Modeling Microsegregation during Metal Additive Manufacturing: Impact of Dendrite Tip Kinetics and Finite Solute Diffusion

Abstract

Rapid solidification during metal additive manufacturing (AM) leads to non-equilibrium microsegregation, which can result in the formation of detrimental phases and cracking. Most of the microsegregation models assume a Scheil-type solidification, where the solidification interface is planar and there exists a local equilibrium at the interface along with either zero or infinite solute diffusion in the respective participating phases—solid and liquid. This assumption leads to errors in prediction. One has to account for finite solute diffusion and the curvature at the dendritic tip for more accurate predictions. In this work, we compare different microsegregation models, that do and do not consider finite diffusion and dendrite tip kinetics, against experiments. We also propose a method to couple dendrite tip kinetics with the diffusion module (DICTRA®) implemented in Thermo-Calc®. The models which accounted for both finite diffusion and dendrite tip kinetics matched well with the experimental data.

Highly 002-Oriented Dendrite-Free Anode Achieved by Enhanced Interfacial Electrostatic Adsorption for Aqueous Zinc-Ion Batteries

“…In this region, the electrocrystalline morphology tends to exhibit dendritic patterns (Figure S10), which are the phenomena observed during the electrodeposition of various metals. 42,43 In the ionsufficient region under CPL, the electrocrystalline morphology is mainly controlled by electrostatic interactions between the electrode and ions, which represents the strength of the 2D diffusion of zinc ions. As Figure 3a shows, the plating morphology in ZnSO 4 becomes denser as the electrostatic interactions increase.…”