Numerical modelling of in-situ alloying of Al and Cu using the laser powder bed fusion process: A study on the effect of energy density and remelting on deposited track homogeneity

Chouhan, Arvind; Hesselmann, Marcel; Toenjes, Anastasiya; Mädler, Lutz; Ellendt, N.

doi:10.1016/j.addma.2022.103179

Cited by 11 publications

(6 citation statements)

References 31 publications

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“…The state-of-theart approach for that is described in the following section using the implementation by Küng et al [26], which we used to simulate powder bed fusion additive manufacturing processes until now. Similar models were also presented by Chouhan et al [29] and Tang et al [41].…”

Section: Conventional Enthalpy Model For Multicomponent Systemssupporting

confidence: 81%

“…As Küng et al [26] and Chouhan et al [29] have shown, the conventional way of coupling CALPHAD calculations with numerical simulations for metal processing is to provide processed data like phase diagrams. In this work, a novel method for directly using composition and temperature-dependent enthalpy surfaces stored in thermodynamic databases as an input to the enthalpy method to model the behaviour of alloy systems is presented.…”

Section: Introductionmentioning

confidence: 99%

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A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions

Scherr,

Liepold,

Markl

et al. 2024

Modelling

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Solid–liquid phase transitions of metals and alloys play an important role in many technical processes. Therefore, corresponding numerical process simulations need adequate models. The enthalpy method is the current state-of-the-art approach for this task. However, this method has some limitations regarding multicomponent alloys as it does not consider the enthalpy of mixing, for example. In this work, we present a novel CALPHAD-informed version of the enthalpy method that removes these drawbacks. In addition, special attention is given to the handling of polymorphic as well as solid–liquid phase transitions. Efficient and robust algorithms for the conversion between enthalpy and temperature were developed. We demonstrate the capabilities of the presented method using two different implementations: a lattice Boltzmann and a finite difference solver. We proof the correct behaviour of the developed method by different validation scenarios. Finally, the model is applied to electron beam powder bed fusion—a modern additive manufacturing process for metals and alloys that allows for different powder mixtures to be alloyed in situ to produce complex engineering parts. We reveal that the enthalpy of mixing has a significant effect on the temperature and lifetime of the melt pool and thus on the part properties.

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Section: Conventional Enthalpy Model For Multicomponent Systemssupporting

confidence: 81%

Section: Introductionmentioning

confidence: 99%

A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions

Scherr,

Liepold,

Markl

et al. 2024

Modelling

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“…the volumetric energy density ( E v ) , is normally associated with better densification of AM specimens [10,28]. Nonetheless, the laser parameters should be carefully selected when processing BMGs, as higher E v may also cause melt overheating which, in turn, reduces the cooling rate and facilitate crystallisation to occur [23,29,30]. Consequently, the synthesis of a fully amorphous bulk metallic glass should consider appropriate heating and cooling rates [22,31].…”

Section: Resultsmentioning

confidence: 99%

Influence of oxygen in the production chain of Cu–Ti-based metallic glasses via laser powder bed fusion

et al. 2023

Self Cite

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Laser powder bed fusion of metals (PBF-LB/M) is advantageous for manufacturing bulk metallic glasses with size and geometrical freedom. However, the oxygen uptake along the production chain can negatively impact the generation of high-quality, amorphous parts. In this context, Cu-Ti-based alloys were gas-atomised and additively manufactured using commercial-(CP) and high-purity (HP) feedstocks. The oxygen absorption in each processing step was tracked and related to the amorphous phase formation and glass-forming ability (GFA) of alloys. Results show an increasing oxygen absorption, considerably influenced by the starting feedstock, especially for CP. In HP material, the most contribution is inherent from the powder oxygen content. Results reveal the lack of influence of the oxygen content in the GFA. TEM analysis of commercial powder and PBF-LB/M sample show uniform and featureless micrographs, displaying the absence of oxygen-induced nucleation. The present contribution enhances the qualification and economic processability of amorphous metals by PBF-LB/M.

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“…Liu et al [23] studied the effect of the remelting process on the forming quality of PBF-LB/M-processed cemented carbide and found that remelting can effectively improve the surface quality and relative density of specimens. Chou et al [24] studied the effects of different laser energy densities and remelting on the uniformity of deposition trajectories by melting a layer of aluminum powder on a Cu substrate, and they found that remelting is an effective strategy for improving homogeneity. Currently, few studies have been conducted on the necessity of the PBF-LB/M remelting process and the relationship between premelting and remelting of the CuCrZr alloy.…”

Section: Introductionmentioning

confidence: 99%

Performance Improvement for the CuCrZr Alloy Produced by Laser Powder Bed Fusion Using the Remelting Process

Xu,

Zhang,

Zhao

et al. 2024

Materials

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Owing to the high optical reflectivity of copper powder, the high-performance fabrication of copper alloys in the laser additive manufacturing (AM) field is problematic. To tackle this issue, this study employs the remelting process during laser powder bed fusion AM to fabricate defect-free and high-performance CuCrZr alloy. Compared to the non-remelting process, the remelting process yields finer grains, smaller precipitates, denser dislocations, and smaller dislocation cells. It realizes not only the dense molding of high laser reflectivity powders but also excellent mechanical properties and electrical conductivity (with an ultimate tensile strength of 329 MPa and conductivity of 96% IACS) without post-heat treatment. Furthermore, this study elucidates the influence of complex thermal gradients and multiple thermal cycles on the manufacturing process under the remelting process, as well as the internal mechanisms of microstructure evolution and performance improvement.

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Numerical modelling of in-situ alloying of Al and Cu using the laser powder bed fusion process: A study on the effect of energy density and remelting on deposited track homogeneity

Cited by 11 publications

References 31 publications

A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions

A CALPHAD-Informed Enthalpy Method for Multicomponent Alloy Systems with Phase Transitions

Influence of oxygen in the production chain of Cu–Ti-based metallic glasses via laser powder bed fusion

Performance Improvement for the CuCrZr Alloy Produced by Laser Powder Bed Fusion Using the Remelting Process

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