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

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Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution. / Jaffar, Syed Murtaza; Kostoglou, Nikolaos; Fukuda, Hiroki et al.
in: MRS Advances, Jahrgang 6, Nr. 15, 06.2021, S. 391-403.

Publikationen: Beitrag in FachzeitschriftArtikelForschung(peer-reviewed)

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Jaffar SM, Kostoglou N, Fukuda H, Rebholz C, Ando T, Liao Y et al. Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution. MRS Advances. 2021 Jun;6(15):391-403. doi: 10.1557/s43580-021-00028-x

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@article{1feeff95399d4a99b840ee0e1b2e7897,
title = "Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution",
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{\textquoteright}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.] ",
keywords = "Additive manufacturing, Mg, Microstructure, Modeling, Spray deposition",
author = "Jaffar, {Syed Murtaza} and Nikolaos Kostoglou and Hiroki Fukuda and Claus Rebholz and Teiichi Ando and Yiliang Liao and Doumanidis, {Charalabos C.}",
note = "Publisher Copyright: {\textcopyright} 2021, The Author(s), under exclusive licence to The Materials Research Society.",
year = "2021",
month = jun,
doi = "10.1557/s43580-021-00028-x",
language = "English",
volume = "6",
pages = "391--403",
journal = "MRS Advances",
issn = "2059-8521",
publisher = "Cambridge University Press",
number = "15",

}

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TY - JOUR

T1 - Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution

AU - Jaffar, Syed Murtaza

AU - Kostoglou, Nikolaos

AU - Fukuda, Hiroki

AU - Rebholz, Claus

AU - Ando, Teiichi

AU - Liao, Yiliang

AU - Doumanidis, Charalabos C.

N1 - Publisher Copyright: © 2021, The Author(s), under exclusive licence to The Materials Research Society.

PY - 2021/6

Y1 - 2021/6

N2 - 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.]

AB - 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.]

KW - Additive manufacturing

KW - Mg

KW - Microstructure

KW - Modeling

KW - Spray deposition

UR - http://www.scopus.com/inward/record.url?scp=85101751496&partnerID=8YFLogxK

U2 - 10.1557/s43580-021-00028-x

DO - 10.1557/s43580-021-00028-x

M3 - Article

VL - 6

SP - 391

EP - 403

JO - MRS Advances

JF - MRS Advances

SN - 2059-8521

IS - 15

ER -