Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution

Publikationen: Beitrag in FachzeitschriftArtikelForschung(peer-reviewed)

Autoren

  • Syed Murtaza Jaffar
  • Hiroki Fukuda
  • Claus Rebholz
  • Teiichi Ando
  • Yiliang Liao
  • Charalabos C. Doumanidis

Externe Organisationseinheiten

  • Fukuda Metal Foil & Powder Co. Ltd
  • Northeastern University, Boston
  • Office of the President, BRAC University
  • Department of Industrial and Manufacturing Systems
  • Khalifa University, Abu Dhabi
  • Universität Zypern

Abstract

Abstract: In this study a material model is developed to predict the solidification microstructure of an additive-manufactured, fully dense magnesium (Mg) alloy using uniform droplet spraying (UDS). Specifically, the crystallite size distribution is simulated by a solidification model, consisting of a nucleation/fragmentation and a constrained growth description, calibrated via microstructural data from a single droplet splat. This is enabled by a semi-analytical thermal modeling framework, based on the superposition of moving Green’s and Rosenthal functions for the temperature field generated by a Gaussian source distribution. The model is implemented for layered ellipsoidal deposit sections on planar substrates by multi-pass spraying, and its predictions are validated against measured crystal sizes by image analysis of experimental micrographs of a Mg 97ZnY 2 alloy, to an error margin of ± 15%. The computationally efficient simulation provides insights to the deposit microstructure, and is intended as a process observer in a closed-loop, adaptive control scheme based on infrared temperature measurements. Graphic abstract: [Figure not available: see fulltext.]

Details

OriginalspracheEnglisch
Seiten (von - bis)391-403
Seitenumfang13
FachzeitschriftMRS Advances
Jahrgang6
Ausgabenummer15
DOIs
StatusVeröffentlicht - Juni 2021