Dendrite Arm Spacing Research Articles

On the control of epitaxial growth and stray grains during laser-directed energy deposited Ni-based single crystal superalloy

Laser-directed energy deposition (L-DED) is considered as an effective repair method for damaged single-crystal (SX) superalloy turbine blades. However, controlling stray grains (SGs) and epitaxial growth is still the major problem. This study investigated the influences of pre-solution treatment and intrinsic heat treatment (IHT) on the formation of SGs and epitaxial growth of L-DED René N5 SX superalloy. The γ/γ’ eutectics and coarse γ’ precipitates at the inter-dendrite region can be eliminated after pre-solution treatment procedures before the L-DED experiment. A lower temperature in pre-solution treatment resulted in the retention of residual γ/γ’ eutectics and coarse γ’ precipitates. Thus, the aggravated element segregation within the local melt pool and interface collapse during the L-DED process can result in stray grains (SGs) formation. Improved pre-solution treatment procedures can also help reduce SGs caused by the carbides in the substrate. Besides, the SG formation in the deposited layers can be attributed to the recrystallization as a result of high thermal stress during the IHT in thermal cycles. The optimized pre-solution treatment procedure reduced the elemental segregation of the substrates, resulting in a larger primary dendrite arm spacing (PDAS) from the bottom of the deposited layers. Due to IHT during thermal cycles in the deposited layers, the equivalent heat treatment process promoted the re-precipitation and growth of γ’ phase. Meanwhile, the optimized pre-solution treatment procedure decreased the size of the heat-affected zone (HAZ) caused by thermal cycles. In summary, by optimizing the substrates' pre-solution treatment procedures to eliminate the γ/γ’ eutectics,coarse precipitaes and decrease the carbides in the subsrtates, the formation of SGs resulting from substrate segregation and heterogeneous microstructure can be controlled. This work provides the potential guidance of substrate pre-treatment for L-DED repair of SX superalloys.

Research on directional solidification combined with electron beam melting and refining for recycling of FGH4096 alloy scraps

The constraints of traditional manufacturing techniques have led to the generation of a considerable amount of waste superalloy, causing substantial resource wastage. The primary concern with waste superalloys lies in the excessive presence of inclusions and impurity elements, rendering them unsuitable for further utilization. This study proposes the use of directional solidification combined with electron beam melting and refining (EBMR) to prepare FGH4096 superalloy ingots (Φ120 mm), which offers a promising approach to produce large-sized powder superalloy master alloy ingots with high-purity and high homogeneity. It is found that the secondary dendrite arm spacing and the size of the γ’ phase in the alloy are significantly reduced after EBMR treatment. The concentration of O and N can be decreased to 5.7 and 0.6 ppmw, respectively. The size of inclusion can be reduced below 8.69 μm and the inclusion numbers reduce by over 50 % compared with both conventional ingots. A droplet transfer mode and melt convection mode mechanism have been proposed, which accurately predicts the melting temperature and melt flow. A quantitative study is conducted on the influence of inclusion density, the contact angle between inclusions and melt, and the surface tension of the melt on capillary forces. The results indicate that the capillary forces between inclusions in the melt range from 1.8 × 10−19 N and 1.9 × 10−17 N. Furthermore, the collision-aggregation behavior of inclusions in the melt is discussed, and an estimate of the tendency of inclusion collision-aggregation is provided. The enrichment of inclusions in the EBMR ingot is primarily the result of turbulent collision. The Marangoni effect and the extremely high surface temperature of the melt promote the collision and agglomeration of inclusions, causing them to accumulate rapidly at the melt surface. Moreover, the thorough removal of inclusions through the decomposition and dissolution process of the electron beam offers theoretical backing for the preparation of superalloys through electron beam melting and high-purity refining.

