Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing
The rapid solidification speed and significant temperature gradient observed in the wire and arc additive manufacturing (WAAM) process result in a deviation of the solid-liquid interface from the equilibrium state assumed by the conventional directional solidification phase field (PF) model. This, i...
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| Format: | Article |
| Language: | English |
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Elsevier
2024-01-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424000218 |
| _version_ | 1797338318925463552 |
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| author | Fuchen Wang Weipeng Chen Dong Wang Hua Hou Yuhong Zhao |
| author_facet | Fuchen Wang Weipeng Chen Dong Wang Hua Hou Yuhong Zhao |
| author_sort | Fuchen Wang |
| collection | DOAJ |
| description | The rapid solidification speed and significant temperature gradient observed in the wire and arc additive manufacturing (WAAM) process result in a deviation of the solid-liquid interface from the equilibrium state assumed by the conventional directional solidification phase field (PF) model. This, in turn, limits the ability of the traditional directional solidification PF model to accurately depict the microstructure evolution in additive manufacturing, where non-equilibrium effects dominate. In this work, we employed a 3D finite element (FE) model to simulate the temperature distribution during the wire and arc additive manufacturing (WAAM) process. Additionally, a modified PF model that applies to additive manufacturing is also used to simulate the dendrite morphology and solute segregation behavior in the WAAM process at different scanning speeds. Experimental validation of the simulation results was also conducted. We observed a significant reduction in dendrite growth velocity and solute segregation with increasing scanning speed, attributable to the combined effects of the temperature gradient G(t) and solidification speed Vp. Furthermore, higher scanning speeds were found to increase the primary dendrite arm spacing (PDAS) and average dendrite width. Importantly, our results demonstrated a quantitative agreement between the simulation results using the modified directional solidification PF model and the experimental observations. This approach provides a foundation for selecting and predicting processing parameters and microstructural characteristics under additive manufacturing conditions, facilitating a comprehensive analysis of dendrite growth and solute segregation at different scanning speeds in the WAAM process. |
| first_indexed | 2024-03-08T09:28:19Z |
| format | Article |
| id | doaj.art-dca5bbd4e332441aa1a607691020b072 |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-08T09:28:19Z |
| publishDate | 2024-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-dca5bbd4e332441aa1a607691020b0722024-01-31T05:44:32ZengElsevierJournal of Materials Research and Technology2238-78542024-01-012845854599Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturingFuchen Wang0Weipeng Chen1Dong Wang2Hua Hou3Yuhong Zhao4School of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, ChinaSchool of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, ChinaSchool of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, ChinaSchool of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, China; School of Materials Science and Engineering, Taiyuan University of Science and Technology, Taiyuan, 030024, ChinaSchool of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, China; Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing, Beijing, 100083, China; Institute of Materials Intelligent Technology, Liaoning Academy of Materials, Shenyang, 110004, China; Corresponding author. School of Materials Science and Engineering, Collaborative Innovation Center of Ministry of Education and Shanxi Province for High-performance Al/Mg Alloy Materials, North University of China, Taiyuan, 030051, China.The rapid solidification speed and significant temperature gradient observed in the wire and arc additive manufacturing (WAAM) process result in a deviation of the solid-liquid interface from the equilibrium state assumed by the conventional directional solidification phase field (PF) model. This, in turn, limits the ability of the traditional directional solidification PF model to accurately depict the microstructure evolution in additive manufacturing, where non-equilibrium effects dominate. In this work, we employed a 3D finite element (FE) model to simulate the temperature distribution during the wire and arc additive manufacturing (WAAM) process. Additionally, a modified PF model that applies to additive manufacturing is also used to simulate the dendrite morphology and solute segregation behavior in the WAAM process at different scanning speeds. Experimental validation of the simulation results was also conducted. We observed a significant reduction in dendrite growth velocity and solute segregation with increasing scanning speed, attributable to the combined effects of the temperature gradient G(t) and solidification speed Vp. Furthermore, higher scanning speeds were found to increase the primary dendrite arm spacing (PDAS) and average dendrite width. Importantly, our results demonstrated a quantitative agreement between the simulation results using the modified directional solidification PF model and the experimental observations. This approach provides a foundation for selecting and predicting processing parameters and microstructural characteristics under additive manufacturing conditions, facilitating a comprehensive analysis of dendrite growth and solute segregation at different scanning speeds in the WAAM process.http://www.sciencedirect.com/science/article/pii/S2238785424000218Rapid solidificationWAAMPhase fieldDendrite growthSolute segregation |
| spellingShingle | Fuchen Wang Weipeng Chen Dong Wang Hua Hou Yuhong Zhao Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing Journal of Materials Research and Technology Rapid solidification WAAM Phase field Dendrite growth Solute segregation |
| title | Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing |
| title_full | Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing |
| title_fullStr | Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing |
| title_full_unstemmed | Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing |
| title_short | Phase-field modeling and Experimental investigation for rapid solidification in wire and arc additive manufacturing |
| title_sort | phase field modeling and experimental investigation for rapid solidification in wire and arc additive manufacturing |
| topic | Rapid solidification WAAM Phase field Dendrite growth Solute segregation |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424000218 |
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