelle; Brooks, Jeffery; Basoalto, Hector

doi:10.1002/9781119075646.ch108

Cited by 18 publications

(15 citation statements)

References 41 publications

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“…The proposed modelling framework for the simulation of precipitation kinetics during the annealing of a SLM component is now presented. The approach involves simulation of the metal melt pool through a volume-offluid (VoF) formulation [7,8], from which the predicted melt pool geometry and the thermal loading are used to calibrate a finite element (FE) model of the heat source model when simulating the AM of a build [6]. The process-induced thermo-mechanical fields predicted by the FE analysis provide the driving forces required for solid-state precipitation reactions.…”

Section: Modelling Frameworkmentioning

confidence: 99%

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Predicting Precipitation Kinetics During the Annealing of Additive Manufactured Inconel 625 Components

Anderson

Benson

Brooks

et al. 2019

Integr Mater Manuf Innov

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The prediction of solidification microstructures associated with additive manufacture of metallic components is fundamental in the identification scanning strategies, process parameters and subsequent heat treatments for optimised component properties. Interactions between the powder particles and the laser heat source result in complex thermal fields in and around the metal melt pool, which will influence the spatial distribution of chemical species as well as solid-state precipitation reactions. This paper demonstrates that a multi-component, multi-phase precipitation model can successfully predict the observed precipitation kinetics in Inconel 625, capturing the anomalous precipitation behaviour exhibited in additively manufactured components. A computer coupling of phase diagrams and thermochemistry (CALPHAD)-based approach captures the impact of dendritic segregation of alloying elements upon precipitation behaviour. The model was successful in capturing the precipitation kinetics during annealing considering the Nb-rich and Nb-depleted regions that are formed during additive manufacturing.

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Section: Modelling Frameworkmentioning

confidence: 99%

“…This includes the "property switching function", a description of the heat source, and a subroutine for updating boundary conditions. The thermal load in the FE model was calibrated so that the calculated peak temperatures aligned with predictions made using VoF approach [7,8].…”

Section: Component-scale Modellingmentioning

confidence: 99%

Predicting Precipitation Kinetics During the Annealing of Additive Manufactured Inconel 625 Components

Anderson

Benson

Brooks

et al. 2019

Integr Mater Manuf Innov

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“…In order to replicate the thermal history during the AM process, a thermal model using finite element methods has been applied using Abaqus/Standard The parameters used to define the heat source have been calibrated using the computational fluid dynamics described by Panwisawas et al [45,46] to calculate the thermal fields during deposition. Typical predicted thermal fields for the largest geometry are shown in Figure 7.…”

Section: Additive Manufacturementioning

confidence: 99%

Mean-field modelling of the intermetallic precipitate phases during heat treatment and additive manufacture of Inconel 718

et al. 2018

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A multi-phase, multi-component mean-field model has been developed for simulating the intermetallic precipitation kinetics in Inconel 718. The aim of this work is to develop predictive capability to aid in process optimisation and explore precipitation kinetics during additive manufacturing (AM). The model has been calibrated to available experimental data, and then applied to predict precipitation kinetics during typical solid solution treatment and aging operations, and during AM. It is shown that a Computer Coupling of Phase Diagrams and Thermochemistry (CALPHAD) based modelling approach provides a unified particle growth rate which can capture the growth, coarsening and dissolution of γ ′ , γ * and δ precipitates under relevant heat treatment conditions. To apply the model to AM, finite element simulations of a simple rectangular build have been carried out, using a property switching method to simulate the material deposition. The component level simulation provides the thermal fields to calculate precipitation kinetics during deposition, also allowing for the examination of the heat affected zone in the substrate. The modelling approach can capture the repeated nucleation and dissolution of precipitates that occurs during AM. The model shows good agreement with experimental data when applied to predicting precipitation kinetics during heat treatment.

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“…The simulation gives many details about thermal history during printing [7,[14][15][16][17], and the computational results could be used for the optimization of the manufacturing process. There are some researches that coupled macroscale thermal simulation coupled with mesoscale microstructural evaluation [18][19][20][21]. There are several published kinds of research on mesoscale microstructural simulations for powder bedbased additive manufacturing in the first layer of the print [22][23][24][25][26][27].…”

Section: -Introductionmentioning

confidence: 99%

Direct Laser Deposition Metal 3D Printing at Different Temperatures of the Printer’s Chamber: Computer Simulation

Hosseinzadeh¹

2020

Preprint

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Metal 3D printing technology is a promising manufacturing method. The quality of the printed product can pass for mechanical application, if the anisotropy of the microstructure, imperfections, deformation, and residual stress of the printed sample could be lower than the appropriate level or if they are fully illuminated. Thermal stress is one of the significant reasons for deformation in the 3D printed samples. Thermal stresses are the direct consequence of the local temperature gradient. In this research, the effect of the temperature printer’s chamber (from room temperature to 900 C) was studied on thermal stress and subsequent total deformation in the printed sample. The printed sample is a six-layers-printed walk, which could be considered as a building block of other complex shapes and give us inside about deformation. The computational results show a meaningful reduction in thermal stress and deformation at the higher temperature of the printer’s chamber. The lower final deformation of the printed sample is an important subject, especially for samples with complex shapes.

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A Multi‐Scale Multi‐Physics Approach to Modelling of Additive Manufacturing in Nickel‐Based Superalloys

Cited by 18 publications

References 41 publications

Predicting Precipitation Kinetics During the Annealing of Additive Manufactured Inconel 625 Components

Predicting Precipitation Kinetics During the Annealing of Additive Manufactured Inconel 625 Components

Mean-field modelling of the intermetallic precipitate phases during heat treatment and additive manufacture of Inconel 718

Direct Laser Deposition Metal 3D Printing at Different Temperatures of the Printer’s Chamber: Computer Simulation

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