Onset Of Solidification Research Articles

Crystallinity and rheological behavior of polyetheretherketone during nonisothermal conditions

AbstractSolidification models are key during simulation of several industrial processes involving thermoplastics. For simplicity, crystallinity is often not considered within these models, despite it being responsible for the phase transition. Several advanced methods, which consider crystallinity as the onset of solidification have been proposed in literature however, these have primarily been applied to classical homopolymers such as polypropylene (PP). The focus of this study is to develop a model that can capture the rheological response observed during the transition from liquid‐like to solid‐like behavior in injection molding grade polyetheretherketone (PEEK) due to crystallinity. Isothermal rheological experiments are performed alongside dynamic scanning calorimetry (DSC) characterization to correlate relative crystallinity to the apparent increase in viscosity. The model is extended to nonisothermal processes through the incorporation of the Nakamura model. Nonisothermal crystallization rheology experiments are performed and compared with a simulation of the oscillating rheometer process for validation. The modeled viscosity response and crystallization half‐time reproduced the experimental data with sufficient accuracy at low cooling rates, with an error of less than 5% up to cooling rates of 20°C min−1. This shows that the method is an accurate means of obtaining the rheological response during crystallization in a numerical simulation.

Unraveling the Regimes of Interfacial Thermal Conductance at a Solid/Liquid Interface.

The interfacial thermal conductance at a solid/liquid interface (G) exhibits an exponential-to-linear crossover with increasing solid/liquid interaction strength, previously attributed to the relative strength of solid/liquid to liquid/liquid interactions. Instead, using a simple Lennard-Jones setup, our molecular simulations reveal that this crossover occurs due to the onset of solidification in the interfacial liquid at high solid/liquid interaction strengths. This solidification subsequently influences interfacial energy transport, leading to the crossover in G. We use the overlap between the spectrally decomposed heat fluxes of the interfacial solid and liquid to pinpoint when "solid-like energy transport" within the interfacial liquid emerges. We also propose a novel decomposition of G into (i) the conductance right at the solid/liquid interface and (ii) the conductance of the nanoscale interfacial liquid region. We demonstrate that the rise of solid-like energy transport within the interfacial liquid influences the relative magnitude of these conductances, which in turn dictates when the crossover occurs. Our results can aid engineers in optimizing G at realistic interfaces, critical to designing effective cooling solutions for electronics among other applications.

Research on gas pore formation and inhibition mechanism of high nitrogen steel during laser direct metal deposition

Nitrogen pore formation is an inherently tricky problem that limits the application of high nitrogen steel (HNS) in various fields. In the present study, a CA-LBM coupling model was proposed to understand the nitrogen pore formation mechanism during laser direct metal deposition (DMD) of HNS. Based on the proposed model and theoretical analysis, the effects of pulse frequency and shielding gas nitrogen content on the porosity were clarified systematically. Results showed that after the onset of solidification, the ferrite phase with extremely low nitrogen solubility precipitated first, inducing the continuous enrichment of nitrogen in the residual liquid phase, which in turn provided the prerequisite for nitrogen pore nucleation. The application of quasi-continuous-wave (QCW) laser mode accelerated the molten pool solidification, and shortened the nitrogen supersaturated region, allowing more nitrogen to be solid dissolved in the matrix. On this basis, the porosity was inhibited to a certain extent. Compared with the high-frequency pulse, the low-frequency pulse showed better porosity inhibition. In addition, following the classic nucleation theory, nitrogen segregation and nitrogen solubility synergistically dominated nitrogen pore formation. The nitrogen partial pressure, determined by the shielding gas nitrogen content, played a dual role in porosity defects. Elevated nitrogen partial pressure served to increase nitrogen solubility while promoting the nitrogen absorption process to intensify nitrogen segregation. However, due to the short duration of the molten pool, the nitrogen absorption process could not be fully processed. Nitrogen solubility enhancement was the key factor in inhibiting porosity during the DMD process.

