Welding in the World最新文献

Surface structure analysis using visual high-resolution in situ process monitoring in laser powder bed fusion 利用可视化高分辨率激光粉末床熔融原位过程监控进行表面结构分析

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-02-25 DOI: 10.1007/s40194-025-01955-1

Jonathan Schmidt, Benjamin Merz, Konstantin Poka, Gunther Mohr, Kai Hilgenberg

{"title":"Surface structure analysis using visual high-resolution in situ process monitoring in laser powder bed fusion","authors":"Jonathan Schmidt, Benjamin Merz, Konstantin Poka, Gunther Mohr, Kai Hilgenberg","doi":"10.1007/s40194-025-01955-1","DOIUrl":"10.1007/s40194-025-01955-1","url":null,"abstract":"<div><p>Parameter studies are a common step in selecting process parameters for laser powder bed fusion of metals (PBF-LB/M). Density cubes are commonly used for this purpose. Density cubes manufactured with varied process parameters can exhibit distinguishable surface structures visible to the human eye. The layer-wise process enables such surface structures to be detected during manufacturing. However, industrial visual in situ monitoring systems for PBF-LB/M currently have limited resolution and are incapable of reliably capturing small differences in the surface structures. In this work, a 65 MPixel high-resolution monochrome camera was integrated into an industrial PBF-LB/M machine together with a high-intensity LED (light-emitting diode) bar. Post-exposure images were taken to analyse differences in light reflection of fused areas. It is revealed that the grey-level co-occurrence matrix can be used to quantify the visual surface structure of nickel-based superalloy Inconel®939 density cubes per layer. The properties of the grey-level co-occurrence matrix correlate to the energy input and the resulting porosity of density cubes. Low-energy samples containing lack of fusion flaws show an increased contrast in the grey-level co-occurrence matrix compared to specimens with optimal energy input. The potential of high-resolution images for quality assurance via in situ process monitoring in PBF-LB/M is further discussed.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1087 - 1101"},"PeriodicalIF":2.4,"publicationDate":"2025-02-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01955-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581306","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effect of surface roughness on rotating fatigue strength of as-built AlSi10Mg produced by laser powder bed fusion 表面粗糙度对激光粉末床熔融法生产的坯料 AlSi10Mg 旋转疲劳强度的影响

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-02-18 DOI: 10.1007/s40194-025-01963-1

Andrea El Hassanin, Umberto Prisco

{"title":"Effect of surface roughness on rotating fatigue strength of as-built AlSi10Mg produced by laser powder bed fusion","authors":"Andrea El Hassanin, Umberto Prisco","doi":"10.1007/s40194-025-01963-1","DOIUrl":"10.1007/s40194-025-01963-1","url":null,"abstract":"<div><p>AlSi10Mg samples with as-built surfaces characterized by three levels of increasing roughness were fabricated varying the building orientation by laser powder bed fusion. In particular, the sample axis was oriented at 0<span>(^{circ })</span>, 90<span>(^{circ })</span>, and 45<span>(^{circ })</span> with respect to the building direction. It is demonstrated that roughness directly influences the fatigue performance of as-built samples, since cracks initiate at surface notches related to features produced by surface roughness. Rougher surfaces generate higher concentration stress and show lower cyclic properties. Then, the rotating fatigue strength of the samples is non-destructively estimated using Murakami’s square root area parameter model. The equivalent size of the defect was calculated from the roughness parameters <b><i>S</i></b><span>(_{text {z}})</span> and <b><i>R</i></b><span>(_{text {Sm}})</span>. The model gives a good correlation with the experimental data, and then it can be applied to evaluate the fatigue strength of as-built AlSi10Mg. These results are important for the reliable design in terms of fatigue strength of selective laser-melted AlSi10Mg components.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1123 - 1133"},"PeriodicalIF":2.4,"publicationDate":"2025-02-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581316","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multiscale FE modeling of SLMed ASS316 L reinforced with nanoparticles during FSP: exploring the impact of particle volume fraction, shape, and type on mechanical strength 用纳米颗粒强化 SLMed ASS316 L 的多尺度 FE 建模：探索颗粒体积分数、形状和类型对机械强度的影响

