Phase-Field Study of Polycrystalline Growth and Texture Selection During Melt Pool Solidification

TL;DR

This study uses advanced phase-field simulations to investigate how melt pool geometry influences grain growth and texture selection during metal additive manufacturing, revealing a shape-dependent transition in grain texture orientation.

Contribution

It introduces a multi-GPU phase-field simulation approach to analyze microstructure evolution in full-scale melt pools during additive manufacturing.

Findings

Aspect ratio affects grain texture orientation.

Wide melt pools promote stronger <10> texture.

Initial grain density has limited impact on texture transition.

Abstract

Grain growth competition during solidification determines microstructural features, such as dendritic arm spacings, segregation pattern, and grain texture, which have a key impact on the final mechanical properties. During metal additive manufacturing (AM), these features are highly sensitive to manufacturing conditions, such as laser power and scanning speed. The melt pool (MP) geometry is also expected to have a strong influence on microstructure selection. Here, taking advantage of a computationally efficient multi-GPU implementation of a quantitative phase-field model, we use two-dimensional cross-section simulations of a shrinking MP during metal AM, at the scale of the full MP, in order to explore the resulting mechanisms of grain growth competition and texture selection. We explore MPs of different aspect ratios, different initial (substrate) grain densities, and repeat each simulation several times with different random grain distributions and orientations along the fusion line in order to obtain a statistically relevant picture of grain texture selection mechanisms. Our results show a transition from a weak to a strong $\langle10\rangle$ texture when the aspect ratio of the melt pool deviates from unity. This is attributed to the shape and directions of thermal gradients during solidification, and seems more pronounced in the case of wide melt pools than in the case of a deeper one. The texture transition was not found to notably depend upon the initial grain density along the fusion line from which the melt pool solidifies epitaxially.