Effects of Superheating Treatment on the Microstructure, Tensile and Thermal Conductivity Properties of Fe-Bearing Al-10Si-Mg Casting Alloy

In this study, we designed and manufactured a new Fe-bearing Al-10Si-Mg casting alloy (F alloy) and investigated its microstructure, mechanical properties, and thermal conductivity. Two types of Fe-bearing Al-10Si-Mg alloys were used: the Conventional-F alloy, injected at 720 ℃ and cooled by water quenching, and the Superheated-F alloy, heated to 820 ℃ and maintained at that temperature for 1 hour. Subsequently, it underwent a degassing process at 720 ℃ before being cooled by water quenching. Both the Conventional-F alloy and the Superheated-F alloy exhibited dendritic microstructures and Fe-intermetallic compounds. The Secondary Dendrite Arm Spacing (SDAS) of the Conventional-F alloy measured 32.4 μm, whereas the Superheated-F alloy measured 28.6 μm. Additionally, the average eutectic Si sizes were 10.3 μm for the Conventional-F alloy and 7.7 μm for the Superheated-F alloy. Fe-rich IMCs were observed in the eutectic region, with their size decreasing due to the superheating treatment. Tensile tests at room temperature were conducted at a strain rate of 10<sup>-3</sup>/s. The Conventional-F alloy exhibited a yield strength (YS) of 93.4 MPa, ultimate tensile strength (UTS) of 183 MPa, and an elongation (El.) of 6.4%. Conversely, the Superheated-F alloy displayed a YS of 115.4 MPa, UTS of 218.2 MPa, and an El. of 5.1%. The mechanical properties notably improved with the superheating treatment. Regarding thermal conductivity, the Conventional-F alloy exhibited 114.9 W/m·K, while the Superheated-F alloy displayed 153.7 W/m·K. This represents a roughly 14% increase compared to the thermal conductivity of the commercial Al-10Si-Mg material (Silafont36: 135.1 W/m·K). The effects of the Superheating Treatment on microstructural characteristics, deformation behavior, and thermal conductivity of the Fe-bearing Al-10Si-Mg casting alloys were discussed.

Dimension Prediction and Microstructure Study of Wire Arc Additive Manufactured 316L Stainless Steel Based on Artificial Neural Network and Finite Element Simulation.

The dimensional accuracy and microstructure affect the service performance of parts fabricated by wire arc additive manufacturing (WAAM). Regulating the geometry and microstructure of such parts presents a challenge. The coupling method of an artificial neural network and finite element (FE) is proposed in this research for this purpose. Back-propagating neural networks (BPNN) based on optimization algorithms were established to predict the bead width (BW) and height (BH) of the deposited layers. Then, the bead geometry was modeled based on the predicted dimension, and 3D FE heat transfer simulation was performed to investigate the evolution of temperature and microstructure. The results showed that the errors in BW and BH were less than 6%, and the beetle antenna search BPNN model had the highest prediction accuracy compared to the other models. The simulated melt pool error was less than 5% with the experimental results. The decrease in the ratio of the temperature gradient and solidification rate induced the transition of solidified grains from cellular crystals to columnar dendrites and then to equiaxed dendrites. Accelerating the cooling rate increased the primary dendrite arm spacing and δ-ferrite content. These results indicate that the coupling model provides a pathway for regulating the dimensions and microstructures of manufactured parts.

Effect of processing parameters on the microstructure of laser-clad Stellite 6 on the X19CrMoNbVN11-1 stainless-steel substrate

This investigation aims to study the effect of laser cladding parameters on the microstructure of Stellite 6 on the X19CrMoNbVN11-1 stainless-steel substrate. First, Stellite 6 powder was coated on the X19CrMoNbVN11-1 substrate using the laser cladding method. The effect of laser cladding parameters (i.e., laser power, scanning speed, and powder feed rate) was studied on the microstructure of deposits. The secondary dendritic arm spacing was assessed, and the structural defects were studied (e.g., lack of bonding, porosity, and crack). The results revealed that the microstructure has changed from coating/substrate interface to coating surface, from plate-cellular to columnar and equiaxed dendrites. Also, an increase in the laser power increased the cellular structure in the coating/substrate interface and equiaxed dendrites in the coating surface. The cooling rate (G × R) increased by increasing the scanning and powder injection rates. The microstructure of the Stellite 6 was composed of cobalt solid-solution γFCC.