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-02-17 DOI: 10.1007/s40194-025-01985-9

Ali Ebrahimpour, Morteza Omidi, Amir Mostafapour

{"title":"Multiscale FE modeling of SLMed ASS316 L reinforced with nanoparticles during FSP: exploring the impact of particle volume fraction, shape, and type on mechanical strength","authors":"Ali Ebrahimpour, Morteza Omidi, Amir Mostafapour","doi":"10.1007/s40194-025-01985-9","DOIUrl":"10.1007/s40194-025-01985-9","url":null,"abstract":"<div><p>This study investigates the effect of nanoparticle volume fraction, shape, and type on the strength of nanocomposites made of selective laser melted (SLM) austenitic stainless steel (AISI 316L) reinforced with nanoparticles during friction stir processing (FSP). Using the mean field homogenization (MFH) method with the Mori–Tanaka model, multiscale finite element simulations were conducted to predict the mechanical behavior of the composites. These simulations were validated through experimental tests, yielding consistent results, with tensile strength reaching 740 MPa for reinforced sample, compared to 670 MPa for unreinforced FSP-treated material. A systematic design of experiments (DOE) was implemented using response surface methodology (RSM), generating 15 sample configurations. The strength of these configurations was calculated via finite element modeling. Analysis of variance (ANOVA) was then performed to evaluate the direct and interaction effects of the parameters, identifying the volume fraction as the most critical factor, with significant contributions from particle shape and type. A mathematical model derived from the ANOVA results demonstrated strong predictive accuracy (<i>R</i><sup>2</sup> = 98.33%) and was validated against simulation data. This integrated framework underscores the potential of combining experimental and computational techniques for optimizing metal matrix nanocomposites in advanced engineering applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1135 - 1147"},"PeriodicalIF":2.4,"publicationDate":"2025-02-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01985-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effect of heat treatment parameters on SLM-fabricated GNPs/IN718 composites: microstructural evolution and mechanical properties

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-02-10 DOI: 10.1007/s40194-025-01958-y

Yang Chu, Haichuan Shi, Peilei Zhang, Boyu Wang, Zhishui Yu, Hua Yan, Qinghua Lu, Kaichang Yu, Zhaolong Li, Yu Lei

{"title":"Effect of heat treatment parameters on SLM-fabricated GNPs/IN718 composites: microstructural evolution and mechanical properties","authors":"Yang Chu, Haichuan Shi, Peilei Zhang, Boyu Wang, Zhishui Yu, Hua Yan, Qinghua Lu, Kaichang Yu, Zhaolong Li, Yu Lei","doi":"10.1007/s40194-025-01958-y","DOIUrl":"10.1007/s40194-025-01958-y","url":null,"abstract":"<div><p>This paper systematically investigated the effects of solution and solution aging treatments on the microstructure evolution and mechanical properties of selective laser melting (SLM) graphene nanoplatelets (GNPs)–reinforced Inconel 718 (IN718) composites. The selective orientation of the grains in the heat-treated SLMed GNPs/IN718 composites gradually disappeared, and the changes in the morphology and precipitation phases of the grains were systematically investigated. Results show that the solution treatment eliminated the dendritic and cellular crystal structure within the composite, while also producing a large number of white carbide particles. The mechanical properties of the composites decreased with increasing temperature after the solution treatment. Solution aging treatments eliminate elemental segregation, precipitate a large number of γ″-strengthened phases, and improve the materials’ tensile strength and wear resistance. Notable changes were observed compared with the untreated specimens. The hardness and tensile strength exhibited respective increases of 26.4% and 1.5%. Conversely, the elongation was reduced by 14%. Moreover, the average coefficient of friction and weight loss dropped by 6.89% and 18.78%, respectively. In the friction test, GNPs act as a lubricating phase, resulting in a significant increase in the friction wear performance of the composite. The heat treatment process releases residual stresses within the composite and improves the internal anisotropy of the material. This work is expected to provide a potential pathway to obtaining attractive mechanical properties for nickel-based superalloy components.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1103 - 1121"},"PeriodicalIF":2.4,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01958-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581183","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Influence of process parameters on residual stress in laser metal deposition of nickel-based superalloy

