Grain growth competition during melt pool solidification -- Comparing phase-field and cellular automaton models

A broad range of computational models have been proposed to predict microstructure development during solidification processing but they have seldom been compared to each other on a quantitative and systematic basis. In this paper, we compare phase-field (PF) and cellular automaton (CA) simulations of polycrystalline growth in a two-dimensional melt pool under conditions relevant to additive manufacturing (powder-bed fusion). We compare the resulting grain structures using local (point-by-point) measurements, as well as averaged grain orientation distributions over several simulations. We explore the effect of the CA spatial discretization level and that of the melt pool aspect ratio upon the selected grain texture. Our simulations show that detailed microscopic features related to transient growth conditions and solid-liquid interface stability (e.g. the initial planar growth stage prior to its cellular/dendritic destabilization, or the early elimination of unfavorably oriented grains due to neighbor grain sidebranching) can only be captured by PF simulations. The resulting disagreement between PF and CA predictions can only be addressed partially by a refinement of the CA grid. However, overall grain distributions averaged over the entire melt pools of several simulations seem to lead to a notably better agreement between PF and CA, with some variability with the melt pool shape and CA grid. While further research remains required, in particular to identify the appropriate selection of CA spatial discretization and its link to characteristic microstructural length scales, this research provides a useful step forward in this direction by comparing both methods quantitatively at process-relevant length and time scales

Efficiency and accuracy of GPU-parallelized Fourier spectral methods for solving phase-field models

Phase-field models are widely employed to simulate microstructure evolution during processes such as solidification or heat treatment. The resulting partial differential equations, often strongly coupled together, may be solved by a broad range of numerical methods, but this often results in a high computational cost, which calls for advanced numerical methods to accelerate their resolution. Here, we quantitatively test the efficiency and accuracy of semi-implicit Fourier spectral-based methods, implemented in Python programming language and parallelized on a graphics processing unit (GPU), for solving a phase-field model coupling Cahn-Hilliard and Allen-Cahn equations. We compare computational performance and accuracy with a standard explicit finite difference (FD) implementation with similar GPU parallelization on the same hardware. For a similar spatial discretization, the semi-implicit Fourier spectral (FS) solvers outperform the FD resolution as soon as the time step can be taken 5 to 6 times higher than afforded for the stability of the FD scheme. The accuracy of the FS methods also remains excellent even for coarse grids, while that of FD deteriorates significantly. Therefore, for an equivalent level of accuracy, semi-implicit FS methods severely outperform explicit FD, by up to 4 orders of magnitude, as they allow much coarser spatial and temporal discretization

Grain growth competition and formation of grain boundaries during solidification of hcp alloys

Grain growth competition during directional solidification of a polycrystal with hexagonal (hcp) symmetry (Mg-1wt%Gd alloy) is studied by phase-field modeling, exploring the effect of the temperature gradient G on the resulting grain boundary (GB) orientation selection. Results show that selection mechanisms and scaling laws derived for cubic (fcc, bcc) crystals also apply to hcp materials (within their basal plane), provided a re-estimation of fitting parameters and re-scaling to account for the sixfold symmetry. While grain growth competition remains stochastic with rare events of unexpected elimination or side-branching along the developing GBs, we also confirm an overall transition from a geometrical limit to a favorably oriented grain limit behavior with an increase of thermal gradient within the dendritic regime, and the progressive alignment of dendrites and GBs toward the temperature gradient direction with an increase of G during the dendritic-to-cellular morphological transition. Comparisons with original thin-sample directional solidification experiments show a qualitative agreement with PF results, yet with notable discrepancies, which nonetheless can be explained based on the stochastic variability of selected GB orientations, and the statistically limited experimental sample size. Overall, our results extend the understanding of GB formation and grain growth competition during solidification of hcp materials, and the effect of thermal conditions, nonetheless concluding on the challenges of extending the current studies to three dimensions, and the need for much broader (statistically significant) data sets of GB orientation selected under well-identified solidification conditions

Direct Simulation of a Solidification Benchmark Experiment

International audienceA solidification benchmark experiment is simulated using a three-dimensional cellular automaton-finite element solidification model. The experiment consists of a rectangular cavity containing a Sn-3 wt pct Pb alloy. The alloy is first melted and then solidified in the cavity. A dense array of thermocouples permits monitoring of temperatures in the cavity and in the heat exchangers surrounding the cavity. After solidification, the grain structure is revealed by metallography. X-ray radiography and inductively coupled plasma spectrometry are also conducted to access a distribution map of Pb, or macrosegregation map. The solidification model consists of solutions for heat, solute mass, and momentum conservations using the finite element method. It is coupled with a description of the development of grain structure using the cellular automaton method. A careful and direct comparison with experimental results is possible thanks to boundary conditions deduced from the temperature measurements, as well as a careful choice of the values of the material properties for simulation. Results show that the temperature maps and the macrosegregation map can only be approached with a three-dimensional simulation that includes the description of the grain structure

BARRANCO DE AZUAJE [Material gráfico]

ADQUIRIDA POR EL COLECCIONISTA EN LAS PALMAS DE G.C.FOTO POSTAL DE "FUENTE DE AZUAJE. MOYA. GRAN CANARIA, LAS PALMAS" (COLOREADA)Copia digital. Madrid : Ministerio de Educación, Cultura y Deporte. Subdirección General de Coordinación Bibliotecaria, 201