Improving Microstructural Homogeneity of Investment‐Cast Single‐Crystalline Ni‐Base Superalloys by Using Fluidized Carbon Bed Cooling

One impeding factor for faster solidification in typical investment casting processes is the limited heat removal capability. This study compares the classical Bridgman technique and the fluidized carbon bed cooling (FCBC) casting method. In particular, the influence of the thermal design is investigated in terms of microstructural and compositional homogeneity in single‐crystalline CMSX‐4. These investment casting processes mainly differ in the baffle type used to insulate the hot and cold zones inside of the casting vessel. While the Bridgman process is based on radiation cooling, the FCBC casting process relies on a dynamic baffle made of expanded graphite that is buoyant on fluidized bed of glassy carbon beads. Such a dynamic insulation layer can adapt to the cross‐sectional variation of ceramic shell molds and provide a better thermal insulation, which results in more uniform solidification conditions. This enables a reduction in the primary dendrite arm spacing by up to 26%, an increase in the homogeneity of the microstructure and composition, as well as a reduction in overall porosity and mean pore size of 41%.

Multi-physics simulation of non-equilibrium solidification in Ti-Nb alloy during selective laser melting

This paper underscores the critical role of temperature distribution in the molten pool on the resulting solidification microstructure during selective laser melting (SLM) process. A powder-resolved computational fluid dynamics (CFD) model of Ti-Nb alloy is established to investigate heat transfer and fluid flow in the molten pool. When comparing the bulk model to the powder bed model, discrepancies in temperature gradient and cooling rate can reach up to 26.29 % and 18.32 %, respectively. Utilizing the powder bed CFD model, temperature gradient and cooling rate data at the molten pool boundary are integrated into the finite interface dissipation phase-field model. The simulation results illuminate the non-equilibrium solidification microstructure in the SLMed Ti-Nb alloy. Results indicate that the rapid solidification fosters a pronounced solute trapping effect, mitigating solute microsegregation. The microstructure manifests as cellular and dendritic structures, with Nb concentration in cellular cores and depletion in intercellular region. Predicted primary dendrite arm spacing (PDAS) or cell size range between 0.4 to 0.6 μm, consistent with experimental observations. In particular, the study reveals a transition from dendritic to cellular and from cellular to planar structures, with an accompanying analysis of the underlying mechanisms.

Powder Synthesis and Characterization of Al0.5CoCrFeNi High-Entropy Alloy for Additive Manufacturing Prepared by the Plasma Rotating Electrode Process.

The Al0.5CoCrFeNi high-entropy alloy powder was produced by using a plasma rotating electrode process. The morphology, microstructure, and physical properties of the powder were characterized. The powder exhibited a smooth surface and a narrow particle size distribution with a single peak. The relationships between particle size and secondary dendrite arm space as well as cooling rate were evaluated as follows: λ = 0.0105d + 0.062 and vc = 4.34 × 10-5d-2 + 2.62 × 10-2d-3/2, respectively. The Al0.5CoCrFeNi powder mainly consisted of fcc + bcc phases. As the powder particle size decreased, the microstructure of the powder changed from dendritic to columnar or equiaxed, along with a decrease in the fcc content and an increase in the bcc content. The tap density (4.76 g cm-3), flowability (15.01 s × 50 g-1), oxygen content (<300 ppm), and sphericity (>94%) of the powder indicated suitability for additive manufacturing.

