The Development of Grain Structure During Additive Manufacturing: a Comparison Between Experiment and Simulation
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The morphology of grains produced during metal Additive Manufacturing (AM) can be very different from that given by conventional processing and is central to controlling the properties of the final build. To understand and control the unusual morphology of grains produced by additive manufacturing, a phase field model is developed that follows the evolution of many thousands of grains in three dimensions in the high velocity limit, which is easily accessible during AM, where the interface is planar or has low amplitude cells, as observed during AM of stainless steel 316L [1]. A comparison between the predicted grain shapes and those measured experimentally using an AM machine and a novel laser-SEM device (developed by the Upadhyay group at Ecole Polytechnique) will be given. The comparison shows the importance of weld pool shape, heat flow, and anisotropy of the interfacial mobility in the observed grain morphologies. Moreover, the resulting builds can contain significant residual stress and evidence of plastic deformation. The relationship between the grain structure, solidification process, and plastic deformation of the build will be discussed.
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