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-02-05 DOI: 10.1007/s40194-025-01940-8

Maohong Yang, Guiyi Wu, Xiangwei Li, Ruiyao Zhang, Shuyan Zhang, Honghong Wang, Illiashenko Yevhenii

{"title":"Influence of process parameters on residual stress in laser metal deposition of nickel-based superalloy","authors":"Maohong Yang, Guiyi Wu, Xiangwei Li, Ruiyao Zhang, Shuyan Zhang, Honghong Wang, Illiashenko Yevhenii","doi":"10.1007/s40194-025-01940-8","DOIUrl":"10.1007/s40194-025-01940-8","url":null,"abstract":"<div><p>This paper studied the impac t of process parameters in laser metal deposition on distribution and magnitude of residual stresses. A finite element method was used to create a residual stress model with parameters as variables. The study used a Taguchi L32 experimental design, with four levels for each parameter, and analyzed residual stresses along critical paths using quadratic functions. The results reveal that the impact of process parameters varies across different regions of the component. Melt pool size primarily affects the location of maximum residual stresses at the interface between the substrate and the deposited layer. Deposition length affects the concentration of residual stresses at the center of the interface between the substrate and the deposited layer. Substrate thickness has a substantial impact on residual stresses. Scanning strategy influences residual stresses at the edges of the upper surface of the deposited layer. Boundary conditions and yield strength affect residual stresses in various regions of the deposited layer. The coefficient of thermal expansion influences residual stresses at the interface between the base material and the deposited layer.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1057 - 1072"},"PeriodicalIF":2.4,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01940-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581108","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Analysis of the impact of isothermal hardening on the mechanical properties and abrasion resistance of welded joints on Hardox Extreme steel 等温淬火对 Hardox Extreme 钢焊接接头机械性能和耐磨性的影响分析

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-01-31 DOI: 10.1007/s40194-025-01948-0

Martyna Zemlik, Łukasz Konat, Beata Białobrzeska, Paweł Skoczylas, Krzysztof Jamroziak

{"title":"Analysis of the impact of isothermal hardening on the mechanical properties and abrasion resistance of welded joints on Hardox Extreme steel","authors":"Martyna Zemlik, Łukasz Konat, Beata Białobrzeska, Paweł Skoczylas, Krzysztof Jamroziak","doi":"10.1007/s40194-025-01948-0","DOIUrl":"10.1007/s40194-025-01948-0","url":null,"abstract":"<div><p>The object of the research reported in this study was a welded joint of Hardox Extreme steel, made using submerged arc welding (SAW) and subjected to thermal treatments involving isothermal hardening in various temperature–time variants. This treatment serves as an alternative to conventional hardening, enabling the achievement of high mechanical indices in selected cases due to the formation of fine-lath martensite or lower bainite microstructures. Heat-treated joints were analyzed macro- and microstructurally using stereoscopic, light (LM), and scanning electron microscopy (SEM). The study also determined selected mechanical properties, such as hardness, tensile strength, relative elongation, and reduction of area at break, as well as impact toughness at ambient and reduced temperatures. A separate section was dedicated to characterizing abrasion resistance in the presence of loose abrasive, along with determining the relationship between this parameter and the identified mechanical characteristics. Based on the analysis of the microphotographic images obtained, the main wear mechanisms were also characterized. The analysis of the results allowed the conclusion that in the case of isothermal hardening, the factor determining the obtained microstructural and mechanical properties is the temperature of the performed thermal operations. Furthermore, after the conducted thermal treatments, the parameters characterizing the ductility of the welded joint improved by several percent compared to the state immediately after welding. Therefore, the main goal of the technological operations conducted on welded joints of high-strength steels can be defined as improving ductility, which is justified in applications considering alternatives even to structural steels.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"793 - 812"},"PeriodicalIF":2.4,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396755","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Effects of process parameters on the crystallographic orientation and elemental segregation behavior of a novel Ni-based superalloy in laser additive manufacturing 工艺参数对激光增材制造中新型镍基超合金晶体取向和元素偏析行为的影响