The microstructure and precipitated phase dependence of plastic deformation and fracture mechanism in repaired IN718 alloy by directed energy deposition

This work studied microstructural evolution, precipitate behaviors, and micro-hardness distribution along the built direction of directed energy deposited IN718 alloy. In combination with digital image correlation and crystallographic orientation analysis, the plastic deformation and fracture mechanisms of coarse columnar grains were explored in detail. The columnar grains in the deposition zone (DZ) grow along the <001> direction in the crystallography and gradually widen with increasing built height. The misorientation angle per unit length within individual columnar grains first decreases and then slows down to ∼ 0.07 °/μm when the deposition height is ∼ 1.8 mm. The micro-hardness in the DZ is gradually decreased along the built direction, which may be due to the increasing average columnar grain width and primary dendrite arm spacing, as well as reducing the volume fraction of the γ'' + γ' phases. During the uniaxial tensile loading, most plastic deformation always occurs in the DZ irrespective of the lowest hardness in the heat-affected zone (HAZ). The nucleation of microvoids is ascribed to the granular Laves phase debonding from the γ matrix. The number of microvoids gradually decreases with increasing distance from the fracture surface, which may be attributed to the strain-controlled nucleation of microvoids. EBSD results substantiated that the columnar grains near the fracture surface occur to severe lattice rotation, leading to the Kernel misorientation angle distribution in each grain interior increasing to about 1° ∼ 4°.

Effect of cooling rate and Nb addition on the strengthening in eutectic CoCr1.3FeMnNi0.7Nbx (0 ≤ x ≤ 0.45) high entropy alloys comprising of low stacking fault energy FCC phase

The CoCr1.3FeNi0.7MnNbx (0.3 ≤ x ≤ 0.45) eutectic high entropy alloy (EHEA) comprising of ultrafine lamellae of low stacking fault energy (SFE = 11 mJ/m2) face centered cubic (FCC) and Laves phase are synthesized at cooling rates of 2.5–10 K/s (arc melted ingots, AMIs) and 4.2 × 102 K/s (suction cast bars, SCBs). The microstructural investigation suggests that secondary dendritic arm spacing (SDAS) and interlamellar spacing are refined in SCBs due to a higher cooling rate than the AMIs. Whereas, deformation twins evolve in FCC phase due to its low SFE. The EHEAs exhibit a high yield strength of 1327 MPa for x = 0.367 SCB and a large fracture strain of 20% for x = 0.3 AMI under compression. Systematic investigation on the influence of Nb addition, microstructure refinement, and evolution of deformation twins during straining on the strengthening mechanisms reveals that the phase interface strengthening, solid solution strengthening, and twin boundary strengthening play critical roles in providing the high flow stress. The post-deformation analysis and the presence of multiple positive slopes in work hardening curves confirms that the concurrent effect of the evolution of dislocations, deformation twins, and their mutual interactions are solely responsible for the severe strain hardening at multiple stages during plastic deformation. The low values of strain rate sensitivity (0.0106–0.0111) and the activation volume (28b3-41b3) suggest that the deformation kinetics is governed by the dislocation interactions with the ultrafine lamellae interface and twin boundaries.

Effect of Y Contents on the Microstructure, Mechanical Properties, and Corrosion Behavior of Biomedical Mg–0.5Zn Alloy

The effects of Y contents on the microstructure, mechanical properties, and corrosion resistance of biomedical Mg–0.5Zn alloy are investigated. In the results, it is shown that an increase in Y content leads to a growth in the amount of the second phase and a decrease in the spacing of the secondary dendrite arms. Additionally, the second phase changes from a uniformly dispersed point‐like shape to a semicontinuous reticular distribution. Meanwhile, the addition of Y obviously reduces the dendritic organization and this contributes to the improvement of mechanical properties. The corrosion resistance of the alloys increased first when Y content is 2 wt% at most, and then decreases in Mg–3Y–0.5Zn alloy. The gradual improvement of corrosion resistance in Mg–1Y–0.5Zn and Mg–2Y–0.5Zn is closely related to the formation of the compact corrosion layer including Y element, while the sudden drop corrosion resistance of Mg–3Y–0.5Zn alloy is mainly attributed to the presence of a great deal of semicontinuous long‐period stacked order and its excessive negative potential compared with Mg matrix, which leads to a severe pitting.

