Interface Response Functions for multicomponent alloy solidification- An application to additive manufacturing

TL;DR

This paper develops advanced sharp interface models incorporating non-linear phase diagram effects to better predict phase selection during rapid solidification in additive manufacturing of multicomponent alloys.

Contribution

It introduces non-linear Calphad-coupled sharp interface models for multicomponent alloys, improving phase prediction accuracy under rapid solidification conditions.

Findings

Model predicts growth-controlled phase selection in multicomponent alloys.

Models successfully applied to steels and nickel-based superalloys.

Results align with experimental observations.

Abstract

The near-rapid solidification conditions during additive manufacturing can lead to selection of non-equilibrium phases. Sharp interface models via interface response functions have been used earlier to explain the microstructure selection under such solidification conditions. However, most of the sharp interface models assume linear superposition of contributions of alloying elements without considering the non-linearity associated with the phase diagram. In this report, both planar and dendritic Calphad coupled sharp interface models have been implemented and used to explain the growth-controlled phase selection observed at high solidification velocities relevant to additive manufacturing. The implemented model predicted the growth-controlled phase selection in multicomponent alloys, which the other models with linear phase diagram could not. These models are calculated for steels and a Nickel-based superalloy and the results are compared with experimental observations.