Toward DS/SX Ni-Based Superalloy Components Using L-DED: A Multi-scale Modeling and Experimental Approach

Bhure, S and Nalajala, D and Choudhury, A (2023) Toward DS/SX Ni-Based Superalloy Components Using L-DED: A Multi-scale Modeling and Experimental Approach. In: Transactions of the Indian Institute of Metals .

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Abstract

Additive manufacturing (AM) provides an alternate and efficient route for producing intricate geometries, such as turbine blades in the high-pressure compression stages of an aero-engine. Herein, we present a multi-scale modeling approach involving the simulation of the laser-based directed energy deposition (L-DED) process and the resulting microstructure evolution to identify the process parameters for producing defect-free directionally solidified (DS)/single-crystalline (SX) Ni-based superalloy components. Notably, our approach involves a novel process model formulated in a diffuse-interface framework in contrast to the volume of fluid (VoF) and level-set methods documented in the literature. The temperature history obtained from the process simulations serves as an input for a Monte Carlo-based solidification microstructure model, which predicts the feasibility of epitaxial growth for a given set of process parameters. A parametric study is conducted using the above models by varying the laser power and scanning velocity to obtain an optimal processing window for epitaxial growth, which is validated experimentally. The study reveals that higher laser power and scanning velocities lead to epitaxial growth. © 2023, The Indian Institute of Metals - IIM.

Item Type:	Journal Article
Publication:	Transactions of the Indian Institute of Metals
Publisher:	Springer
Additional Information:	The copyright for this article belongs to Springer.
Keywords:	Aircraft engines; Epitaxial growth; Microstructure; Monte Carlo methods; Nickel alloys; Numerical methods; Single crystals; Superalloys; Turbomachine blades, Dendrite; Directed energy; Directionally solidified; Energy depositions; Laser-based; Laser-based directed energy deposition; Modeling approach; Multiscale modeling; Ni-based superalloys; Process parameters, Solidification
Department/Centre:	Division of Mechanical Sciences > Materials Engineering (formerly Metallurgy)
Date Deposited:	01 Mar 2024 05:45
Last Modified:	01 Mar 2024 05:45
URI:	https://eprints.iisc.ac.in/id/eprint/83828

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