Additive manufacturing of magnesium alloy using uniform droplet spraying: modeling of microstructure evolution
Research output: Contribution to journal › Article › Research › peer-review
Authors
Organisational units
External Organisational units
- Fukuda Metal Foil & Powder Co. Ltd
- Northeastern University, Boston
- Office of the President, BRAC University
- Department of Industrial and Manufacturing Systems
- Khalifa University
- Research Unit for Nanostructured Materials Systems, Department of Mechanical Engineering and Materials Science and Engineering, Cyprus University of Technology
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
Original language | English |
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Pages (from-to) | 391-403 |
Number of pages | 13 |
Journal | MRS Advances |
Volume | 6 |
Issue number | 15 |
DOIs | |
Publication status | Published - Jun 2021 |