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-01-29 DOI: 10.1007/s40194-025-01947-1

Lei Yao, Lianqi Shang, Shaofeng Chen, Liang Cao, Jingjing Liang

{"title":"Effects of process parameters on the crystallographic orientation and elemental segregation behavior of a novel Ni-based superalloy in laser additive manufacturing","authors":"Lei Yao, Lianqi Shang, Shaofeng Chen, Liang Cao, Jingjing Liang","doi":"10.1007/s40194-025-01947-1","DOIUrl":"10.1007/s40194-025-01947-1","url":null,"abstract":"<div><p>The effect of process parameters of DED technology on elemental segregation and crystallographic orientation of alloys was investigated. The results show that the degree of elemental segregation decreases with the increase of scanning rate, and the degree of segregation rather increases with the increase of deposition height. The microstructure of all specimens consists mostly of columnar grains grown epitaxially along the build direction, showing a clear [001] orientation. The increase in scanning rate weakens the effect of epitaxial growth of crystals, leading to a significant weakening of the strength of the weave in the [001] direction texture. In addition, the actual growth direction of the dendrites is not strictly parallel to the building direction, but is tilted towards the laser scanning direction, resulting in a large deflection angle from the building direction. Based on the synergistic effect of the local temperature gradient and the optimal grain orientation, a composite temperature gradient model is established in combination with the numerical simulation of the temperature field, which reasonably explains this phenomenon. The fundamental reason for the deflection of the dendrite growth direction is that the direction of the composite temperature gradient deviates from the build direction, and the transverse temperature gradient is larger after the scanning rate is increased, resulting in a larger deflection angle.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1073 - 1085"},"PeriodicalIF":2.4,"publicationDate":"2025-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01947-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581317","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Formulation for evaluating tensile strength of girth weld joint of linepipe with softened HAZ under internal pressure

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-01-29 DOI: 10.1007/s40194-025-01941-7

S. Onuki, M. Mitsuya, M. Ohata

{"title":"Formulation for evaluating tensile strength of girth weld joint of linepipe with softened HAZ under internal pressure","authors":"S. Onuki, M. Mitsuya, M. Ohata","doi":"10.1007/s40194-025-01941-7","DOIUrl":"10.1007/s40194-025-01941-7","url":null,"abstract":"<div><p>Buried gas pipeline is subjected to a large axial load due to earthquake-induced ground flow. The deformability of the pipeline depends on the strength of the girth weld joint. Since the heat-affected zone (HAZ) of tempered steels is locally softened due to the heat input of girth welding, the strength of the girth weld may be affected by softened HAZ. In addition, as for gas pipeline, the effect of internal pressure on the strength of the girth weld joint should be considered. Therefore, this paper proposes a tensile strength evaluation formula for girth weld joint with softened HAZ under internal pressure. The formula is developed by modifying the existing tensile strength evaluation formula of the wide plate of weld joint with softened HAZ, considering the effect of internal pressure using the elastoplastic finite element analysis. In this modification, the effect of both internal pressures on the apparent tensile strength of pipe material and the shrinkage behaviour of pipe material are focused on. Furthermore, the validity of the modified formula is demonstrated by conducting full-scale pipe tension tests.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"781 - 792"},"PeriodicalIF":2.4,"publicationDate":"2025-01-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396640","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Investigation of resistance to gaseous hydrogen of a longitudinal weld seam in a X65 pipeline using the hollow specimen technique 利用空心试样技术研究 X65 管道纵向焊缝的抗气态氢性能

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-01-28 DOI: 10.1007/s40194-025-01953-3

Florian Konert, Jonathan Nietzke, Tomás Freitas, Michael Rhode, Oded Sobol, Thomas Böllinghaus

