Numerical Analysis of Microstructure Development during Laser Welding Nickel-Based Single-Crystal Superalloy Part I: Stray Grain Formation

Abstract

The mathematical modeling of microstructure development is further extended through coupling of heat transfer model and columnar/equiaxed transition (CET) model during nickel-based single-crystal superalloy weld pool solidification with different welding conditions (laser power, welding speed and welding configuration). It is indicated that crystallographic orientation plays an important role in stray grain formation ahead of the solid/liquid interface on the basis of constitutional undercooling mechanism. (001) and [100] welding configuration promotes symmetrical distribution of microstructure morphology about the weld pool centerline that is favored for reduction of stray grain formation, while detrimental (001) and [110] welding configuration induces asymmetrical distribution of microstructure morphology with more stray grain formation and deteriorates the weldability. The mechanism of increasing stray grain formation due to misorientation of dendrite growth crystallography is proposed. Appropriate low heat inputs (low laser power or high welding speed) of solidification conditions prevents stray grain formation and vice versa, and suppress the size of vulnerable [100] dendrite growth region. Weld pool geometry, θ-φ of solid/liquid interface, morphology transition and stray grain formation on either side of weld are closely correlated. In order to eliminate stray grain formation through microstructure control, it is imperative to optimize the welding configurations for defect-free weld through useful welding configuration-microstructure map. The theoretical predictions are verified by the experiment results in a consistent way. In addition, the model is also applicable to other single-crystal superalloys with similar metallurgical properties by feasible laser welding or laser cladding.