Solidification Characteristics of Laser-Powder Bed Fused AlSi10Mg: Role of Building Direction

TL;DR

This study investigates how the building direction in laser-powder bed fusion affects the microstructure and solidification behavior of AlSi10Mg alloy, combining thermal modeling and phase field simulations to explain morphological differences.

Contribution

It introduces a combined thermal and phase field modeling approach to analyze the influence of building direction on microstructure evolution in LPBF AlSi10Mg.

Findings

Nucleation rate is higher in horizontally built samples due to increased constitutional undercooling.

Building direction significantly impacts local cooling conditions and grain morphology.

The phase field model accurately predicts morphological transitions during solidification.

Abstract

In this work, the effect of building direction on the microstructure evolution of laser-powder bed fusion (LPBF) processed AlSi10Mg alloy was investigated. The building direction, as shown in experimentally fabricated parts, can influence the solidification behavior and promote morphological transitions in cellular dendritic microstructures. We develop a thermal model to systemically address the impact of laser processing conditions, and building direction on the thermal characteristics of the molten pool during laser processing of AlSi10Mg alloy. We then employ a multi-order parameter phase field model to study the microstructure evolution of LPBF-AlSi10Mg in the dilute limit, using the underlying thermal conditions for horizontal and vertical building directions as input. The phase field model employed here is designed to simulate solidification using heterogeneous nucleation from inoculant particles allowing to take into account morphological phenomena including the columnar-to-equiaxed transition (CET). The phase field model is first validated against the predictions of the previously developed steady-state CET theory of Hunt \cite{hunt1984steady}. It is then used under transient conditions to study microstructure evolution, revealing that the nucleation rate is noticeably higher in the horizontally built samples due to larger constitutional undercooling, which is consistent with experimental observations. We further quantify the effect of building direction on the local cooling conditions, and consequently on the grain morphology.