Effects of shell mold heating temperature on microstructures and freckle formation of single crystal superalloys

To study the effects of shell mold heating temperature on the microstructure and freckle formation of single crystal superalloys, the directional solidification experiment and simulation were conducted with designed stepwise specimens. The temperature field and morphology of mushy zone were analyzed. The results show that the primary and secondary dendrite arm spacings both decrease with the rise of shell mold heating temperature. This reduces the permeability of the liquid in the mushy zone and the width of the thermal-solutal convection channel, which reduces the formation tendency of freckles, the width of freckles and the number of dendritic fragments in freckled areas. In addition, with the increase of shell mold heating temperature, the cooling rate of liquid in the mushy zone increases, which reduces the cooling time of the melt in the mushy zone, weakens the breaking capability of liquid flow to the dendrite, and further reduces the tendency of freckle formation in single crystal superalloy castings.

Influence of minor cerium addition on microstructure and fluidity of as-cast Al-Cu-Mn-Mg alloy

Al-Cu-Mn alloys are widely used to produce automobile components like cylinder heads and engine blocks because of their capability to retain excellent thermal and mechanical characteristics at high temperatures. However, the Al-Cu-Mn-based alloys demonstrate restricted fluidity, leading to casting defects such as shrinkage and incomplete filling. This research investigated the microstructure and fluidity of Al-4.7Cu-1.0Mn-0.5Mg (wt%) alloy with minor cerium (Ce) addition. The as-cast alloys predominantly comprise α-Al matrix, accompanied by the presence of Al2Cu, Al6Mn, and Al8Cu4Ce phases. The influence of adding Ce on the fluidity of the Al-4.7Cu-1.0Mn-0.5Mg alloy was investigated using a tri-spiral fluidity test mold in this research. The findings suggest that the addition of Ce within the range of 0.1 wt% to 0.5 wt% in the Al-4.7Cu-1.0Mn-0.5Mg alloy results in an enhancement in fluidity. Specifically, the alloy containing 0.4 wt% Ce exhibits a significant increase in fluidity distance, from 349.7 to 485.7 mm. This improvement can be attributed to the reduction in viscosity, the refinement of secondary dendrite arm spacing, and the modification of secondary phase particles. However, a higher concentration of Ce leads to a decrease in fluidity length, potentially due to the formation of Al8Cu4Ce.

New model for predicting homogenization kinetics of typical wrought superalloy

A new homogenization kinetics prediction model for wrought superalloys based on the concept of diffusion distance was proposed. The micro-segregation and homogenization kinetics of Ni-based wrought superalloy, GH4141, were systematically studied by using the quantitative electron prob X-ray micro-analyzer (EPMA) analyses. There is a discrepancy between the predicted homogenization kinetics by the residual segregation index model and the experimental measurement. Both the experiments and theoretical analyses reveal that the homogenization kinetics can be reasonably predicted by the diffusion distance model under 1D-diffusion condition, with considering the diffusion-direction factor that is usually ignored. The new model provides a new option for predicting the homogenization kinetics with only necessarily knowing the original dendrite arm spacing and diffusion coefficient.

Effect of local loading on microstructure and enhanced mechanical property of large complex castings prepared by Al–Si–Fe–Mn–Mg–Cu alloy during squeeze casting

Flywheel shells with a complex structure and large wall-thickness difference, as key components in heavy trucks, serve to connect the engine and transmission. Formability and mechanical performance control of such components should be taken into consideration. In this work, an Al–Si–Fe–Mn–Mg–Cu alloy was used to manufacture the flywheel shell via squeeze casting. The role of local loading on microstructure and mechanical property at thick-walled positions was investigated. Furthermore, the effect of the squeeze casting specific pressure and heat treatment on the microstructure and mechanical property of the Al–Si–Fe–Mn–Mg–Cu alloy flywheel shells was also analyzed. The results showed that at the thick-walled positions, local loading not only helped eliminate the solidification defects, but also refined the microstructure including α-Al grains and secondary dendrite arm spacing. With increasing the squeeze casting specific pressure from 24 MPa to 32 MPa, microstructure refinement and mechanical property enhancement of squeeze casting flywheel shells were obtained. After T6 heat treatment, the yield strength and ultimate tensile strength of flywheel shells were further increased to 261.8 and 318.4 MPa, respectively, owing to the formation of spherical eutectic Si phases and nano-sized β'', Q and S precipitates.