Columnar and Equiaxed Solidification of Al-7 wt.% Si Alloys in Reduced Gravity in the Framework of the CETSOL Project

International audienceDuring casting, often a dendritic microstructure is formed, resulting in a columnar or an equiaxed grain structure, or leading to a transition from columnar to equiaxed growth (CET). The detailed knowledge of the critical parameters for the CET is important because the microstructure affects materials properties. To provide unique data for testing of fundamental theories of grain and microstructure formation, solidification experiments in microgravity environment were performed within the European Space Agency Microgravity Application Promotion (ESA MAP) project Columnar-to-Equiaxed Transition in SOLidification Processing (CETSOL). Reduced gravity allows for purely diffusive solidification conditions, i.e., suppressing melt flow and sedimentation and floatation effects. On-board the International Space Station, Al-7 wt.% Si alloys with and without grain refiners were solidified in different temperature gradients and with different cooling conditions. Detailed analysis of the microstructure and the grain structure showed purely columnar growth for nonrefined alloys. The CET was detected only for refined alloys, either as a sharp CET in the case of a sudden increase in the solidification velocity or as a progressive CET in the case of a continuous decrease of the temperature gradient. The present experimental data were used for numerical modeling of the CET with three different approaches: (1) a front tracking model using an equiaxed growth model, (2) a three-dimensional (3D) cellular automaton–finite element model, and (3) a 3D dendrite needle network method. Each model allows for predicting the columnar dendrite tip undercooling and the growth rate with respect to time. Furthermore, the positions of CET and the spatial extent of the CET, being sharp or progressive, are in reasonably good quantitative agreement with experimental measurements

Interactions between Kluyveromyces marxianus from cheese origin and the intestinal symbiont Bacteroides thetaiotaomicron: Impressive antioxidative effects

The effects of yeast Kluyveromyces marxianus S-2-05, of cheese origin, were assessed on the intestine anaerobe symbiont Bacteroides thetaiotaomicron ATCC 29741 to unveil any changes in its antioxidant properties. To this end, these microorganisms were grown and incubated either separately, or co-incubated, under anaerobic atmosphere. Afterwards, the microbial cells were recovered and washed, and extracts were prepared using a sterile detergent solution to mimic the intestine detergent content. The extracts prepared from K. marxianus S-2-05 and reference strain K. marxianus MUCL 29917, grown under different conditions, were assessed for their antioxidant properties against superoxide anion and hydrogen peroxide. Extracts from both yeasts showed antioxidative effects, which were particularly important for K. marxianus S-02-5 after anaerobic incubation. Moreover, K. marxianus S-02-5 displayed a high level of activity against the aforementioned reactive oxygen species, enhancing that of B. thetaiotaomicron ATCC 29741, after the co-incubation process. Two-dimensional polyacrylamide gel electrophoresis was used to separate the proteins extracted. Superoxide dismutase, thiol peroxidase, rubrerythrin -intensively produced by B. thetaiotaomicron induced by the yeast-were identified by mass spectrometry. The antioxidative potential evidenced for K. marxianus S-02-5 is another advantage which could justify the utilization of this strain as a probiotic for countering intestinal inflammatory processes. © 2017 Elsevier Lt

3D Pattern Adjustment During Directional 1 Solidification of a Transparent Alloy Conducted on DECLIC-DSI

No abstract availabl

Virulence Potential and Genomic Mapping of the Worldwide Clone Escherichia coli ST131

Recently, the worldwide propagation of clonal CTX-M-15-producing Escherichia coli isolates, namely ST131 and O25b:H4, has been reported. Like the majority of extra-intestinal pathogenic E. coli isolates, the pandemic clone ST131 belongs to phylogenetic group B2, and has recently been shown to be highly virulent in a mouse model, even though it lacks several genes encoding key virulence factors (Pap, Cnf1 and HlyA). Using two animal models, Caenorhabditis elegans and zebrafish embryos, we assessed the virulence of three E. coli ST131 strains (2 CTX-M-15- producing urine and 1 non-ESBL-producing faecal isolate), comparing them with five non-ST131 B2 and a group A uropathogenic E. coli (UPEC). In C. elegans, the three ST131 strains showed intermediate virulence between the non virulent group A isolate and the virulent non-ST131 B2 strains. In zebrafish, the CTX-M-15-producing ST131 UPEC isolates were also less virulent than the non-ST131 B2 strains, suggesting that the production of CTX-M-15 is not correlated with enhanced virulence. Amongst the non-ST131 B2 group isolates, variation in pathogenic potential in zebrafish embryos was observed ranging from intermediate to highly virulent. Interestingly, the ST131 strains were equally persistent in surviving embryos as the non-ST131-group B2 strains, suggesting similar mechanisms may account for development of persistent infection. Optical maps of the genome of the ST131 strains were compared with those of 24 reference E. coli strains. Although small differences were seen within the ST131 strains, the tree built on the optical maps showed that these strains belonged to a specific cluster (86% similarity) with only 45% similarity with the other group B2 strains and 25% with strains of group A and D. Thus, the ST131 clone has a genetic composition that differs from other group B2 strains, and appears to be less virulent than previously suspected