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Laser-based additive manufacturing offers a promising route for 3D printingof metallic parts. We evidence experimentally a particular columnarsolidification microstructure in a Laser Powder-Bed Fusion processed Inconel718 nickel-based alloy, that we interpret using phase-field simulations andclassical dendritic growth theories. Owing to the large temperature gradientand cooling rate, solidification takes places through dendritic arrays whereinthe characteristic length scales, i.e tip radius, diffusion length and primaryspacing, are of the same order. This leads to a weak mutual interaction betweendendrite tips, and a drastic reduction of side-branching. The resultingirregular cellular-like solidification pattern then remains stable on timescales comparable to the complete melt pool solidification, as observed in theas-built material.

Strongly out-of-equilibrium columnar solidification during the Laser Powder-Bed Fusion additive manufacturing process