Additive manufacturability of superalloys: Process-induced porosity, cooling rate and metal vapour

Chinnapat Panwisawas; Yilun Gong; Yuanbo Tony Tang; Roger C. Reed; Junji Shinjo

doi:10.1016/j.addma.2021.102339

Additive manufacturability of superalloys: Process-induced porosity, cooling rate and metal vapour

Chinnapat Panwisawas^*, Yilun Gong, Yuanbo Tony Tang, Roger C. Reed, Junji Shinjo

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

Abstract

Digital technology such as metal additive manufacturing (AM) provides flexible process design freedom to fabricate intricate three-dimensional structures layer-by-layer. However, its manufacturability relies on the fundamental understanding of melt pool physics and fluid (metal) dynamics. The effect of metal vapour and porosity induced during the laser-materials interaction can influence the additive manufacturability. In this work, composition-process relationship of laser-based powder-bed fusion (L-PBF) AM is studied via computational fluid dynamics modelling to rationalise solid-liquid-vapour transformation where empirical-based approach is used to generate thermo-physical property of about 100 nickel-based superalloys at the liquid state. It is found that with larger vapor mass loss, the porosity tends to be higher. However, the higher vapour mass loss means faster cooling rate. This is indicated that the thermal-fluid flow process, which is also governed by the thermo-physical property, strongly affects the additive manufacturability. Additive manufacturability map based upon porosity, cooling rate from liquid to solid, volatile mass loss criteria has been established to link the composition in nickel-based superalloys with their thermo-physical property. This offers a thermal-fluid science based tool in designing compositions of novel superalloys for AM applications.

Original language	English
Article number	102339
Number of pages	12
Journal	Additive Manufacturing
Volume	47
Early online date	20 Sept 2021
DOIs	https://doi.org/10.1016/j.addma.2021.102339
Publication status	Published - Nov 2021

Bibliographical note

Acknowledgments:
Chinnapat Panwisawas and Yuanbo Tony Tang would like to acknowledge the grant from Innovation Fellowship funded by Engineering and Physical Science Research Council (EPSRC), UK Research and Innovation (UKRI), United Kingdom (grant number: EP/S000828/2). Chinnapat Panwisawas also acknowledges the support by Professor Hongbiao Dong and NISCO UK Research Centre at School of Engineering, University of Leicester. All authors would like to acknowledge the grant from the Next Generation Tatara Co-Creation Centre (NEXTA), which is established with Grant-in-aid for the Promotion of Regional Industries and University from Cabinet Office, Japan.

Keywords

Metal vapour
Liquid metal
Thermal-fluid dynamics
Additive manufacturability
Superalloys

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Cite this

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title = "Additive manufacturability of superalloys: Process-induced porosity, cooling rate and metal vapour",

abstract = "Digital technology such as metal additive manufacturing (AM) provides flexible process design freedom to fabricate intricate three-dimensional structures layer-by-layer. However, its manufacturability relies on the fundamental understanding of melt pool physics and fluid (metal) dynamics. The effect of metal vapour and porosity induced during the laser-materials interaction can influence the additive manufacturability. In this work, composition-process relationship of laser-based powder-bed fusion (L-PBF) AM is studied via computational fluid dynamics modelling to rationalise solid-liquid-vapour transformation where empirical-based approach is used to generate thermo-physical property of about 100 nickel-based superalloys at the liquid state. It is found that with larger vapor mass loss, the porosity tends to be higher. However, the higher vapour mass loss means faster cooling rate. This is indicated that the thermal-fluid flow process, which is also governed by the thermo-physical property, strongly affects the additive manufacturability. Additive manufacturability map based upon porosity, cooling rate from liquid to solid, volatile mass loss criteria has been established to link the composition in nickel-based superalloys with their thermo-physical property. This offers a thermal-fluid science based tool in designing compositions of novel superalloys for AM applications.",

keywords = "Metal vapour, Liquid metal, Thermal-fluid dynamics, Additive manufacturability, Superalloys",

