Bonnie C. Whitney , Theron M. Rodgers , Anthony G. Spangenberger , Aashique A. Rezwan , David Montes de Oca Zapiain , Diana A. Lados
{"title":"Solidification and crystallographic texture modeling of laser powder bed fusion Ti-6Al-4V using finite difference-monte carlo method","authors":"Bonnie C. Whitney , Theron M. Rodgers , Anthony G. Spangenberger , Aashique A. Rezwan , David Montes de Oca Zapiain , Diana A. Lados","doi":"10.1016/j.mtla.2024.102279","DOIUrl":null,"url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) additive manufacturing makes near-net-shaped parts with reduced material cost and time, rising as a promising technology to fabricate Ti-6Al-4 V, a widely used titanium alloy in aerospace and medical industries. However, LPBF Ti-6Al-4 V parts produced with 67° rotation between layers, a scan strategy commonly used to reduce microstructure and property inhomogeneity, have varying grain morphologies and weak crystallographic textures that change depending on processing parameters. This study predicts LPBF Ti-6Al-4 V solidification at three energy levels using a finite difference-Monte Carlo method and validates the simulations with large-area electron backscatter diffraction (EBSD) scans. The developed model accurately shows that a 〈001〉 texture forms at low energy and a 〈111〉 texture occurs at higher energies parallel to the build direction but with a lower strength than the textures observed from EBSD. A validated and well-established method of combining spatial correlation and general spherical harmonics representation of texture is developed to calculate a difference score between simulations and experiments. The quantitative comparison enables effective fine-tuning of nucleation density <span><math><mrow><mo>(</mo><msub><mi>N</mi><mn>0</mn></msub><mo>)</mo></mrow></math></span> input, which shows a nonlinear relationship with increasing energy level. Future improvements in texture prediction code and a more comprehensive study of <span><math><msub><mi>N</mi><mn>0</mn></msub></math></span> with different energy levels will further advance the optimization of LPBF Ti-6Al-4 V components. These developments contribute a novel understanding of crystallographic texture formation in LPBF Ti-6Al-4 V, the development of robust model validation and calibration pipeline methodologies, and provide a platform for mechanical property prediction and process parameter optimization.</div></div>","PeriodicalId":47623,"journal":{"name":"Materialia","volume":"38 ","pages":"Article 102279"},"PeriodicalIF":3.0000,"publicationDate":"2024-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Materialia","FirstCategoryId":"1085","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S258915292400276X","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
Abstract
Laser powder bed fusion (LPBF) additive manufacturing makes near-net-shaped parts with reduced material cost and time, rising as a promising technology to fabricate Ti-6Al-4 V, a widely used titanium alloy in aerospace and medical industries. However, LPBF Ti-6Al-4 V parts produced with 67° rotation between layers, a scan strategy commonly used to reduce microstructure and property inhomogeneity, have varying grain morphologies and weak crystallographic textures that change depending on processing parameters. This study predicts LPBF Ti-6Al-4 V solidification at three energy levels using a finite difference-Monte Carlo method and validates the simulations with large-area electron backscatter diffraction (EBSD) scans. The developed model accurately shows that a 〈001〉 texture forms at low energy and a 〈111〉 texture occurs at higher energies parallel to the build direction but with a lower strength than the textures observed from EBSD. A validated and well-established method of combining spatial correlation and general spherical harmonics representation of texture is developed to calculate a difference score between simulations and experiments. The quantitative comparison enables effective fine-tuning of nucleation density input, which shows a nonlinear relationship with increasing energy level. Future improvements in texture prediction code and a more comprehensive study of with different energy levels will further advance the optimization of LPBF Ti-6Al-4 V components. These developments contribute a novel understanding of crystallographic texture formation in LPBF Ti-6Al-4 V, the development of robust model validation and calibration pipeline methodologies, and provide a platform for mechanical property prediction and process parameter optimization.
期刊介绍:
Materialia is a multidisciplinary journal of materials science and engineering that publishes original peer-reviewed research articles. Articles in Materialia advance the understanding of the relationship between processing, structure, property, and function of materials.
Materialia publishes full-length research articles, review articles, and letters (short communications). In addition to receiving direct submissions, Materialia also accepts transfers from Acta Materialia, Inc. partner journals. Materialia offers authors the choice to publish on an open access model (with author fee), or on a subscription model (with no author fee).