Phospholipase-catalyzed degradation drives domain morphology and rheology transitions in model lung surfactant monolayers.

Lung surfactant is inactivated in acute respiratory distress syndrome (ARDS) by a mechanism that remains unclear. Phospholipase (PLA2) plays an essential role in the normal lipid recycling processes, but is present in elevated levels in ARDS, suggesting it plays a role in ARDS pathophysiology. PLA2 hydrolyzes lipids such as DPPC-the primary component of lung surfactant-into palmitic acid (PA) and lyso-PC (LPC). Because PA co-crystallizes with DPPC to form rigid, elastic domains, we hypothesize that PLA2-catalyzed degradation establishes a stiff, heterogeneous rheology in the monolayer, and suggests a potential mechanical role in disrupting lung surfactant function during ARDS. Here we study the morphological and rheological changes of DPPC monolayers as they are degraded by PLA2 using interfacial microbutton microrheometry coupled with fluorescence microscopy. While degrading, domain morphology passes through qualitatively distinct transitions: compactification, coarsening, solidification, aggregation, network percolation, network erosion, and nucleation of PLA2-rich domains. Initially, condensed domains relax to more compact shapes, and coarsen via Ostwald ripening and coalescence up until the domains solidify, marked by a distinct roughening of domain boundaries that does not relax. Domains aggregate and eventually form a percolated network, whose elements then erode and whose connections are broken as degradation continues. The relative enzymatic activity of PLA2, set by the age of the sample, impacts the order and the duration of morphology transitions. The fresher the PLA2, the faster the overall degradation, and the earlier the onset of domain solidification: domains solidify before aggregating with fresh PLA2 samples, but aggregate and percolate before solidification with aged PLA2. Irrespective of the activity of the PLA2, all measured linear viscoelastic surface shear moduli obey the same dependence on condensed phase area fraction (log|G*| ∝ ϕ) throughout monolayer degradation. Moreover, the onset of domain solidification coincides with the time when the relative surface elasticity begins to increase.

Scaling Law for the Onset of Solidification at Extreme Undercooling.

Quasi-isentropic compression enables one to study the solidification of metastable liquid states that are inaccessible through other experimental means. The onset of this nonequilibrium solidification is known to depend on the compression rate and material-specific factors, but this complex interdependence has not been well characterized. In this study, we use a combination of experiments, theory, and computational simulations to derive a general scaling law that quantifies this dependence. One of its applications is a novel means to elucidate melt temperatures at high pressures.

Additive manufacturing of crack-free Al-alloy with coarsening-resistant τ1-CeAlSi strengthening phase

Wrought aluminium alloys popular for automotive and aerospace applications are susceptible to solidification cracking when fabricated via laser powder bed fusion (LPBF). Another long-standing and common issue for these alloys is microstructure coarsening and corresponding strength loss caused by elevated temperature exposure. To tackle these challenges, this study designs and develops a class of 1–4 wt% Ce modified Al6061 alloys. The best alloy, with 3 wt% Ce, achieves crack-free fabrication via LPBF due to a reduction in the solidification temperature range and a new solidification pathway that achieved 0.9 solid mass fraction at just 14 °C below the solidification onset. Furthermore, a fine microstructure consisting of coarsening-resistant τ1-CeAlSi eutectic forms, and after hot isostatic pressing, the tensile strength and elongation of the 3 wt% Ce alloy can reach 153 ± 6 MPa and 18.3% at room temperature and 89 ± 6 MPa and 32.5% at 200 °C, respectively. The observed ductility is attributed to nanoscale dispersion of discrete, coarsening resistant τ1-CeAlSi particles within grains and to the presence of large columnar α-Al grains. Meanwhile, solidification cracking was inhibited by continuous grain boundary τ1-CeAlSi eutectic accumulation, which converted to discrete nanoscale τ1-CeAlSi after hot isostatic pressing. This research uncovers a simple and effective approach of designing Al-alloys for LPBF with great potential for both room temperature and high temperature applications in automotive and aerospace industries.

