Journal Home Online First Current Issue Archive For Authors Journal Information 中文版

Engineering >> 2017, Volume 3, Issue 5 doi: 10.1016/J.ENG.2017.05.023

A Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and Solidification Microstructure of Inconel 718 Products Made by Laser Powder-Bed Fusion

a Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA
b Department of Materials Science and Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA

Accepted: 2017-08-24 Available online: 2017-10-31

Next Previous

Abstract

The finite-element (FE) model and the Rosenthal equation are used to study the thermal and microstructural phenomena in the laser powder-bed fusion of Inconel 718. A primary aim is to comprehend the advantages and disadvantages of the Rosenthal equation (which provides an analytical alternative to FE analysis), and to investigate the influence of underlying assumptions on estimated results. Various physical characteristics are compared among the FE model, Rosenthal equation, and experiments. The predicted melt pool shapes compared with reported experimental results from the literature show that both the FE model and the analytical (Rosenthal) equation provide a reasonably accurate estimation. At high heat input, under conditions leading to keyholing, the reported melt width is narrower than predicted by the analytical equation. Moreover, a sensitivity analysis based on choices of the absorptivity is performed, which shows that the Rosenthal approach is more sensitive to absorptivity, compared with the FE approach. The primary reason could be the effect of radiative and convective losses, which are assumed to be negligible in the Rosenthal equation. In addition, both methods predict a columnar solidification microstructure, which agrees well with experimental reports, and the primary dendrite arm spacing (PDAS) predicted with the two approaches is comparable with measurements.

Figures

Fig 1

Fig 2

Fig 3

Fig 4

Fig 5

Fig 6

Fig 7

Fig 8

Fig 9

Fig 10

References

[ 1 ] Petrick IJ, Simpson TW. 3D printing disrupts manufacturing: How economies of one create new rules of competition. Res Technol Manag 2013;56(6):12–6 link1

[ 2 ] Zhao X, Promoppatum P, Yao SC. Numerical modeling of non-linear thermal stress in direct metal laser sintering process of titanium alloy products. In: Proceedings of the First Thermal and Fluids Engineering Summer Conference; 2015 Aug 9–12; New York, NY, USA. New York: American Society of Thermal and Fluids Engineers; 2015. p. 1519–31.

[ 3 ] Kumar LJ, Nair CGK. Current trends of additive manufacturing in the aerospace industry. In: Wimpenny DI, Pandey PM, Kumar LJ, editors Advances in 3D printing & additive manufacturing technologies. Singapore: Springer; 2017. p. 39–54.

[ 4 ] Jia Q, Gu D. Selective laser melting additive manufactured Inconel 718 superalloy parts: High-temperature oxidation property and its mechanisms. Opt Laser Technol 2014;62:161–71 link1

[ 5 ] Wang X, Keya T, Chou K. Build height effect on the Inconel 718 parts fabricated by selective laser melting. Procedia Manuf 2016;5:1006–17 link1

[ 6 ] Promoppatum P, Onler R, Yao SC. Numerical and experimental investigations of micro and macro characteristics of direct metal laser sintered Ti-6Al-4V products. J Mater Process Technol 2017;240:262–73 link1

[ 7 ] Sadowski M, Ladani L, Brindley W, Romano J. Optimizing quality of additively manufactured Inconel 718 using powder bed laser melting process. Addit Manuf 2016;11:60–70 link1

[ 8 ] Rosenthal D. Mathematical theory of heat distribution during welding and cutting. Weld J 1941;20(5):220–34.

[ 9 ] Tang M, Pistorius PC, Beuth JL. Prediction of lack-of-fusion porosity for powder bed fusion. Addit Manuf 2017;14:39–48 link1

[10] Liang YJ, Li A, Cheng X, Pang XT, Wang HM. Prediction of primary dendritic arm spacing during laser rapid directional solidification of single-crystal nickel-base superalloys. J Alloys Compd 2016;688(Pt A):133–42.

