Predicting the Microstructural Evolution of Electron Beam Melting of Alloy 718 with Phase-Field Modeling

Electron beam melting (EBM) is a powder bed additive manufacturing process where a powder material is melted selectively in a layer-by-layer approach using an electron beam. EBM has some unique features during the manufacture of components with high-performance superalloys that are commonly used in gas turbines such as Alloy 718. EBM has a high deposition rate due to its high beam energy and speed, comparatively low residual stresses, and limited problems with oxidation. However, due to the layer-by-layer melting approach and high powder bed temperature, the as-built EBM Alloy 718 exhibits a microstructural gradient starting from the top of the sample. In this study, we conducted modeling to obtain a deeper understanding of microstructural development during EBM and the homogenization that occurs during manufacturing with Alloy 718. A multicomponent phase-field modeling approach was combined with transformation kinetic modeling to predict the microstructural gradient and the results were compared with experimental observations. In particular, we investigated the segregation of elements during solidification and the subsequent “in situ” homogenization heat treatment at the elevated powder bed temperature. The predicted elemental composition was then used for thermodynamic modeling to predict the changes in the continuous cooling transformation and time–temperature transformation diagrams for Alloy 718, which helped to explain the observed phase evolution within the microstructure. The results indicate that the proposed approach can be employed as a valuable tool for understanding processes and for process development, including post-heat treatments

Microstructure Modelling of Additive Manufacturing of Alloy 718

In recent years, additive manufacturing (AM) of Alloy 718 has received increasing interest in the field of manufacturing engineering owing to its attractive features compared to those of conventional manufacturing methods. The ability to produce complicated geometries, low cost of retooling, and control of the microstructure are some of the advantages of the AM process over traditional manufacturing methods. Nevertheless, during the building process, the build material undergoes complex thermal conditions owing to the inherent nature of the process. This results in phase transformation from liquid to solid and solid state. Thus, it creates microstructural gradients in the built objects, and as a result,heterogeneous material properties. The manufacturing process, including the following heat treatment that is used to minimise the heterogeneity, will cause the additively manufactured material to behave differently when compared to components produced by conventional manufacturing methods. Therefore, understanding the microstructure formation during the building and subsequent post-heat treatment is important, which is the objective of this work. Alloy 718 is a nickel-iron based super alloy that is widely used in the aerospace industry and in the gas turbine power plants for making components subjected tohigh temperatures. Good weldability, good mechanical properties at high temperatures, and high corrosion resistance make this alloy particularly suitablefor these applications. Nevertheless, the manufacturing of Alloy 718 components through traditional manufacturing methods is time-consuming and expensive. For example, machining of Alloy 718 to obtain the desired shape is difficult and resource-consuming, owing to significant material waste. Therefore, the application of novel non-conventional processing methods, such as AM, seems to be a promising technique for manufacturing near-net-shape complex components.In this work, microstructure modelling was carried out by using multiphase-field modelling to model the microstructure evolution in electron beam melting (EBM) and laser metal powder directed energy deposition (LMPDED) of Alloy 718 and x subsequent heat treatments. The thermal conditions that are generated during the building process were used as input to the models to predict the as-built microstructure. This as-built microstructure was then used as an input for the heat treatment simulations to predict the microstructural evolution during heat treatments. The results showed smaller dendrite arm spacing (one order of magnitude smaller than the casting material) in these additive manufactured microstructures, which creates a shorter diffusion length for the elements compared to the cast material. In EBM Alloy 718, this caused the material to have a faster homogenisation during in-situ heat treatment that resulting from the elevated powder bed temperature (> 1000 °C). In addition, the compositional segregation that occurs during solidification was shown to alter the local thermodynamic and kinetic properties of the alloy. This was observed in the predicted TTT and CCT diagrams using the JMat Pro software based on the predicted local segregated compositions from the multiphase-field models. In the LMPDED Alloy 718 samples, this resulted in the formation of δ phase in the interdendritic region during the solution heat treatment. Moreover, this resulted in different-size precipitation of γ'/γ'' in the inter-dendritic region and in the dendrite core. Themicro structure modelling predictions agreed well with the experimental observations. The proposed methodology used in this thesis work can be an appropriate tool to understand how the thermal conditions in AM affect themicro structure formation during the building process and how these as-built microstructures behave under different heat treatments