Experimental footprints of a water-rich depletion layer in the Herschel–Bulkley pipe flow of solidifying polyelectrolytes

A fundamental understanding of the transition from fluid-like to gel-like behavior is critical for a range of applications including personal care, pharmaceuticals, food products, batteries, painting, biomaterials, and concrete. The pipe flow behavior of a Herschel–Bulkley fluid is examined by a combination of rheology, ultrasound imaging velocimetry, and pressure measurements together with modeling. The system is a solution of 0.50 wt. % polyelectrolytes of sulfated polysaccharides in water that solidifies on cooling. Fluids with different ionic strengths were pumped at various rates from a reservoir at 80 °C into a pipe submerged in a bath maintained at 20 °C. The fluid velocity, pressure drop ΔP, and temperature were monitored. The same quantities were extracted by solving continuity, energy, and momentum equations. Moreover, the modeling results demonstrate that the local pressure gradient along the pipe dPdx|x is related to the local yield stress near the pipe wall τywall|x, which explains the variations of dPdx|x along the pipe. Experimental results show much lower values for ΔP compared to those from modeling. This discrepancy is exacerbated at higher ionic strengths and smaller flow rates, where fluid shows a higher degree of solidification. The tabulated experimental ΔP data against the solidification onset length Lonset (where the fluid is cool enough to solidify) along with the ultrasound imaging velocimetry associate these discrepancies between experiments and models to a depletion layer of ∼1 μm, reflecting the lubrication effects caused by the water layer at the wall.

Offset impacting of a liquid aluminum droplet train on a molten pool on a horizontally moving substrate during TIG-assisted droplet deposition manufacturing

Internal metallurgical defects and poor mechanical properties and surface quality of the formed parts are the most important challenges of metal micro-droplets deposition manufacturing technology. Lack of strong coalescence between neighboring droplets and the blocking effects of periodic ripples on the fusion process are major sources of abovementioned problems. To address this issue, a tungsten inert gas (TIG) welding arc was introduced to pre-melt the material below the droplet impacting location, thus, one droplet train will be deposited on a curved molten pool surface to fabricate deposited layers in an additive approach. In the present work, a numerical model based on the computational fluid dynamics (CFD) method was developed to investigate the dynamic behaviors of successive droplets’ impact and coalescence on the molten pool created by a tilted TIG welding arc, and focuses on the effect of the offset distance between the impacting point of droplet and the longitudinal plane of molten pool on the deposition morphology and the impact-induced molten pool behaviors. The simulated tracks exhibit regular scaly shapes at different offset distances, which is validated against the corresponding experiments. The results indicated that as the lateral offset distance increases, the symmetric spreading and recoiling of the subsequent droplets on the pre-existing bead will be broken due to the inclined and curved solidification front morphologies, the inclined front morphologies are caused by the increased growth rate of the solidification front at the impact zone. With an increased lateral offset distance, the volume of the molten pool decreases, the width of the rear molten pool increases slightly. The calculated solidification parameters are found to be dependent of the offset distance, and vary significantly at the onset of solidification at different portions of the molten pool. The scientific findings provide useful insights for further researches of TIG-assisted DDM.

