Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor
Understanding the formation of solidified microstructures adjacent to the fusion boundary of a melt pool can provide valuable insights for optimizing process parameters and achieving the desired microstructure in directed energy deposition (DED). However, existing analytical models fail to consider...
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Elsevier
2025-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424030527 |
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| author | Shanshan Xu Bo Yin Jiale Wang Liquan Jin Yu Yin Zhenhua Li David H. StJohn Petro Pavlenko Yueling Guo |
| author_facet | Shanshan Xu Bo Yin Jiale Wang Liquan Jin Yu Yin Zhenhua Li David H. StJohn Petro Pavlenko Yueling Guo |
| author_sort | Shanshan Xu |
| collection | DOAJ |
| description | Understanding the formation of solidified microstructures adjacent to the fusion boundary of a melt pool can provide valuable insights for optimizing process parameters and achieving the desired microstructure in directed energy deposition (DED). However, existing analytical models fail to consider internal and external factors, particularly the solute concentration and scan speed, leading to low prediction accuracy of the solidified microstructure. A vc model of grain growth rate is developed based on the continuous growth restriction factor QC, that considers the coupling effect of both the internal factors and external factors. QC can also be used to describe the evolution of the growth restriction factor Q along the solidification path of liquid metal within the melt pool. The vc model can accurately predict variations in the rate of grain growth and evaluate the influence of solute concentration and scan speed on the Planar to Cellular Transition (PCT) of the Solid/Liquid interface and grain size. The QC value increases with the rise of solute concentration and scan speed, resulting in further growth resistance decreasing the vc value, thereby permitting secondary embryos to nucleate only after the S/L interface moves a short distance. This study fills the gap left by the inability of Q to explain the influence of solutes on the microstructure during DED, and presents a novel approach for analyzing the formation mechanism of solidified microstructure adjacent to the fusion boundary of the melt pool. |
| format | Article |
| id | doaj-art-d1b036b2f9f843d496bcccc98fe1d0a3 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-d1b036b2f9f843d496bcccc98fe1d0a32025-01-19T06:25:57ZengElsevierJournal of Materials Research and Technology2238-78542025-01-013423442357Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factorShanshan Xu0Bo Yin1Jiale Wang2Liquan Jin3Yu Yin4Zhenhua Li5David H. StJohn6Petro Pavlenko7Yueling Guo8School of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, ChinaSchool of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, China; Corresponding author.School of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, ChinaSchool of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, ChinaSchool of Advanced Manufacturing, Sun Yat-sen University, Shenzhen, 518107, ChinaSchool of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, ChinaSchool of Mechanical and Mining Engineering, The University of Queensland, St Lucia, QLD, 4072, Australia; Corresponding author.School of Marine Engineering Equipments, Zhejiang Ocean University, Zhoushan, 316022, ChinaSchool of Mechanical Engineering, Beijing Institute of Technology, Beijing, 100081, China; Corresponding author.Understanding the formation of solidified microstructures adjacent to the fusion boundary of a melt pool can provide valuable insights for optimizing process parameters and achieving the desired microstructure in directed energy deposition (DED). However, existing analytical models fail to consider internal and external factors, particularly the solute concentration and scan speed, leading to low prediction accuracy of the solidified microstructure. A vc model of grain growth rate is developed based on the continuous growth restriction factor QC, that considers the coupling effect of both the internal factors and external factors. QC can also be used to describe the evolution of the growth restriction factor Q along the solidification path of liquid metal within the melt pool. The vc model can accurately predict variations in the rate of grain growth and evaluate the influence of solute concentration and scan speed on the Planar to Cellular Transition (PCT) of the Solid/Liquid interface and grain size. The QC value increases with the rise of solute concentration and scan speed, resulting in further growth resistance decreasing the vc value, thereby permitting secondary embryos to nucleate only after the S/L interface moves a short distance. This study fills the gap left by the inability of Q to explain the influence of solutes on the microstructure during DED, and presents a novel approach for analyzing the formation mechanism of solidified microstructure adjacent to the fusion boundary of the melt pool.http://www.sciencedirect.com/science/article/pii/S2238785424030527Directed energy depositionContinuous growth restriction factorGrain growth ratePlanar to cellular transitionSolidified microstructure |
| spellingShingle | Shanshan Xu Bo Yin Jiale Wang Liquan Jin Yu Yin Zhenhua Li David H. StJohn Petro Pavlenko Yueling Guo Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor Journal of Materials Research and Technology Directed energy deposition Continuous growth restriction factor Grain growth rate Planar to cellular transition Solidified microstructure |
| title | Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| title_full | Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| title_fullStr | Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| title_full_unstemmed | Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| title_short | Controlling the formation of microstructure at the melt-pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| title_sort | controlling the formation of microstructure at the melt pool boundaries during directed energy deposition of aluminum alloy with a modified continuous growth restriction factor |
| topic | Directed energy deposition Continuous growth restriction factor Grain growth rate Planar to cellular transition Solidified microstructure |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424030527 |
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