{"title":"Investigation of resistance to gaseous hydrogen of a longitudinal weld seam in a X65 pipeline using the hollow specimen technique","authors":"Florian Konert, Jonathan Nietzke, Tomás Freitas, Michael Rhode, Oded Sobol, Thomas Böllinghaus","doi":"10.1007/s40194-025-01953-3","DOIUrl":"10.1007/s40194-025-01953-3","url":null,"abstract":"<div><p>The constantly increasing demand for renewable energy sources leads to the necessity of transporting large amounts of hydrogen. Since pipelines enable a cost-effective way for the distribution of gaseous hydrogen, the interaction of hydrogen and the pipeline materials must be carefully investigated as hydrogen can cause a degradation of the mechanical properties under certain conditions. Especially welds, which are assumed to be more susceptible to the degradation enhanced by hydrogen, are of great interest. The aim of this study is to investigate the effect of gaseous hydrogen on the mechanical properties of an X65 pipeline, and the longitudinal submerged arc welding (SAW) welded joint. The tests are conducted using the hollow specimen technique on two types of specimens: one extracted from the base material (BM) and the other extracted as a cross-weld (CW) specimen consisting of BM and weld seam. The specimens are charged in situ under a pressure of 60 bar and tested using slow strain rate (SSR) tensile tests with a nominal strain rate of 10<sup>−5</sup> s<sup>−1</sup>. The properties obtained of specimens tested in hydrogen atmosphere are compared to the properties of comparable specimen in inert argon atmosphere as a reference. The performed tests showed a decrease of the reduction of area (RA) from 72% in inert atmosphere to 52% in hydrogen atmosphere for the CW specimen and a decrease from 73% in inert atmosphere to 51% for the BM. Metallographic analyses showed the crack initiation between fine-grained heat-affected zone (FGHAZ) and BM for the specimens tested in hydrogen atmosphere as well as for the reference specimens. This leads to the conclusion that the location of the crack initiation does not change due to the presence of gaseous hydrogen.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"861 - 870"},"PeriodicalIF":2.4,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01953-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multi-component and multi-phase-field modelling of solidification microstructural evolution in Inconel 625 alloy during laser powder bed fusion additive manufacturing

IF 2.4 4区材料科学

Welding in the World Pub Date : 2025-01-22 DOI: 10.1007/s40194-025-01932-8

Soma Maji, Murugaiyan Amirthalingam

{"title":"Multi-component and multi-phase-field modelling of solidification microstructural evolution in Inconel 625 alloy during laser powder bed fusion additive manufacturing","authors":"Soma Maji, Murugaiyan Amirthalingam","doi":"10.1007/s40194-025-01932-8","DOIUrl":"10.1007/s40194-025-01932-8","url":null,"abstract":"<div><p>Inconel 625 alloy, known for exceptional mechanical properties and corrosion resistance, is widely used in aerospace, power generation, and marine applications. Laser powder bed fusion (LPBF) excels in manufacturing complex geometries with good surface finish. However, LPBF printed microstructure is highly heterogeneous due to the rapid and complex thermal cycles, necessitating careful parameter selection to prevent the stabilisation of detrimental phases. Experimental parametric optimisation of LPBF is challenging due to the cost and complex inter-playing process variables. Therefore, mathematical modelling is advantageous for optimising LPBF parameters. A 3D heat source model was developed using finite element method (FEM) to analyse thermal cycles with bed-preheating and varying laser parameters in LPBF of IN625. The model focused on a simplified thermal cycle method, where all elements in a layer were set to melt at once to reduce the computational time. A multi-phase-field method (M-PFM) was developed to simulate the microstructural evolution as a function of FEM-generated thermal boundary conditions. The morphological and elemental segregation behaviour of evolving microstructure was simulated. The dendrite morphology predicted by simulations showed strong agreement with experimental observations. The primary dendritic arm spacing (PDAS) obtained from phase-field and analytical models matched the experimental trends, validating the adapted modelling approach. The segregation and the microstructural evolution were found to be strongly influenced by the prevailing temperature gradients and the cooling rates of the melt pool, along with the peak temperatures reached during the remelting cycles.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1023 - 1043"},"PeriodicalIF":2.4,"publicationDate":"2025-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01932-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0