author = "Chinnapat Panwisawas and Yilun Gong and Tang, {Yuanbo Tony} and Reed, {Roger C.} and Junji Shinjo",

note = "Acknowledgments: Chinnapat Panwisawas and Yuanbo Tony Tang would like to acknowledge the grant from Innovation Fellowship funded by Engineering and Physical Science Research Council (EPSRC), UK Research and Innovation (UKRI), United Kingdom (grant number: EP/S000828/2). Chinnapat Panwisawas also acknowledges the support by Professor Hongbiao Dong and NISCO UK Research Centre at School of Engineering, University of Leicester. All authors would like to acknowledge the grant from the Next Generation Tatara Co-Creation Centre (NEXTA), which is established with Grant-in-aid for the Promotion of Regional Industries and University from Cabinet Office, Japan.",

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AU - Reed, Roger C.

AU - Shinjo, Junji

N1 - Acknowledgments: Chinnapat Panwisawas and Yuanbo Tony Tang would like to acknowledge the grant from Innovation Fellowship funded by Engineering and Physical Science Research Council (EPSRC), UK Research and Innovation (UKRI), United Kingdom (grant number: EP/S000828/2). Chinnapat Panwisawas also acknowledges the support by Professor Hongbiao Dong and NISCO UK Research Centre at School of Engineering, University of Leicester. All authors would like to acknowledge the grant from the Next Generation Tatara Co-Creation Centre (NEXTA), which is established with Grant-in-aid for the Promotion of Regional Industries and University from Cabinet Office, Japan.

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N2 - Digital technology such as metal additive manufacturing (AM) provides flexible process design freedom to fabricate intricate three-dimensional structures layer-by-layer. However, its manufacturability relies on the fundamental understanding of melt pool physics and fluid (metal) dynamics. The effect of metal vapour and porosity induced during the laser-materials interaction can influence the additive manufacturability. In this work, composition-process relationship of laser-based powder-bed fusion (L-PBF) AM is studied via computational fluid dynamics modelling to rationalise solid-liquid-vapour transformation where empirical-based approach is used to generate thermo-physical property of about 100 nickel-based superalloys at the liquid state. It is found that with larger vapor mass loss, the porosity tends to be higher. However, the higher vapour mass loss means faster cooling rate. This is indicated that the thermal-fluid flow process, which is also governed by the thermo-physical property, strongly affects the additive manufacturability. Additive manufacturability map based upon porosity, cooling rate from liquid to solid, volatile mass loss criteria has been established to link the composition in nickel-based superalloys with their thermo-physical property. This offers a thermal-fluid science based tool in designing compositions of novel superalloys for AM applications.

AB - Digital technology such as metal additive manufacturing (AM) provides flexible process design freedom to fabricate intricate three-dimensional structures layer-by-layer. However, its manufacturability relies on the fundamental understanding of melt pool physics and fluid (metal) dynamics. The effect of metal vapour and porosity induced during the laser-materials interaction can influence the additive manufacturability. In this work, composition-process relationship of laser-based powder-bed fusion (L-PBF) AM is studied via computational fluid dynamics modelling to rationalise solid-liquid-vapour transformation where empirical-based approach is used to generate thermo-physical property of about 100 nickel-based superalloys at the liquid state. It is found that with larger vapor mass loss, the porosity tends to be higher. However, the higher vapour mass loss means faster cooling rate. This is indicated that the thermal-fluid flow process, which is also governed by the thermo-physical property, strongly affects the additive manufacturability. Additive manufacturability map based upon porosity, cooling rate from liquid to solid, volatile mass loss criteria has been established to link the composition in nickel-based superalloys with their thermo-physical property. This offers a thermal-fluid science based tool in designing compositions of novel superalloys for AM applications.

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Additive manufacturability of superalloys: Process-induced porosity, cooling rate and metal vapour

Abstract

Bibliographical note

Keywords

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