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Thermodynamics-guided alloy and process design for additive manufacturing

Author

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  • Zhongji Sun

    (Max-Planck-Institut für Eisenforschung GmbH
    Institute of Materials Research and Engineering, A*STAR (Agency for Science, Technology and Research))

  • Yan Ma

    (Max-Planck-Institut für Eisenforschung GmbH)

  • Dirk Ponge

    (Max-Planck-Institut für Eisenforschung GmbH)

  • Stefan Zaefferer

    (Max-Planck-Institut für Eisenforschung GmbH)

  • Eric A. Jägle

    (Universität der Bundeswehr München)

  • Baptiste Gault

    (Max-Planck-Institut für Eisenforschung GmbH
    Imperial College London)

  • Anthony D. Rollett

    (Carnegie Mellon University)

  • Dierk Raabe

    (Max-Planck-Institut für Eisenforschung GmbH)

Abstract

In conventional processing, metals go through multiple manufacturing steps including casting, plastic deformation, and heat treatment to achieve the desired property. In additive manufacturing (AM) the same target must be reached in one fabrication process, involving solidification and cyclic remelting. The thermodynamic and kinetic differences between the solid and liquid phases lead to constitutional undercooling, local variations in the solidification interval, and unexpected precipitation of secondary phases. These features may cause many undesired defects, one of which is the so-called hot cracking. The response of the thermodynamic and kinetic nature of these phenomena to high cooling rates provides access to the knowledge-based and tailored design of alloys for AM. Here, we illustrate such an approach by solving the hot cracking problem, using the commercially important IN738LC superalloy as a model material. The same approach could also be applied to adapt other hot-cracking susceptible alloy systems for AM.

Suggested Citation

  • Zhongji Sun & Yan Ma & Dirk Ponge & Stefan Zaefferer & Eric A. Jägle & Baptiste Gault & Anthony D. Rollett & Dierk Raabe, 2022. "Thermodynamics-guided alloy and process design for additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-12, December.
    • Handle: RePEc:nat:natcom:v:13:y:2022:i:1:d:10.1038_s41467-022-31969-y
    DOI: 10.1038/s41467-022-31969-y
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    References listed on IDEAS

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    1. John H. Martin & Brennan D. Yahata & Jacob M. Hundley & Justin A. Mayer & Tobias A. Schaedler & Tresa M. Pollock, 2017. "3D printing of high-strength aluminium alloys," Nature, Nature, vol. 549(7672), pages 365-369, September.
    2. Sean P. Murray & Kira M. Pusch & Andrew T. Polonsky & Chris J. Torbet & Gareth G. E. Seward & Ning Zhou & Stéphane A. J. Forsik & Peeyush Nandwana & Michael M. Kirka & Ryan R. Dehoff & William E. Slye, 2020. "A defect-resistant Co–Ni superalloy for 3D printing," Nature Communications, Nature, vol. 11(1), pages 1-11, December.
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    1. Kai Zhang & Yunhui Chen & Sebastian Marussi & Xianqiang Fan & Maureen Fitzpatrick & Shishira Bhagavath & Marta Majkut & Bratislav Lukic & Kudakwashe Jakata & Alexander Rack & Martyn A. Jones & Junji S, 2024. "Pore evolution mechanisms during directed energy deposition additive manufacturing," Nature Communications, Nature, vol. 15(1), pages 1-14, December.

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