Size evolution during laser-ignited single iron particle combustion

To further our understanding of iron particle combustion, especially in the liquid state, insitu optical measurements are performed for the size evolution and temperature of laser-ignited iron particles in a narrow size range around 45–55μ m. The particle size evolution is monitored by a high-speed shadowgraphy system, and the particle temperature is probed using a two-color pyrometer synchronized with the shadowgraphy system. Before a particle reaches the peak temperature, its diameter grows linearly with elapsed time. Near the peak temperature, three types of particle size behavior are detected, namely, smooth transition, micro-explosion, and rapid inflation. For particles with smooth transition, the size and temperature reach the maximum values at the same time, and thereafter the size remains constant, while the temperature drops until rapid solidification of the iron oxide droplet. The micro-explosion and rapid inflation clearly indicate towards a quick gas release inside the particle. The ambient oxygen concentration has a strong effect on the growth rate of the particle size before the peak temperature but no influence on the final particle size. The measured relative particle diameter at the peak temperature suggests that iron has been fully oxidized and the degree of oxidation could be higher than FeO. At the onset of solidification, gas release occurs again, resulting in a second inflation or burst of already inflated particles. This suggests that the oxygen dissolved in the liquid iron oxide is at least more than needed to form solid Fe3O4, and the solidification process is accompanied with gaseous oxygen release via the phase transition: L2 ⟶ Fe3O4(s) + O2(g) at 1855 K, where L2 represents liquid iron oxide with dissolved excess oxygen.

Formation of three-phase eutectic grains on primary phases: Observations from correlative imaging

We investigate the interaction between three-phase eutectic and a primary phase during solidification of an off-eutectic Al-Ag-Cu alloy through correlative imaging. In situ synchrotron X-radiography reveals the locations and orientations of primary Al2Cu rods, with respect to the surrounding eutectic. We also identified an unusually high and anisotropic eutectic growth velocity, often exceeding 100 μm/s when the growth front was parallel to the surface of a primary Al2Cu rod. By combining these results with three-dimensional (3D) focused ion beam tomography, scanning electron microscopy, and electron backscatter diffraction, we demonstrate that this anomaly results from two-dimensional (2D) dendrites, or ‘fingers’, of Al and Ag2Al that spread along the primary Al2Cu rod surfaces; meanwhile, protrusions of Al2Cu grow in between pockets of the fingers and into the surrounding eutectic, preserving their crystallographic orientations and morphology in the process. We propose a competitive growth relationship between the three phases of the eutectic to explain these features as well as the diversity of two- and three-phase microstructures obtained at the onset of eutectic solidification.

The onset of solidification: From interface formation to the Stefan regime.

The onset of a solidification process is considered in a situation where the free surface of a warm liquid is touched by a sufficiently cold solid. The process is analyzed in terms of a model that takes into account the formation of a liquid-solid interface as the two media are brought in contact and then the appearance of the solidified liquid as a third bulk phase. As is shown, the temperature at the liquid-solid interface and then at the solidification front evolves in a non-monotone way, and when the solidification front appears and starts to move, its velocity is not a function of its temperature. The classical Stefan regime of solidification appears as a limit as the temperature at the solidification front evolves toward the melting temperature.

Numerical Analysis of Nucleation and Growth of Stray Grain Formation during Laser Welding Nickel-Based Single-Crystal Superalloy Part II: Solidification Cracking Diminution through Single-Crystallinity Control

The effect of thermo-metallurgical factors, such as heat input and welding configuration, on solidification cracking driving forces nearby dendrite tip, such as solidification temperature range and columnar/equiaxed transition (CET) was thermodynamically and kinetically discussed with aid of comprehensive numerical analysis for multicomponent melt-pool solidification during laser processing under non-equilibrium solidification conditions to better understand problematical solidification cracking phenomena. By using (001)/[100] welding configuration, axisymmetrical distributions of columnar/equiaxed transition and solidification temperature range alongside solidification interface are homogeneously produced on both sides of weld pool. By using (001)/[110] welding configuration, nonaxisymmetrical distributions are heterogeneously produced, and are able to bring about infelicitous microstructure degradation. Unidirectional region of [001] columnar dendrite is more prone to epitaxial growth without morphology transition to conservatively better crystallography-assisted single-crystal growth. Unidirectional epitaxial growth is collapsed, and onset of stray grain nucleation and solidification cracking eventuates in [100] region of equiaxed dendrite growth. Low heat input relatively broadens portion of unidirectional columnar dendrite, where stray grain is infrequently nucleated and grown, and thus morphology transition seldom happens, as long as undercooling and solidification temperature range alongside dendrite tip are sufficient low to challengingly develop crackless dendrite growth and high-quality weld by thermometallurgy-aided single-crystallinity control. Auspicious (001)/[100] welding configuration simultaneously abates overall stray grain nucleation and constricts solidification temperature range nearby fusion boundary to wane microstructure heterogeneity. Conversely, plenteous stray grain formation is kinetically attained and extensive solidification temperature range nearby fusion boundary is thermodynamically obtained by problematical (001)/[110] welding configuration to metallurgically induce pernicious equiaxed dendrite and disintegrate dendrite growth. Moreover, the mechanism of solidification cracking diminution as consequence of appropriate optimization of thermo-metallurgical determinants during multicomponent nickel-based single-crystal superalloy melt-pool non-equilibrium solidification is also proposed. The potent consistency between the predicted and experimented results is exceedingly tenable.

