Multi-physics simulation of non-equilibrium solidification in Ti-Nb alloy during selective laser melting

This paper underscores the critical role of temperature distribution in the molten pool on the resulting solidification microstructure during selective laser melting (SLM) process. A powder-resolved computational fluid dynamics (CFD) model of Ti-Nb alloy is established to investigate heat transfer and fluid flow in the molten pool. When comparing the bulk model to the powder bed model, discrepancies in temperature gradient and cooling rate can reach up to 26.29 % and 18.32 %, respectively. Utilizing the powder bed CFD model, temperature gradient and cooling rate data at the molten pool boundary are integrated into the finite interface dissipation phase-field model. The simulation results illuminate the non-equilibrium solidification microstructure in the SLMed Ti-Nb alloy. Results indicate that the rapid solidification fosters a pronounced solute trapping effect, mitigating solute microsegregation. The microstructure manifests as cellular and dendritic structures, with Nb concentration in cellular cores and depletion in intercellular region. Predicted primary dendrite arm spacing (PDAS) or cell size range between 0.4 to 0.6 μm, consistent with experimental observations. In particular, the study reveals a transition from dendritic to cellular and from cellular to planar structures, with an accompanying analysis of the underlying mechanisms. [Display omitted] (a) Temperature distribution in the molten pool of SLMed Ti-25Nb alloy; (b-d) solidification microstructure at various heights along the molten pool boundary: (b) top; (c) middle; (d) bottom; and (e) comparison with experimental observation (Reprinted from Acta Mater. 68 (2014) 150–158 with permission from Elsevier).