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  Thermodynamics-guided alloy and process design for additive manufacturing

Sun, Z., Ma, Y., Ponge, D., Zaefferer, S., Jägle, E. A., Gault, B., et al. (2022). Thermodynamics-guided alloy and process design for additive manufacturing. Nature Communications, 13: 4361. doi:10.1038/s41467-022-31969-y.

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 Creators:
Sun, Zhongji1, 2, Author           
Ma, Yan3, Author           
Ponge, Dirk3, Author           
Zaefferer, Stefan4, Author           
Jägle, Eric Aimé5, Author           
Gault, Baptiste6, 7, Author           
Rollett, Anthony D.8, Author
Raabe, Dierk9, Author           
Affiliations:
1Alloys for Additive Manufacturing, Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH, Max Planck Society, ou_2117289              
2Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore, ou_persistent22              
3Mechanism-based Alloy Design, Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH, Max Planck Society, ou_1863383              
4Microscopy and Diffraction, Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH, Max Planck Society, ou_1863391              
5Institute of Materials Science, Universität der Bundeswehr München, Neubiberg, Germany, ou_persistent22              
6Atom Probe Tomography, Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH, Max Planck Society, ou_1863384              
7Imperial College, Royal School of Mines, Department of Materials, London, SW7 2AZ, UK, ou_persistent22              
8Department of Materials Science and Engineering, Carnegie Mellon University, Pittsburgh, PA, 15213-3890, USA, ou_persistent22              
9Microstructure Physics and Alloy Design, Max-Planck-Institut für Eisenforschung GmbH, Max Planck Society, ou_1863381              

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 Abstract: Production defects prevent many industrially important materials from being adopted by metal additive manufacturing. Here, the authors propose a universal thermodynamics-guided alloy design approach to assist the discovery of crack-free materials. In conventional processing, metals go through multiple manufacturing steps including casting, plastic deformation, and heat treatment to achieve the desired property. In additive manufacturing (AM) the same target must be reached in one fabrication process, involving solidification and cyclic remelting. The thermodynamic and kinetic differences between the solid and liquid phases lead to constitutional undercooling, local variations in the solidification interval, and unexpected precipitation of secondary phases. These features may cause many undesired defects, one of which is the so-called hot cracking. The response of the thermodynamic and kinetic nature of these phenomena to high cooling rates provides access to the knowledge-based and tailored design of alloys for AM. Here, we illustrate such an approach by solving the hot cracking problem, using the commercially important IN738LC superalloy as a model material. The same approach could also be applied to adapt other hot-cracking susceptible alloy systems for AM.

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Language(s): eng - English
 Dates: 2022-07-27
 Publication Status: Published in print
 Pages: -
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 Table of Contents: -
 Rev. Type: Peer
 Identifiers: DOI: 10.1038/s41467-022-31969-y
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Title: Nature Communications
  Abbreviation : Nat. Commun.
Source Genre: Journal
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Publ. Info: London : Nature Publishing Group
Pages: - Volume / Issue: 13 Sequence Number: 4361 Start / End Page: - Identifier: ISSN: 2041-1723
CoNE: https://pure.mpg.de/cone/journals/resource/2041-1723