Effect of Al–5Ti–1B–La intermediate alloy on microstructure and mechanical properties of A356.2 aluminum alloy

This study delves into the effects of Al–5Ti–1B–1La intermediate alloy, a newly developed refinement agent, on the microstructure and mechanical properties of A356.2 aluminum-silicon alloy modified by Al–10Sr. The decomposition of Ti2Al20La, where La element was concentrated in the Al–5Ti–1B–1La intermediate alloy, hardly affected the conventional nucleation mechanism of TiAl3–TiB2; nonetheless, the La element significantly refined the dendritic arms of α-Al. Notably, the secondary dendrite arm spacing was reduced from 49 μm to 27 μm, when 0.025 wt% ∼0.2 wt% Al–5Ti–1B–1La intermediate alloy and 0.014 wt% Al–10Sr modifier was incorporated to the A356.2 aluminum alloy. Although the room-temperature ultimate tensile strength was increased only by 30 MPa, the elongation was remarkably improved from 10% to 26%. The hardness of the alloy was also enhanced from 75 HBW to 84 HBW. The experimental outcomes underscore the efficacy of minimal La element incorporation in enhancing the performance of Al–5Ti–1B intermediate alloy, and the findings are significant for improving the serviceability of automobile wheels made from A356.2 aluminum alloy. The method used in this study can also be employed to regulate the microstructure and enhance mechanical properties of other sub-eutectic aluminum-silicon alloys.

Effects of the synergistic addition of AlCrNiTi and Ce on the microstructure and mechanical properties of hypoeutectic Al-7Si alloy

A new strategy is proposed in this study to modify the microstructure of the Al-7Si alloy, which is widely employed in the aerospace and transportation sectors due to its lightweight, high specific strength, and specific modulus. The primary challenge of the Al-7Si alloy is its coarse microstructure, which undermines its mechanical properties. This research focuses on the effects of adding the AlCrNiTi master alloy and Ce to the Al-7Si alloy. The impact on both the microstructure evolution and the mechanical properties is examined, including analysis and discussion of the underlying mechanisms for refinement and strengthening. When the alloy was modified by 0.9 wt% of the AlCrNiTi master alloy and 0.1 wt% of Ce, there was a notable refinement of the α-Al phase, transforming it from a coarse dendritic structure to fine equiaxed grains. The addition of 0.9 wt% of the AlCrNiTi master alloy and 0.1 wt% of Ce can also reduce the secondary dendrite arm spacing (SDAS) to 5.9 μm. The eutectic Si phase underwent a significant transformation, changing from coarse flakes to fine granularity with rounded edges. Furthermore, CeSi2Ni2, Al3Ni intermetallic compounds, and nanoscale Al45Cr7 particles were observed in the modified Al-7Si alloy. Tensile tests showed that the addition of the inoculant in the Al-7Si alloy enhanced the ultimate tensile strength (UTS) from 173 MPa to 211 MPa and increased the elongation (El) from 7.9% to 14.1%.

Directed energy deposition of PH 13–8 Mo stainless steel: microstructure and mechanical property analysis

Laser metal deposition (LMD) is of the directed energy deposition (DED) process which is widely used for producing large-scale, dense, and functional parts in the field of additive manufacturing (AM). This research work investigates the microstructure and mechanical properties of PH 13–8 Mo martensitic stainless-steel parts produced via LMD. The workshop trials were conducted using an LMD system collaborated with a robotic arm to deposit single-track thin walls and horizontal blocks. The microstructural characteristics of the additively manufactured parts were analyzed using an optical microscope. The mechanical properties were evaluated through hardness measurements and uniaxial tensile tests. The influence of energy density and powder deposition density on the characteristic geometry of straight walls was also investigated. The microstructural analysis showed that the microstructure consisted of columnar dendrites that grew epitaxially from the substrate, with primary austenite cells containing intercellular ferrite and martensite laths that were roughly parallel with the retained austenite. When the energy density increased from 43 to 86 J/mm2 (a doubling of energy density), there was an increase in secondary dendritic arm spacing (SDAS) by approximately 250% in the first layer and approximately 90% in the top layer. The difference in SDAS change between the first and top layers can be attributed to the difference in cooling rates experienced by each layer during the additive manufacturing process. Increasing powder deposition density from 0.5 to 1 g/min results in a decrease in porosity from 3% to less than 1% and an increase in strength from 800 to over 1000 MPa. The hardness of the deposits was found to range from 300 to 400 HV. This variation in hardness can be attributed to differences in microstructure resulting from changes in cooling rates at different heights.

