Numerical modeling of oxide particle evolution during additive manufacturing

Abstract

In this study, oxide particle evolution during additive manufacturing was modelled to elucidate the evolution and suggest effective ways to increase oxide-dispersion strengthening. The model coupled the Kampmann and Wagner numerical model with an estimated temperature profile, solidification calculation, and thermodynamic databases. The calculated results from the model matched experimental data obtained from both directed-energy deposition and powder-bed fusion processes that use an austenitic stainless-steel powder. According to the calculation, most of the oxide particles nucleated during solidification. The oxygen concentration in the melt pool briefly reached 0.6–0.7 wt%. The interfacial energy between Si-Mn-Cr-O oxide and the melt pool was estimated to be 0.4–0.5 N/m. Finally, ways to maximize the dispersion strengthening effect in the AM material were identified and evaluated using the model.