Integrated Simulation Framework for Additively Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response

Rongpei Shi, Saad Khairallah, Tae Wook Heo, Matthew Rolchigo, Joseph T. McKeown, Manyalibo J. Matthews

Research output: Contribution to journalArticlepeer-review

64 Scopus citations

Abstract

To accelerate the establishment of fundamental understanding of the additive manufacturing (AM) process and its influence on microstructural evolution and related properties, we develop a multiphysics and multiscale modeling framework that integrates: (1) a high-fidelity powder-scale three-dimensional simulation of transient heat transfer and melt flow dynamics, (2) cellular automaton simulation of solidification grain structure and texture, (3) phase-field modeling of precipitation and dissolution of second-phase precipitate during repeated thermal cycles, and (4) microstructure-based micro- and mesoscopic elastic response calculation. Using Ti-6Al-4V as a model system, we demonstrate the application of the integrated framework to simulate complex microstructure evolution during a single-track laser powder bed fusion process and the associated mechanical response. Our modeling framework successfully captures the solidification β grain structure as a function of laser power and scanning speed, α precipitation upon subsequent cooling with different rates, and elastic response of the resulting (α + β) two-phase microstructure. The key features of solidification and second-phase precipitate microstructures, and their dependence on processing parameters, agree well with existing experimental observations. The established modeling framework is generally applicable to other metallic materials fabricated by AM.

Original languageEnglish
Pages (from-to)3640-3655
Number of pages16
JournalJOM
Volume71
Issue number10
DOIs
StatePublished - Oct 1 2019
Externally publishedYes

Funding

This work was performed under the auspices of the US Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344, supported by the Office of Laboratory Directed Research and Development (18-SI-003) and by the Exascale Computing Project (17-SC-20-SC), a collaborative effort of the US Department of Energy Office of Science and the National Nuclear Security Administration. R.S. thanks Prof. Yunzhi Wang at The Ohio State University for many useful discussions.

Fingerprint

Dive into the research topics of 'Integrated Simulation Framework for Additively Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response'. Together they form a unique fingerprint.

Cite this