Solute trapping and non-equilibrium microstructure during rapid solidification of additive manufacturing

Neng Ren, Jun Li (), Ruiyao Zhang, Chinnapat Panwisawas (), Mingxu Xia, Hongbiao Dong and Jianguo Li
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Neng Ren: Shanghai Jiao Tong University
Jun Li: Shanghai Jiao Tong University
Ruiyao Zhang: Centre of Excellence for Advanced Materials
Chinnapat Panwisawas: Queen Mary University of London
Mingxu Xia: Shanghai Jiao Tong University
Hongbiao Dong: University of Leicester
Jianguo Li: Shanghai Jiao Tong University

Nature Communications, 2023, vol. 14, issue 1, 1-13

Abstract: Abstract Solute transport during rapid and repeated thermal cycle in additive manufacturing (AM) leading to non-equilibrium, non-uniform microstructure remains to be studied. Here, a fully-coupled fluid dynamics and microstructure modelling is developed to rationalise the dynamic solute transport process and elemental segregation in AM, and to gain better understanding of non-equilibrium nature of intercellular solute segregation and cellular structures at sub-grain scale during the melting-solidification of the laser powder bed fusion process. It reveals the solute transport induced by melt convection dilutes the partitioned solute at the solidification front and promotes solute trapping, and elucidates the mechanisms of the subsequent microstructural morphology transitions to ultra-fine cells and then to coarse cells. These suggest solute trapping effect could be made used for reducing crack susceptibility by accelerating the solidification process. The rapid solidification characteristics exhibit promising potential of additive manufacturing for hard-to-print superalloys and aid in alloy design for better printability.

Date: 2023
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DOI: 10.1038/s41467-023-43563-x

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