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130 records · Page 8

Phase-field predictions of the influence of cooling rates during AM on the Evolution of Microstructures in Nickel-Based Single Crystal Superalloys

Additive manufacturing of single crystals made of Ni-based superalloys offers major cost savings for gas turbine engines with the inclusion of internal cooling channels. However, the lack of understanding of the effect of transient thermal conditions on solidification grain structure during additive manufacturing hinders the potential for process control to maintain the single crystal quality. The use of high-fidelity simulations through high performance computing to predict the evolution of the solidification microstructure will enhance the abilities to tailor the microstructures through process optimization. Phase field simulations are used to determine the effect local thermal conditions and defects on the stability of the solidification morphology, specifically with respect to the onset of columnar-to-equiaxed transition that results in the loss of the single crystal. The results are expected to be instrumental for developing future surrogate models to speed up the integration of design and manufacturing of turbine blades under the harsh in-service conditions.

36 MATERIALS SCIENCE↗

Constitutive and Stability Behavior of Granular Materials Under Very Low Effective Stresses

The study of the behavior of granular materials such as sand is of great importance to the understanding of the response of foundations resting on surface and near-surface soil deposits. A clear understanding of the behavior of such materials can also provide insights into other related issues where low effective stresses are encountered such as liquefaction. The main sources of the constitutive and stability properties of cohesionless granular materials is interparticle friction, which in turn under low confinement stress levels is strongly affected by gravitational body forces under terrestrial (1 gravity) conditions. Under moderate-to-high stress levels, the influence of gravity on the behavior of experiments may not be pronounced and therefore the test results in a terrestrial environment may be acceptable for engineering purposes. However, the conduct of experiments on granular materials under very low stress levels and under quasi-static conditions can only be performed in a microgravity environment. A series of displacement-controlled cyclic triaxial compression experiments were performed in a SPACEHAB module on the Space Shuttle during the STS-79 mission to Mir in September, 1996, and the STS-89 mission in January, 1998. The experiments were conducted on six right cylindrical specimens 75 mm in diameter and 150 mm long at effective confining pressures of 0.05, 0.52 and 1.30 kPa. The results show very high peak strength friction angles in the range of 47.6 to 70.0 degrees, which are mainly due to overconsolidation and grain interlocking effects. It was observed that the residual strength levels were in the same range as that observed at higher confining stress levels. The dilatancy angles were unusually high in the range of 30 to 31 degrees. All specimens display substantial initial stiffnesses and elastic moduli during unloading and reloading events, which are nearly an order of magnitude higher than conventional theories predict. A periodic instability phenomenon which appears to result from buckling of multiple internal arches and columnar systems, augmented by stick-slips was observed in the experiments. Computed Tomography (CT) measurements revealed valuable data about the internal fabric and the specimens deformation patterns. Uniform diffuse bifurcation with multiple radial shear bands was observed in the specimens tested in a microgravity environment. In the axial direction, two major conical surfaces were developed. Spatial nonsymmetrical deformations were observed in specimens tested in terrestrial laboratory.

Alshibli, Khalid A.↗

Mechanics of Granular Materials (MGM) Microgravity Experiment

The second series of MGM experiment was conducted during the STS-89 mission in January 1998. The experiment was previously flow on Atlantis's STS-79 mission in September 1996. Six displacement-controlled, drained triaxial compression experiments were performed at very low effective confining stresses. The confining stresses were in the ranges 0.05, 0.52 and 1.30 kPa. Three experiments were subjected to monotonic loading and unloading cycles while the other three experiments were subjected to cyclic loading. The results show very high peak strength friction angles in the range of 47.6 to 70.0 degrees, which are mainly due to overconsolidation and grain interlocking effects. It was observed that the residual strength levels in the monotonic loading experiments were in the same range as that observed at higher confining stress levels. The dilatancy angles were unusually high in the range of 30 to 31 degrees. All specimens display substantial initial stiffnesses and elastic moduli during unloading and reloading events, which are nearly an order of magnitude higher than conventional theories predict. A periodic instability phenomenon which appears to result from buckling of multiple internal arches and columnar systems, augmented by stick-slips was observed in the experiments. Computed Tomography (CT) measurements revealed valuable data about the internal fabric and the specimens deformation patterns. Uniform diffuse bifurcation with multiple radial shear bands was observed in the specimens tested in a microgravity environment. In the axial direction, two major conical surfaces were developed. Spatial nonsymmetrical deformations were observed in specimens tested in terrestrial laboratory.

Alshibli, Khalid A.↗

Columnar-to-equiaxed transition in a laser scan for metal additive manufacturing

In laser powder bed fusion additive manufacturing (LPBFAM), different solidification conditions, e.g., thermal gradient and cooling rate, can be achieved by controlling the process parameters, such as laser power and laser speed. Tailoring the behaviour of the columnar to equiaxed transition (CET) of the printed alloy during fabrication can facilitate the production of highly customized microstructures. In this study, effective analytical solutions for both thermal conduction and solidification are employed to model solidifying melt pools. Microstructure textures and solidification conditions are evaluated for numerous combinations of laser power and laser speed under bead-on-plate conditions. This analytical-based high-throughput tool was demonstrated to select specific process parameters that lead to desired microstructures. Two selected process conditions were examined in detail by a highly parallelized microstructural solidification model to reveal both nucleation and grain growth. Both numerical solutions agree well with experiments that are performed based on bead-on-plate conditions, indicating that these numerical models aid evaluation of the nucleation parameters, providing insights for controlling CET during the LPBFAM processing.

Lang, Yuan↗