Effect of growth rate on microstructure evolution in directionally solidified Ti–47Al alloy

The microstructures and morphologies of directionally solidified Ti–47Al alloys with different growth rates ranging from 1 to 200 μm/s were investigated using the Bridgman directionally solidified method. The results showed that numerous columnar grains were formed along the growth direction with the onset of directional solidification. With a variation in the growth rate, the solid/liquid interface changed from a flat to cellular and to dendritic interface. The flat-to-cellular interface transition rate of the Ti–47Al alloy varied from 1 to 3 μm/s. When the growth rate was higher than 10 μm/s, the solid/liquid interface showed typical dendritic growth. During the directional solidification process, the main phase of the directionally solidified Ti–47Al alloy was the α phase, which can be attributed to the solute segregation, supercooling of the components, and contamination of the alloy melt by the Y2O3 ceramic shell. After reaching the steady growth state during the directional solidification process, the solidification path of the alloy was: L→α→α+γ→(α2+γ) + γ. With an increase in the growth rate, the primary dendrite spacing (λ) and lamellar spacing (λs) of the alloy decreased gradually.

Influence of surfactants on the performance enhancement of water-based gamma Al2O3 phase change material for cool thermal energy storage system

The current work investigates the effect of various surfactants on the performance enhancement of water-based gamma Al2O3 PCM (Phase change material) during the solidification process suitable CTES (cool thermal energy storage) system. Two surfactants, one from cationic group (CTAB – cetyl trimethyl ammonium bromide) and other from anionic group (SDBS – sodium dodecylbenzene sulfonate) are selected for this study. Both the nanoparticles and surfactants with 0.1 wt% are dispersed in the base fluid. The freezing experiments were conducted at various surrounding bath temperatures of −6 ℃, −9 ℃ and −12 ℃. The outcomes reveal a reduction in subcooling, advanced onset of solidification and increased heat transfer performance by use of nanofluids. Further it is noted that the performance is also influenced due to the surfactant. The anionic surfactant NFPCM (nanofluid phase change material) displace better performance than cationic surfactant NFPCM during the solidification process. The enhanced performance of NFPCM will pave the way to design an energy efficient CTES system.

Dependence of mechanical properties and microstructure on solidification onset temperature for Al2024–CaB6 alloys processed using laser powder bed fusion

The addition of a sufficient amount of the potent heterogeneous nucleating agent CaB6 enables the fabrication of crack-free specimens from the solidification-crack susceptible high-strength 2024 (Al–Cu–Mg) aluminum (Al) alloy using laser powder bed fusion (LPBF). The present work investigates the effects of varying addition contents of CaB6 nanoparticles (0.0–2.0 wt%) on the alloys' solidification behavior as well as the specimens’ solidification-crack volume, microstructure, and mechanical properties.The findings of X-ray microscopy (XRM) analyses on LPBF specimens and in-situ differential fast scanning calorimetry (DFSC) analyses on single powder particles at LPBF-like high heating and cooling rates reveal decreasing crack volumes with decreasing solidification supercooling. A CaB6 content of equal to or greater than 0.5 wt% effectively suppresses solidification cracking. 1.0 wt% is defined as the optimum CaB6 content in terms of mechanical properties. With this content an average grain size of 0.77 μm, an ultimate tensile strength (UTS) of 478 ± 4 MPa and an elongation (A) of 13.2 ± 0.1% are achieved. When the CaB6 content is further increased, the alloy's average grain size asymptotically approaches a minimum size of ∼0.7 μm for the given process parameters. This value corresponds to the nucleation-free zone (NFZ), within which the CaB6 nanoparticles present are not activated as nucleating agents, resulting in deposition along the grain boundaries.

