Experimental validation of Scheil–Gulliver simulations for gradient path planning in additively manufactured functionally graded materials

Bocklund, Brandon; Bobbio, Lourdes D.; Otis, Richard; Beese, Allison M.; Liu, Zhe

doi:10.1016/j.mtla.2020.100689

Cited by 47 publications

(15 citation statements)

References 24 publications

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“…More recently, investigators have utilized the CALculation of PHAse (CALPHAD) diagram computations to predict the formation of brittle phases and possible crack susceptibility in complex Ni-base superalloy systems. [28][29][30] Without a doubt, these computational tools are powerful methods that can utilize Scheil solidification modeling to predict cracking susceptibility of alloy systems, both simple and complex. However, the goal of this work was to demonstrate the effectiveness of the simple model, under the original constraints of the Scheil equation.…”

Section: Cracking Susceptibility and Effect Of Diffusionmentioning

confidence: 99%

“…3(a). 7as a function of (a) cell size, and (b) cooling rate determined for LPBF AlSi10Mg alloys [28] 5 Cracking Susceptibility of AA5083 Alloy AA5083 with 4.0 * 5.0 wt.% Mg, 0.4 * 1.0 wt.% Mn [27] is widely used in marine applications, and is known to be both castable and weldable. [27] However, investigators Zhou et al [5] clearly demonstrated that processing of corrosion resistant AA5083 by LPBF resulted in solidification cracking, regardless the LPBF parameter employed.…”

Section: Cracking Susceptibility and Effect Of Diffusion For Lpbf Alsmentioning

confidence: 99%

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Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Hyer

Zhou

Mehta

et al. 2020

J. Phase Equilib. Diffus.

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Laser powder bed fusion (LPBF) has demonstrated its unique ability to produce customized, complex engineering components. However, processing of many commercial Al-alloys by LPBF remains challenging due to the formation of solidification cracking, although they are labelled castable or weldable. In order to elucidate this divergence, solidification cracking susceptibility from the steepness of the solidification curves, specifically |dT/df S 1/2 |, as the fraction solidified nears 1 towards complete solidification, was calculated via Scheil-Gulliver model as a function of solute concentration in simple binary Al-Si, Al-Mg, and Al-Cu systems. Introduction of ''diffusion in solid'' into Scheil-Gulliver model resulted in a drastic reduction in the cracking susceptibility (i.e., reduction in the magnitude of |dT/df S 1/2 |) and a shift in the maximum |dT/df S 1/2 | to higher concentrations of solute. Overall, the calculated solidification cracking susceptibility correlated well with experimental observation made using LPBF AA5083 (e.g., Al-Mg) and Al-Si binary alloys with varying Si concentration. Cracking susceptibility was found to be highly sensitive to the composition of the alloy, which governs the variation of |dT/df S 1/2 |. Furthermore, experimental observation suggests that the contribution of ''diffusion in solids'' to reduce the cracking susceptibility can be more significant than what is expected from an instinctive assumption of negligible diffusion and rapid cooling typically associated with LPBF.

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Section: Cracking Susceptibility and Effect Of Diffusionmentioning

confidence: 99%

Section: Cracking Susceptibility and Effect Of Diffusion For Lpbf Alsmentioning

confidence: 99%

Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Hyer

Zhou

Mehta

et al. 2020

J. Phase Equilib. Diffus.

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“…In addition to thermodynamic driving force, we can also use the non-equilibrium phase diagram, predicted by the Scheil-Gulliver simulations 47,48 (see its definition in the Introduction section), to predict the formation of IMCs in fast cooling processes, such as the AM process 49,50 . Here, we used the PyCalphad software 50,87 to calculate this non-equilibrium phase diagram with the thermodynamic description modelled by Sundman et al 9 .…”

Section: Formation Of Non-equilibrium Imcs Through Thermodynamic Analysismentioning

confidence: 99%

“…Additionally, non-equilibrium simulations in terms of the Scheil-Gulliver model 47,48 can be used to analyze the forming IMCs in fast cooling processes by assuming that no diffusion takes place in the solid and that solute redistribution in the liquid is infinitely fast [49][50][51] . The Scheil simulations have been used to, for example, design optimal composition for additively manufactured functionally graded metals 49,50 and predict liquidus and solidus temperatures of steel 51 . In addition to phase diagram, non-equilibrium IMCs can be predicted by calculating thermodynamic driving forces for the phases of interest with respect to supercooled liquid and associated solid phases; see the predicted interface phases at the Cu/solder joints by Lee et al 52 .…”

Section: Introductionmentioning

confidence: 99%

“…Phase diagram, as the beginning of wisdom to guide any work in materials science and engineering 46 , is the most used tool to analyze equilibrium IMCs under a given temperature and composition (usually under external pressure P = 0 GPa). Additionally, non-equilibrium simulations in terms of the Scheil-Gulliver model 47,48 can be used to analyze the forming IMCs in fast cooling processes by assuming that no diffusion takes place in the solid and that solute redistribution in the liquid is infinitely fast [49][50][51] . The Scheil simulations have been used to, for example, design optimal composition for additively manufactured functionally graded metals 49,50 and predict liquidus and solidus temperatures of steel 51 .…”