Experimental study of SS316L, Inconel 625, and SS316L-IN625 functionally graded material produced by direct laser metal deposition process

Three types of walls were produced by the direct laser metal deposition (DLMD) process; SS316L, Inconel 625 (IN625), and SS316L-Inconel 625 FGM. The thin walls were deposited on an AISI 4130 austenitic steel substrate in five layers with a length of 2 cm. The solidification behavior, secondary dendrite arm spacing (SADS) value, chemical composition, and hardness of samples were studied. Microstructures were evaluated using optical microscopy (OM) images, scanning electron microscopy (SEM), EDS Line, EDAX, and Map analyses. OM and SEM images showed an acceptable bonding between the layers in all samples. The main solidification was equiaxed dendritic and columnar dendritic in most parts. The growth of dendrites was perpendicular to the substrate. Some dendrites grew epitaxially at the interface of two sequential layers. The standard deviation of SDAS value for SS316L, IN625, and SS316L-IN625 FGM was 0.63, 0.71, and 0.73, respectively. The lowest value of SDAS was obtained in layer one, while the highest value was obtained in layer five of the thin walls. The average SDAS values for SS316L, IN625, and SS316L-IN625 FGM were 4.40, 4.53, and 4.76 µm, respectively. Therefore, the difference between the SDAS values was not significant. EDAX and Map analyses showed that the segregation of Nb and Mo to the dendritic boundary and the formation of eutectic, secondary phases, and brittle Laves phases have occurred. Additionally, the segregation of Nb and Mo to the dendritic boundary in the SS316L-IN625 FGM sample was higher than SS316L and IN625 samples. The microhardness values oscillated significantly and decreased by moving away from the substrate (in the build direction). The microhardness values of different points of the SS316L-IN625 FGM walls were in the range of 218–278 HV. EDS line scan, microstructure, and microhardness analyses indicated the successful fabrication of the SS316L-IN625 FGM by the DLMD process.

A novel method for evaluating solidification cracking susceptibility of austenitic stainless steel using trapezoidal hot cracking test during laser welding

A novel evaluation method was developed for evaluating solidification cracking susceptibility of austenitic stainless steel using trapezoidal hot cracking test laser welding. By changing different chemical compositions and welding speeds, the critical restraint width was named and regarded as a new index to evaluate cracking susceptibility. First of all, the average critical restraint width of SUS310S, 316 and 302 was measured as 22.97 mm, 18.17 mm and 17.38 mm during laser welding at a speed of 1.0 m/min, respectability. Single phase austenite under mode A appeared in 310S while the other could form austenite and a small amount of ferrite based on mode FA, therefore, the solidification cracking susceptibility was 310S > 316 > 302. Then, the critical restraint widths of SUS310S and 304 had a tendency of decrease with increasing welding speed from 0.5 m/min to 1.0 m/min during laser welding. The lower heat input could decrease primary and secondary dendrite arm spacings, causing a reduction in the segregation degree. In addition, the fine dendrite along grain boundary of weld center could contribute to form zigzag interface which would be beneficial to interrupt the continuous residual liquid film. Thus, the solidification cracking susceptibility tended to decrease with an increase in laser welding speed from 0.5 m/min to 1.0 m/min. Above all, the developed evaluation method could improve the applicability, feasibility and progressiveness of hot cracking test.