[11] Romano J, Ladani L, Sadowski M. Laser additive melting and solidification of Inconel 718: Finite element simulation and experiment. JOM 2016;68(3):967–77 link1

[12] Romano J, Ladani L, Sadowski M. Thermal modeling of laser based additive manufacturing processes within common materials. Procedia Manuf 2015;1:238–50 link1

[13] Yan W, Ge W, Smith J, Lin S, Kafka OL, Lin F, et al.Multi-scale modeling of electron beam melting of functionally graded materials. Acta Mater 2016;115:403–12 link1

[14] Yan W, Ge W, Qian Y, Lin S, Zhou B, Liu WK, et al.Multi-physics modeling of single/multiple-track defect mechanisms in electron beam selective melting. Acta Mater 2017;134:324–33 link1

[15] Bonacina C, Comini G, Fasano A, Primicerio M. Numerical solution of phase-change problems. Int J Heat Mass Transfer 1973;16(10):1825–32 link1

[16] Hosaeus H, Seifter A, Kaschnitz E, Pottlacher G. Thermophysical properties of solid and liquid Inconel 718 alloy. High Temp High Press 2001;33(4):405–10 link1

[17] Hu D, Kovacevic R. Modelling and measuring the thermal behaviour of the molten pool in closed-loop controlled laser-based additive manufacturing. Proc Inst Mech Eng Part B 2003;217(4):441–52 link1

[18] Sainte-Catherine C, Jeandin M, Kechemair D, Ricaud JP, Sabatier L. Study of dynamic absorptivity at 10.6 μm (CO2) and 1.06 μm (Nd-YAG) wavelengths as a function of temperature. J Phys IV France 1991;1(C7):C7-151–7.

[19] Montgomery C, Beuth J, Sheridan L, Klingbeil N. Process mapping of Inconel 625 in laser powder bed additive manufacturing. In: Proceedings: 26th Annual International Solid Freeform Fabrication Symposium—An additive manufacturing conference; 2015 Aug 10–12; Austin, T X, USA; 2015. p. 1195–204.

[20] Lee YS, Zhang W. Modeling of heat transfer, fluid flow and solidification microstructure of nickel-base superalloy fabricated by laser powder bed fusion. Addit Manuf 2016;12(Pt B):178–88.

[21] Gong H, Gu H, Zeng K, Dilip JJS, Pal D, Stucker B, et al.Melt pool characterization for selective laser melting of Ti-6Al-4V pre-alloyed powder. In: Proceedings of the 25th Annual International Solid Freeform Fabrication Symposium ; 2014 Aug 4–6; Austin, TX, USA; 2014. p. 256–67.

[22] Bontha S, Klingbeil NW, Kobryn PA, Fraser HL. Effects of process variables and size-scale on solidification microstructure in beam-based fabrication of bulky 3D structures. Mater Sci Eng A 2009;513– 514:311–8.

[23] Goldak J, Chakravarti A, Bibby M. A new finite element model for welding heat sources. Metall Mater Trans B 1984;15(2):299–305 link1

[24] Wei HL, Mukherjee T, DebRoy T. Grain growth modeling for additive manufacturing of nickel based superalloys. In: Holm EA, Farjami S, Manohar P, Rohrer GS, Rollett AD, Srolovitz D, et al., editors Proceedings of the 6th International Conference on Recrystallization and Grain Growth (ReX&GG 2016); 2016 Jul 17–21; Pittsburgh, PA , USA. Cham: Springer; 2016. p. 265–9.

[25] ]Wang X, Gong X, Chou K. Review on powder-bed laser additive manufacturing of Inconel 718 parts. In: Proceedings of the ASME 10th International Manufacturing Science and Engineering Conference 2015: Volume 1; 2015 Jun 8–12; Charlotte, NC , USA. New York: American Society of Mechanical Engineers; 2015. p. V001T02A063.

[26] Nastac L, Valencia JJ, Tims ML, Dax FR. Advances in the solidification of IN718 and RS5 alloys. In: Loria EA, editor Superalloys 718, 625, 706, and various derivatives: Proceedings of the International Symposium on Superalloys 718, 625, 706 and Various Derivatives; 2001 Jun 17–20; Pittsburgh , PA, USA. Pittsburgh: The Minerals, Metals & Materials Society; 2001. p. 103–12.

[27] Lu SZ, Hunt JD. A numerical analysis of dendritic and cellular array growth: The spacing adjustment mechanisms. J Cryst Growth 1992;123(1–2):17–34. link1

[28] Kurz W, Fisher DJ. Dendrite growth at the limit of stability: Tip radius and spacing. Acta Metall 1981;29(1):11–20 link1

[29] Wang G, Liang J, Zhou Y, Jin T, Sun X, Hu Z. Prediction of dendrite orientation and stray grain distribution in laser surface-melted single crystal superalloy. J Mater Sci Technol (Shenyang, China) 2017;33(5):499–506 link1

Related Research