Modelling of the temperature field in TIG arc heat treated super duplex stainless steel samples

Super Duplex Stainless Steels have superior corrosion resistance properties and strength compared to conventional steels. However, these properties are influenced by the different phases that precipitate during the heat treatment process. The conventional way of studying the time and temperature effects on the properties and micro-structure of SDSS is to prepare many samples at different temperatures and holding times. The welding research group at Production Technology Center, Trollhättan, Sweden, has recently developed a unique heat treatment method to produce a wide range of temperature by using a stationary TIG arc heat source. It results in a graded micro-structure in a single sample at a specific time period. The accuracy of the results ob-ained from this process is highly related to the accuracy of the temperature field model next to weld pool. In this work, a model was developed by using OpenFOAM CDF code, to predict the temperature field of the super duplex stainless steel samples that have been subjected to this novel TIG arc heat treatment process. The developed model was able to capture the trend in the overall temperature field in the heat affected zone. However, there was some mismatch between the modelled and experimental temperature profiles in certain locations in the heat affected zone. Further improvements have to be done to the developed model in order to take the phase transformation effect into account. A preliminary investigation has been carried out on how to implement this in the current model and reported in the thesis

Microstructure Modelling of Additive Manufacturing of Alloy 718

In recent years, additive manufacturing (AM) of Alloy 718 has received increasing interest in the field of manufacturing engineering because of its attractive features compared with those of conventional manufacturing methods. Nevertheless, owing to the inherent nature of the process, the build material is exposed to complex thermal conditions that affect the microstructure. In addition, the post heattreatments applied to the built component further cause microstructural changes. Thus, obtaining the desired microstructure that gives the desired properties is still a challenging task. Therefore, understanding the microstructure formation during the build and subsequent post-heat treatment is important and is the objective of this thesis work. To this end, a computational modelling approach was used that combines multiphase-field modelling with transformation kinetics modelling. Two different AM processes, laser metal powder directed energy deposition (LM-PDED) and electron beam powder bed fusion (EB-PBF), were considered in this study.Based on the modelling work, it was observed that solidification conditions (thermal gradients and cooling rates) that occur during the AM process have an impact on the as-solidified microstructure in Alloy 718 and the resultant Laves phase formation. With an increase in cooling rate, the Laves phase volume fraction becomes lower and the morphology tends to become discrete particles,which is important for resisting the formation of liquation cracks in Alloy 718. It was also found that the precipitates formed during the solidification process did not undergo any significant change during subsequent thermal cycles associated with the deposition of subsequent layers, given that the deposition of the subsequent layer does not increase the global temperature of the build to> 600 °C. If the global temperature increases above 600 °C, then phase changes are expected, depending on the temperature value. In the case of the EB-PBF process, the high build temperature maintained in the build chamber resulted in an ‘‘in situ’’ heat treatment, which had a homogenisation effect on the as-solidified microstructure because of the smaller dendrite spacing and relatively low Lavesphase size. In the case of the LM-PDED, the microsegregation of composition observed in the as-built microstructure was shown to change the equilibrium conditions and precipitation kinetics of Alloy 718. As a result, excess precipitationof γ'/γ″ and δ was observed in the interdendritic region compared with the dendrite core, depending on the type of heat treatment used. In addition, modelling was performed to evaluate the elastic properties of EB-PBF Alloy 718. To this end, crystallographic orientation data gathered from EBSD data and single-crystal elastic constants were used. The prediction showed good agreement with published literature data. The hatch (bulk) region of the EB-PBF samples showed significant anisotropic elastic properties because of the strong crystallographic texture observed in the microstructure. The lowest Young’s modulus was observed along the build direction. Normal to the build direction, the elastic properties were shown to be isotropic. Overall, the elastic behaviour of the hatch region was similar to that of a transversely isotropic cas

Toward a better understanding of phase transformations in additive manufacturing of Alloy 718