Section: Introductionmentioning

confidence: 99%

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Forming Mechanism of Equilibrium and Non-equilibrium Metallurgical Phases in Dissimilar Materials: Illustrated With Aluminum/steel (Al-Fe) Joints

Shang

Sun

Pan

et al. 2021

Preprint

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Forming metallurgical phases has a critical impact on the performance of dissimilar materials joints. Here, we shed light on the forming mechanism of equilibrium and non-equilibrium intermetallic compounds (IMCs) in the dissimilar aluminum/steel joints with respect to processing history (e.g., the pressure- and temperature-profiles) and chemical composition, where the used knowledge of free energy and atomic diffusion in the Al-Fe system was taken from first-principles phonon calculations and data available in the literature. We found that the metastable while ductile (judged by the presently predicted elastic constants) Al6Fe is a pressure (P) favored IMC observed in the processes involving high pressures. The MoSi2-type Al2Fe is a brittle and a strong P-favored IMC observed at high pressures. The stable, brittle h-Al5Fe2 is the most commonly observed IMC (followed by q-Al13Fe4) in almost all processes, such as fusion/solid-state welding and additive manufacturing (AM), since h-Al5Fe2 is temperature-favored, possessing high thermodynamic driving force of formation and the fastest atomic diffusivity among all Al-Fe IMCs. Notably the ductile AlFe3, the less ductile AlFe, and most of the other IMCs can be formed during AM, making AM a superior process to achieve desired IMCs in dissimilar materials. In addition, the unknown configurations of Al2Fe and Al5Fe2 were also examined by machine learning based datamining together with first-principles verifications and structure predictor. All the IMCs, which are not P-favored, can be identified using the conventional equilibrium phase diagram and the Scheil-Gulliver non-equilibrium simulations.

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Impact of Arc‐Based Welding on the Microstructure Evolution and Mechanical Properties in Newly Developed Cr_29.7Co_29.7Ni_35.4Al₄Ti_1.2 Multi‐Principal Element Alloy

et al. 2023

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Multi‐principal element alloys (MPEAs) have been subjected to extensive research due to their promising potential for numerous applications. Up to now, most of the existing research has been focused on unraveling the microstructural evolution and describing the exceptional performance of these alloys when exposed to demanding environments. Nevertheless, it is especially important to understand their processability so that these advanced engineering alloys can be considered for real‐life applications where conventional manufacturing processes, such as welding, are widely used. Herein, gas tungsten arc welding (GTAW) is used for similar welding of a recently developed precipitation‐hardened Cr29.7Co29.7Ni35.4Al4Ti1.2 MPEA. The microstructural evolution and resulting mechanical properties are characterized by combining optical and electron microscopy, synchrotron X‐ray diffraction, microhardness mapping, and tensile testing. The different microstructure features across the welded joint are correlated to the weld thermal cycle and resulting local mechanical properties. Overall, the Cr29.7Co29.7Ni35.4Al4Ti1.2 MPEA exhibits excellent weldability and mechanical properties, reaching a tensile strength of ≈750 MPa and a fracture strain of ≈33% during tensile tests, making this alloy viable for structural applications. The innovative aspect of this work includes the expansion of the current understanding on the physical metallurgy of MPEAs, as well as the examination of this particular MPEA's processability.

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Experimental validation of Scheil–Gulliver simulations for gradient path planning in additively manufactured functionally graded materials

Cited by 47 publications

References 24 publications

Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Forming Mechanism of Equilibrium and Non-equilibrium Metallurgical Phases in Dissimilar Materials: Illustrated With Aluminum/steel (Al-Fe) Joints

Impact of Arc‐Based Welding on the Microstructure Evolution and Mechanical Properties in Newly Developed Cr_29.7Co_29.7Ni_35.4Al₄Ti_1.2 Multi‐Principal Element Alloy

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Experimental validation of Scheil–Gulliver simulations for gradient path planning in additively manufactured functionally graded materials

Cited by 47 publications

References 24 publications

Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Effects of Alloy Composition and Solid-State Diffusion Kinetics on Powder Bed Fusion Cracking Susceptibility

Forming Mechanism of Equilibrium and Non-equilibrium Metallurgical Phases in Dissimilar Materials: Illustrated With Aluminum/steel (Al-Fe) Joints

Impact of Arc‐Based Welding on the Microstructure Evolution and Mechanical Properties in Newly Developed Cr29.7Co29.7Ni35.4Al4Ti1.2 Multi‐Principal Element Alloy

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Product

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About

Impact of Arc‐Based Welding on the Microstructure Evolution and Mechanical Properties in Newly Developed Cr_29.7Co_29.7Ni_35.4Al₄Ti_1.2 Multi‐Principal Element Alloy