Spurious grain formation due to Marangoni convection during directional solidification of alloys in µ-g environment of International Space Station

During directional solidification of alloys in the microgravity environment of the International Space Station (ISS), growth of dendritic array is expected to be under purely diffusive transport conditions. The resulting microstructure is expected to make up uniformly arranged primary dendrites on sample cross-sections without any defects, such as macrosegregation and spurious (misoriented) grains. However, spurious grains have been seen in recently directionally solidified Al-7 wt% Si samples under the joint NASA-ESA project (MICAST) and also in SCN-0.24 wt% H2O samples grown under the NASA-PFMI project. Careful examination of both these experiments shows the presence of voids at the melt-crucible interface which are the likely source of the convective flows responsible for the fragmentation of dendrite-side arms, and their rotation which creates the nucleus for the spurious grains. In this paper, we assume that side-arm of a primary dendrite has gotten detached from the primary trunk during remelting and isothermal hold, prior to the onset of directional solidification on the Space Station, in the vicinity of a pore at the melt-crucible interface. We numerically simulate the influence of the Marangoni convection on the trajectory of such a dendrite fragment in the alloy melt and compare with the experimental observations. The experimentally observed rotation behavior of the fragmented side-arm in transparent SCN-0.24 wt% H2O, observed from the PFMI video, shows a good agreement with simulation results. The predicted rotational speeds of broken-off secondary arm in the Al-7 wt% Si (MICAST) samples is significantly higher than those in the SCN-0.24 wt% H2O (PFMI). The strength of the convection is dependent on the Marangoni Number and location of the surface pore relative to the Mushy zone. Marangoni convection is strong enough to force the rotation of broken-off side arms and should be considered an important source of microstructural inhomogeneity during terrestrial solidification processing applications.

Modeling the effects of coordinated multi-beam additive manufacturing

In additive manufacturing (AM), it is necessary to know the influence of processing parameters in order to have better control over the microstructure and mechanical performance of the part. Laser powder bed fusion (LPBF) AM is beneficial for many reasons; however, it is limited by the thermal solidification conditions achievable in the available processing parameter ranges for single-beam processing methods. Therefore, this work investigates the effect of multiple, coordinated heat sources, which are used to strategically modify the melting and solidifying in the AM process. To model this, existing thermal models of the LPBF process have been modified to include the effects of multiple, coordinated laser beams. These computational models are used to calculate melt pool dimensions and thermal conditions (thermal gradient and cooling rate). Furthermore, the results of the simulations are used to determine the influence of the distance between the coordinated laser beams in different configurations. The multi-beam scanning strategies modeled in the present study are shown to alter both melt pool shape and size, and the thermal conditions at the onset of solidification. However, these variations are not shown to result in alterations in the grain morphology of Ti-6Al-4V components. This predictive method used in this research provides insight into the effects of using multiple coordinated beams in LPBF, which is a necessary step in increasing the capabilities of the AM process.