This paper presents a discussion on the phase-transformation aspects of additively manufactured Alloy 718 during the additive manufacturing (AM) process and subsequent commonly used post-heat treatments. To this end, fundamental theoretical principles, thermodynamic and kinetics modeling, and existing literature data are employed. Two different AM processes, namely, laser-directed energy deposition and electron-beam powder-bed fusion are considered. The general aspects of phase formation during solidification and solid state in Alloy 718 are first examined, followed by a detailed discussion on phase transformations during the two processes and subsequent standard post heat-treatments. The effect of cooling rates, thermal gradients, and thermal cycling on the phase transformation in Alloy 718 during the AM processes are considered. Special attention is given to illustrate how the segregated composition during the solidification could affect the phase transformations in the Alloy 718. The information provided in this study will contribute to a better understanding of the overall process-structure-property relationship in the AM of Alloy 718 718.Funding Agencies|European Regional Development FundEuropean Union (EU); KK Foundation (Stiftelsen for Kunskaps-och Kompetensutveckling)</p

Microstructure modelling of laser metal powder directed energy deposition of alloy 718

A multi-component and multi-phase-field modelling approach, combined with transformation kinetics modelling, was used to model microstructure evolution during laser metal powder directed energy deposition of Alloy 718 and subsequent heat treatments. Experimental temperature measurements were utilised to predict microstructural evolution during successive addition of layers. Segregation of alloying elements as well as formation of Laves and delta phase was specifically modelled. The predicted elemental concentrations were then used in transformation kinetics to estimate changes in Continuous Cooling Transformation (CCT) and Time Temperature Transformation (TTT) diagrams for Alloy 718. Modelling results showed good agreement with experimentally observed phase evolution within the microstructure. The results indicate that the approach can be a valuable tool, both for improving process understanding and for process development including subsequent heat treatment.Funding Agencies|European Regional Development Fund; KK Foundation (Stiftelsen for Kunskaps- och Kompetensutveckling)</p

On the Microstructure of Laser Beam Powder Bed Fusion Alloy 718 and Its Influence on the Low Cycle Fatigue Behaviour

Additive manufacturing of Alloy 718 has become a popular subject of research in recent years. Understanding the process-microstructure-property relationship of additively manufactured Alloy 718 is crucial for maturing the technology to manufacture critical components. Fatigue behaviour is a key mechanical property that is required in applications such as gas turbines. Therefore, in the present work, low cycle fatigue behaviour of Alloy 718 manufactured by laser beam powder bed fusion process has been investigated. The material was tested in as-built condition as well as after two different thermal post-treatments. Three orientations with respect to the building direction were tested to evaluate the anisotropy. Testing was performed at room temperature under controlled amplitudes of strain. It was found that defects, inclusions, strengthening precipitates, and Youngs modulus influence the fatigue behaviour under strain-controlled conditions. The strengthening precipitates affected the deformation mechanism as well as the cycle-dependent hardening/softening behaviour. The defects and the inclusions had a detrimental effect on fatigue life. The presence of Laves phase in LB-PBF Alloy 718 did not have a detrimental effect on fatigue life. Youngs modulus was anisotropic and it contributed to the anisotropy in strain-life relationship. Pseudo-elastic stress vs. fatigue life approach could be used to handle the modulus-induced anisotropy in the strain-life relationship.Funding Agencies|Vastra Gotalandsregionen; Tillvaxtverket; European Regional Development FundEuropean Union (EU); GKN Aerospace Sweden AB through the Spacelab project [20201639]</p

Scanning electron microscopy and atom probe tomography characterization of laser powder bed fusion precipitation strengthening nickel-based superalloy

Atom probe tomography (APT) was utilized to supplement scanning electron microscopy (SEM) characterization of a precipitation strengthening nickel-based superalloy, Alloy 247LC, processed by laser powder bed fusion (L-PBF). It was observed that the material in the as-built condition had a relatively high strength. Using both SEM and APT, it was concluded that the high strength was not attributed to the typical precipitation strengthening effect of γ’. In the absence of γ’ it could be reasonably inferred that the numerous black dots observed in the cells/grains with SEM were dislocations and as such should be contributing significantly to the strengthening. Thus, the current investigation demonstrated that relatively high strengthening can be attained in L-PBF even in the absence of precipitated γ’. Even though γ’ was not precipitated, the APT analysis displayed a nanometer scale partitioning of Cr that could be contributing to the strengthening. After heat-treatment, γ’ was precipitated and it demonstrated the expected high strengthening behavior. Al, Ta and Ti partitioned to γ’. The strong partitioning of Ta in γ’ is indicative that the element, together with Al and Ti, was contributing to the strain-age cracking occurring during heat-treatment. Cr, Mo and Co partitioned to the matrix γ phase. Hf, Ta, Ti and W were found in the carbides corroborating previous reports that they are MC