Integration of Processing and Microstructure Models for Non-Equilibrium Solidification in Additive Manufacturing

Integration of models that capture the complex physics solidification on macro and microstructural scale with flexibility to consider multicomponent materials systems is a significant challenge in modeling additive manufacturing processes. This work aims link process variables, such as energy density, non-equilibrium by integrating simulations thermodynamics diffusion. Temperature histories are generated using semi-analytic laser powder bed fusion model feed into CALPHAD-based ICME (CALPHAD: Calculation Phase Diagrams, ICME: Integrated Computational Materials Engineering) framework function both composition processing parameters. Solidification cracking susceptibility modeled composition, cooling rate, density Al-Cu Alloys stainless steel 316L (SS316L). Trends predicted validated experimental measurements alloys. Non-equilibrium additively manufactured SS316L investigated determine if this approach can be applied commercial materials. Modeling results show linear relationship between SS316L. shows integration microstructure essential for during manufacturing.