Fast solution strategy for transient heat conduction for arbitrary scan paths in additive manufacturing

Wolfer, Alexander J.; Aires, Jeremy; Wheeler, Kevin R.; Delplanque, Jean‐Pierre; Rubenchik, Alexander M.; Anderson, Andy; Khairallah, Saad A.

doi:10.1016/j.addma.2019.100898

Cited by 29 publications

(13 citation statements)

References 24 publications

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“…To understand the influence of process conditions on microstructure development, a simplified semi-analytical heat conduction model was utilized to approximate the trends in solidification conditions. Similar approaches have been successfully implemented in other studies to rationalize the influence of process conditions on microstructure and defects 40 – 44 . The model used here relies on the mathematical solution for a moving volumetric Gaussian heat source originally derived by Nguyen et al 45 , and uses an adaptive Gaussian quadrature scheme to efficiently and accurately compute the melt pool behavior over long length and time scales 46 .…”

Section: Methodsmentioning

confidence: 95%

Microstructure and properties of additively manufactured Al–Ce–Mg alloys

Sisco

Plotkowski

Yang

et al. 2021

Sci Rep

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Additive manufacturing of aluminum alloys is largely dominated by a near-eutectic Al-Si compositions, which are highly weldable, but have mechanical properties that are not competitive with conventional wrought Al alloys. In addition, there is a need for new Al alloys with improved high temperature properties and thermal stability for applications in the automotive and aerospace fields. In this work, we considered laser powder bed fusion additive manufacturing of two alloys in the Al–Ce–Mg system, designed as near-eutectic (Al–11Ce–7Mg) and hyper-eutectic (Al–15Ce–9Mg) compositions with respect to the binary L → Al + Al11Ce eutectic reaction. The addition of magnesium is used to promote solid solution strengthening. A custom laser scan pattern was used to reduce the formation of keyhole porosity, which was caused by excessive vaporization due to the high vapor pressure of magnesium. The microstructure and tensile mechanical properties of the alloys were characterized in the as-fabricated condition and following hot isostatic pressing. The two alloys exhibit significant variations in solidification structure morphology. These variations in non-equilibrium solidification structure were rationalized using a combination of thermodynamic and thermal modeling. Both alloys showed higher yield strength than AM Al-10Si-Mg for temperatures up to 350 °C and better strength retention at elevated temperatures than additively manufactured Scalmaloy.

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Section: Methodsmentioning

confidence: 95%

Microstructure and properties of additively manufactured Al–Ce–Mg alloys

Sisco

Plotkowski

Yang

et al. 2021

Sci Rep

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“…One-dimensional DICTRA solidification models are implemented using the TC-Python application programming interface to enable batch calculations as a function of both processing conditions and composition. The semi-analytic laser powder bed fusion (LPBF) process model developed by Wolfer et al [21], which uses a Green's function approach, is coupled with DICTRA simulations and the Kou SCS model [13,14] to create a CALPHAD-based ICME framework for modeling non-equilibrium solidification in additively manufactured materials. Temperature histories under different processing conditions are used as an input for DICTRA solidification calculations to investigate the relationship between the additive manufacturing process and non-equilibrium solidification.…”

Section: Methodsmentioning

confidence: 99%

Integration of Processing and Microstructure Models for Non-Equilibrium Solidification in Additive Manufacturing

Sargent

Jones

Otis

et al. 2021

Metals

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Integration of models that capture the complex physics of solidification on the macro and microstructural scale with the flexibility to consider multicomponent materials systems is a significant challenge in modeling additive manufacturing processes. This work aims to link process variables, such as energy density, with non-equilibrium solidification by integrating additive manufacturing process simulations with solidification models that consider thermodynamics and diffusion. Temperature histories are generated using a semi-analytic laser powder bed fusion process model and feed into a CALPHAD-based ICME (CALPHAD: Calculation of Phase Diagrams, ICME: Integrated Computational Materials Engineering) framework to model non-equilibrium solidification as a function of both composition and processing parameters. Solidification cracking susceptibility is modeled as a function of composition, cooling rate, and energy density in Al-Cu Alloys and stainless steel 316L (SS316L). Trends in solidification cracking susceptibility predicted by the model are validated by experimental solidification cracking measurements of Al-Cu alloys. Non-equilibrium solidification in additively manufactured SS316L is investigated to determine if this approach can be applied to commercial materials. Modeling results show a linear relationship between energy density and solidification cracking susceptibility in additively manufactured SS316L. This work shows that integration of process and microstructure models is essential for modeling solidification during additive manufacturing.

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“…To understand the influence of process conditions on microstructure development, a simplified semianalytical heat conduction model was utilized to approximate the trends in solidification conditions. Similar approaches have been successfully implemented in other studies to rationalize the influence of process conditions on microstructure and defects [37][38][39][40][41] . The model used here relies on the mathematical solution for a moving volumetric Gaussian heat source originally derived by Nguyen et al 42 , and uses an adaptive Gaussian quadrature scheme to efficiently and accurately compute the melt pool behavior over long length and time scales 43 .…”

Section: Solidification Condition Calculationsmentioning

confidence: 96%

Microstructure and Properties of Additively Manufactured Al-Ce-Mg Alloys

Sisco

Plotkowski

Yang

et al. 2020

Preprint

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Additive manufacturing of aluminum alloys is largely dominated by a near-eutectic Al-Si compositions, which are highly weldable, but have mechanical properties that are not competitive with conventional wrought Al alloys. In addition, there is a need for new Al alloys with improved high temperature properties and thermal stability for applications in the automotive and aerospace fields. In this work, we considered laser powder bed fusion additive manufacturing of two alloys in the Al-Ce-Mg system, designed as near-eutectic (Al-11Ce-7Mg) and hyper-eutectic (Al-15Ce-9Mg) compositions with respect to the binary L→Al+Al11Ce eutectic reaction. The addition of magnesium is used to promote solid solution strengthening. A custom laser scan pattern was used to reduce the formation of keyhole porosity, which was caused by excessive vaporization due to the high vapor pressure of magnesium. The microstructure and tensile mechanical properties of the alloys were characterized in the as-fabricated condition and following hot isostatic pressing. The two alloys exhibit significant variations in solidification structure morphology. These variations in non-equilibrium solidification structure were rationalized using a combination of thermodynamic and thermal modeling. Both alloys showed higher yield strength than AM Al-10Si-Mg for temperatures up to 350°C and better strength retention at elevated temperatures than additively manufactured Scalmaloy.

show abstract

Fast solution strategy for transient heat conduction for arbitrary scan paths in additive manufacturing

Cited by 29 publications

References 24 publications

Microstructure and properties of additively manufactured Al–Ce–Mg alloys

Microstructure and properties of additively manufactured Al–Ce–Mg alloys

Integration of Processing and Microstructure Models for Non-Equilibrium Solidification in Additive Manufacturing

Microstructure and Properties of Additively Manufactured Al-Ce-Mg Alloys

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