A Phase-Field Model for In-Space Manufacturing of Binary Alloys

• Published in: Materials Vol. 16; no. 1; p. 383
• Main Authors: Ghosh, Manoj, Hendy, Muhannad, Raush, Jonathan, Momeni, Kasra
• Format: Journal Article
• Language: English
• Published: Switzerland MDPI AG 31.12.2022; MDPI
• Subjects: Additive manufacturing; Alloys; Approximation; Binary alloys; Chemistry; Diffuse interphase; Dilution; Energy; Equilibrium; Evolution; Fused deposition modeling; Growth models; Integrity; Landau-Ginzburg equations; MATERIALS SCIENCE; Mathematical models; Metallurgy & Metallurgical Engineering; Nickel base alloys; Partitionless solidification; Phase transformation; Phase transitions; Physics; Solidification; Solids; Space manufacturing; Specialty metals industry; Supercooling; additive manufacturing; diffuse interphase; phase transformation; partitionless solidification
• ISSN: 1996-1944; 1996-1944
• DOI: 10.3390/ma16010383

The integrity of the final printed components is mostly dictated by the adhesion between the particles and phases that form upon solidification, which is a major problem in printing metallic parts using available In-Space Manufacturing (ISM) technologies based on the Fused Deposition Modeling (FDM) methodology. Understanding the melting/solidification process helps increase particle adherence and allows to produce components with greater mechanical integrity. We developed a phase-field model of solidification for binary alloys. The phase-field approach is unique in capturing the microstructure with computationally tractable costs. The developed phase-field model of solidification of binary alloys satisfies the stability conditions at all temperatures. The suggested model is tuned for Ni-Cu alloy feedstocks. We derived the Ginzburg-Landau equations governing the phase transformation kinetics and solved them analytically for the dilute solution. We calculated the concentration profile as a function of interface velocity for a one-dimensional steady-state diffuse interface neglecting elasticity and obtained the partition coefficient, k, as a function of interface velocity. Numerical simulations for the diluted solution are used to study the interface velocity as a function of undercooling for the classic sharp interface model, partitionless solidification, and thin interface.