Experimental and Numerical Investigation of the Thermal Performance of a Hybrid Battery Thermal Management System for an Electric Van

The temperature and the temperature gradient within the battery pack of an electric vehicle have a strong effect on the life time of the battery cells. In the case of automotive applications, a battery thermal management (BTM) system is required to maintain the temperature of the cells within a prescribed and safe range, and to prevent excessively high thermal gradients within the battery pack. This work documents the assessment of a thermal management system for a battery pack for an electric van, which adopts a combination of active/passive solutions: the battery cells are arranged in a matrix or composite made of expanded graphite and a phase change material (PCM), which can be actively cooled by forced air convection. The thermal dissipation of the cells was predicted based on an equivalent circuit model of the cells (LG Chem MJ1) that was empirically calibrated in a previous study. It resulted that, in order to keep the temperature of the battery pack at or below 40 °C during certain charge/discharge cycles, a purely passive BTM would require a considerable amount of PCM material that would unacceptably increase the battery pack weight. Therefore, the passive solution was combined with an air cooling system that could be activated when necessary. To assess the resulting hybrid BTM concept, CFD simulations were performed and an experimental test setup was built to validate the simulations. In particular, PCM melting and solidification times, the thermal discrepancy among the cells and the melting/solidification temperatures were examined. The melting time experimentally observed was higher than that predicted by the CFD model, but this discrepancy was not observed during the solidification of the PCM. This deviation between the CFD model results and the experimental data during PCM melting can be attributed to the thermal losses occurring through the mock-up casing as the heating elements are in direct contact with the external walls of the casing. Moreover, the temperature range over which the PCM solidifies was 6 °C lower than that estimated in the numerical simulations. This occurs because the simple thermodynamic model cannot predict the metastable state of the liquid phase which occurs before the onset of PCM solidification. The mockup was also used to emulate the heat dissipation of the cells during a highway driving cycle of the eVan and the thermal management solution as designed. Results showed that for this mission of the vehicle and starting from an initial temperature of the cells of 40 °C, the battery pack temperature could be maintained below 40 °C over the entire mission by a cooling air flow at 2.5 m/s and at a temperature of 30 °C.

Metallographic Preparation of Single Powder Particles

Abstract This work developed a systematic method for a metallographic preparation of single powder particles with diameters of approx. 20 to 40 μm. It was motivated by the objective of understanding additive manufacturing processes such as Laser Powder Bed Fusion. A fundamental aspect of the relationship between manufacturing, structure, and properties is the correlation of rapid solidification and resulting microstructure. During powder-based additive manufacturing processes, cooling rates up to 1 MK/s are attained. A thermal analysis determining the characteristics of solidification at such rapid cooling rates can be performed with the aid of chip sensor-based, dynamic Differential Fast Scanning Calorimetry, DFSC. For this purpose, the heat flow during the solidification of single powder particles is measured and, for instance, the solidification onset temperature is evaluated as a function of cooling rate. It is thus possible to estimate the undercooling which has a significant impact on the resulting structure. Subsequently, cross sections of single powder particles must be prepared for the analysis of the resulting structure.

Assessment of AlZnMgCu alloy powder modification for crack-free laser powder bed fusion by differential fast scanning calorimetry

Additive manufacturing, e.g. by laser powder bed fusion (LPBF), is very attractive for lightweight constructions, as complex and stress-optimised structures integrating multiple functions can be produced within one process. Unfortunately, high strength AlZnMgCu alloys tend to hot cracking during LPBF and thus have not so far been applicable. In this work the melting and solidification behaviour of AlZnMgCu alloy powder variants with particle surface inoculation was analysed by Differential Fast Scanning Calorimetry. The aim is to establish a method that makes it possible to assess powder modifications in terms of their suitability for LPBF on a laboratory scale requiring only small amounts of powder.Therefore, solidification undercooling is evaluated at cooling rates relevant for LPBF. A method for the temperature correction and normalisation of the DFSC results is proposed. Two ways of powder modification were tested for the powder particles surface inoculation by titanium carbide (TiC) nanoparticles: via wet-chemical deposition and via mechanical mixing.A low undercooling from DFSC correlates with a low number of cracks of LPBF-manufactured cubes. It appears that a reduced undercooling combined with reduced solidification onset scatter indicates the possibility of crack-free LPBF of alloys that otherwise tend to hot cracking.