激光粉末床熔融成形Inconel 718合金未熔合缺陷与晶粒生长过程相场法模拟

陈苗苗; 石仁海; 刘壮壮; 李映晖; 杜强; 赵宇宏; 谢建新

doi:10.1007/s12613-023-2664-z

Volume 30 Issue 11

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文章导航 > 矿物冶金与材料学报（英文） > 2023 > 30(11): 2224-2235

Miaomiao Chen, Renhai Shi, Zhuangzhuang Liu, Yinghui Li, Qiang Du, Yuhong Zhao, and Jianxin Xie, Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718, Int. J. Miner. Metall. Mater., 30(2023), No. 11, pp. 2224-2235. https://doi.org/10.1007/s12613-023-2664-z

Cite this article as:

Miaomiao Chen, Renhai Shi, Zhuangzhuang Liu, Yinghui Li, Qiang Du, Yuhong Zhao, and Jianxin Xie, Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718, Int. J. Miner. Metall. Mater., 30(2023), No. 11, pp. 2224-2235. https://doi.org/10.1007/s12613-023-2664-z

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研究论文

激光粉末床熔融成形Inconel 718合金未熔合缺陷与晶粒生长过程相场法模拟

1)
北京科技大学北京材料基因工程高精尖创新中心，北京 100083
2)
北京科技大学新材料技术研究院材料先进制备技术教育部重点实验室，北京 100083
3)
北京科技大学新材料技术研究院现代交通金属材料与加工技术北京实验室，北京 100083
4)
挪威科技工业研究所(SINTEF)，奥斯陆 0314
5)
中北大学材料科学与工程学院，太原 030051

通讯作者:
石仁海    E-mail: jxxie@mater.ustb.edu.cn

刘壮壮    E-mail: renhai.shi.nick@gmail.com

谢建新    E-mail: liuzhuangzhuang@ustb.edu.cn

文章亮点

(1) 提出了一种描述因重熔程度不足而产生LoF缺陷的相场模型

(2) 同时实现了L-PBF成形Inconel 718过程中的缺陷抑制与凝固晶粒组织调控

(3) 确定了Inconel 718合金晶粒细化且无LoF缺陷的L-PBF成形参数

中文摘要

Inconel 718在激光粉末床熔融成形（Laser Powder Bed Fusion, L-PBF）过程中外延生长趋势强烈，组织和性能各向异性显著，对合金构件（如涡轮盘等）的使用性能产生较大影响。L-PBF成形的零部件中的未熔合缺陷（Lack-of-fusion, LoF）同样对合金力学性能不利。为研究激光扫描参数对晶粒外延生长和LoF缺陷形成规律的影响，并获得晶粒细化且无LoF缺陷的参数空间，本文采用有限元法温度场模拟和相场法组织模拟相结合的方法，构建了跨尺度模型，模拟了熔池温度场和晶粒外延生长过程。提出了一种描述因重熔程度不足而产生LoF缺陷的相场模型，可同步实现L-PBF成形过程中的缺陷抑制与组织优化。采用上述模型，确定了当层间旋转角度为0°–90°时，无LoF缺陷且晶粒相对细化、均匀组织的存在于能量密度55.0–62.5 J·mm^–3之间。然后进一步计算筛选出一组优化工艺参数，即激光功率280 W，扫描速率 1160 mm·s^–1，层间旋转角度67°。在此条件下，L-PBF成形的Inconel 718合金样品的平均晶粒尺寸为7.0 μm，室温抗拉强度UTS和屈服强度YS分别达到（1111 ± 3）MPa、（820 ± 7）MPa。与优化前相比，UTS和YS分别提高8.8%和10.5%。本文提出的相场模型，可为L-PBF成形过程凝固组织调控和LoF缺陷抑制提供指导

关键词:

Research Article

Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718

+ Author Affiliations

1)
Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing, Beijing 100083, China
2)
Key Laboratory for Advanced Materials Processing (MOE), Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China
3)
Beijing Laboratory of Metallic Materials and Processing for Modern Transportation, Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China
4)
SINTEF Industry, Oslo 0314, Norway
5)
School of Materials Science and Engineering, North University of China, Taiyuan 030051, China

The authors declare that they have no known competing interests or personal relationships that could have appeared to influence the work reported in this paper.
The online version contains supplementary material available at https://doi.org/10.1007/s12613-023-2664-z.

Corresponding authors:
Renhai Shi    E-mail: jxxie@mater.ustb.edu.cn

Zhuangzhuang Liu    E-mail: renhai.shi.nick@gmail.com

Jianxin Xie    E-mail: liuzhuangzhuang@ustb.edu.cn
Received: 16 March 2023; Revised: 24 April 2023; Accepted: 25 April 2023; Available online: 26 April 2023

Abstract

Abstract

The anisotropy of the structure and properties caused by the strong epitaxial growth of grains during laser powder bed fusion (L-PBF) significantly affects the mechanical performance of Inconel 718 alloy components such as turbine disks. The defects (lack-of-fusion, LoF) in components processed via L-PBF are detrimental to the strength of the alloy. The purpose of this study is to investigate the effect of laser scanning parameters on the epitaxial grain growth and LoF formation in order to obtain the parameter space in which the microstructure is refined and LoF defect is suppressed. The temperature field of the molten pool and the epitaxial grain growth are simulated using a multiscale model combining the finite element method with the phase-field method. The LoF model is proposed to predict the formation of LoF defects resulting from insufficient melting during L-PBF. Defect mitigation and grain-structure control during L-PBF can be realized simultaneously in the model. The simulation shows the input laser energy density for the as-deposited structure with fine grains and without LoF defects varied from 55.0–62.5 J·mm^–3 when the interlayer rotation angle was 0°–90°. The optimized process parameters (laser power of 280 W, scanning speed of 1160 mm·s^–1, and rotation angle of 67°) were computationally screened. In these conditions, the average grain size was 7.0 μm, and the ultimate tensile strength and yield strength at room temperature were (1111 ± 3) MPa and (820 ± 7) MPa, respectively, which is 8.8% and 10.5% higher than those of reported. The results indicating the proposed multiscale computational approach for predicting grain growth and LoF defects could allow simultaneous grain-structure control and defect mitigation during L-PBF.
- Inconel 718 alloy;
- laser powder bed fusion;
- scanning parameter optimization;
- lack-of-fusion phase-field method;
- finite element method

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激光粉末床熔融成形Inconel 718合金未熔合缺陷与晶粒生长过程相场法模拟

文章亮点

中文摘要

Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718

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