Due to the repeated thermal cycling that occurs with the processing of each subsequent layer, the microstructure of additively manufactured parts undergoes complex changes throughout the deposition process. Understanding and modeling this evolution poses a greater challenge than for single-cycle heat treatments. Following the work of Kelly and Charles, a Ti-6Al-4V microstructural model has been developed which calculates the phase fractions, morphology, and alpha lath width given a measured or modeled thermal history. Dissolution of the alpha phase is modeled as 1D plate growth of the beta phase, while alpha growth is modeled by the technique of Johnson–Mehl–Avrami (JMA). The alpha phase is divided into colony and basketweave morphologies based on an intragranular nucleation temperature. Evolution of alpha lath width is calculated using an Arrhenius equation. Key parameters of the combined Kelly–Charles model developed here are optimized using the Nelder–Mead simplex algorithm. For the deposition of two L-shaped geometries with different processing parameters, the optimized model gives a mean error over 24 different locations of 37% relative to experimentally measured lath widths, compared to 106% for the original Kelly–Charles model.
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November 2016
Research-Article
Predicting Microstructure From Thermal History During Additive Manufacturing for Ti-6Al-4V
Jeff Irwin,
Jeff Irwin
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
17 Reber Building,
University Park, PA 16801
e-mail: jei5028@psu.edu
Nuclear Engineering,
The Pennsylvania State University,
17 Reber Building,
University Park, PA 16801
e-mail: jei5028@psu.edu
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Edward W. Reutzel,
Edward W. Reutzel
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
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Pan Michaleris,
Pan Michaleris
Associate Professor
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
University Park, PA 16801;
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
University Park, PA 16801;
Pan Computing LLC,
State College, PA 16803
State College, PA 16803
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Jay Keist,
Jay Keist
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
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Abdalla R. Nassar
Abdalla R. Nassar
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
Search for other works by this author on:
Jeff Irwin
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
17 Reber Building,
University Park, PA 16801
e-mail: jei5028@psu.edu
Nuclear Engineering,
The Pennsylvania State University,
17 Reber Building,
University Park, PA 16801
e-mail: jei5028@psu.edu
Edward W. Reutzel
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
Pan Michaleris
Associate Professor
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
University Park, PA 16801;
Department of Mechanical and
Nuclear Engineering,
The Pennsylvania State University,
University Park, PA 16801;
Pan Computing LLC,
State College, PA 16803
State College, PA 16803
Jay Keist
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
Abdalla R. Nassar
Applied Research Laboratory,
The Pennsylvania State University,
University Park, PA 16801
The Pennsylvania State University,
University Park, PA 16801
Manuscript received September 8, 2015; final manuscript received April 25, 2016; published online June 23, 2016. Assoc. Editor: Donggang Yao.
J. Manuf. Sci. Eng. Nov 2016, 138(11): 111007 (11 pages)
Published Online: June 23, 2016
Article history
Received:
September 8, 2015
Revised:
April 25, 2016
Citation
Irwin, J., Reutzel, E. W., Michaleris, P., Keist, J., and Nassar, A. R. (June 23, 2016). "Predicting Microstructure From Thermal History During Additive Manufacturing for Ti-6Al-4V." ASME. J. Manuf. Sci. Eng. November 2016; 138(11): 111007. https://doi.org/10.1115/1.4033525
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