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Solidification microstructure is formed under high cooling rates and temperature gradients in powder-based additive manufacturing. In this study, a non-equilibrium multi-phase field method (MPFM), which was based on a finite interface dissipation model proposed by Steinbach et. al., coupled with a CALPHAD database was developed for a multicomponent Ni alloy. A quasiequilibrium MPFM was also developed for comparison. Two-dimensional equiaxed microstructural evolution for the Ni (Bal.)–Al–Co–Cr–Mo–Ta–Ti–W–C alloy was performed at various cooling rates. The temperature–γ fraction profiles obtained under 10 K/s using nonand quasi-equilibrium MPFMs were in good agreement with each other. Over 10 K/s, the differences between nonand quasi-equilibrium methods grew as the cooling rate increased. The non-equilibrium solidification was strengthened over a cooling rate of 10 K/s. Columnar-solidification microstructural evolution was performed under cooling rates from 5×10 K/s to 1×10 K/s at various temperature gradient values under the constant interface velocity (0.1 m/s). The results showed that as the cooling rate increased, the cell space decreased in both methods, and the non-equilibrium MPFM agreed well with experimental measurements. Our results show that the non-equilibrium MPFM can simulate solidification microstructure in powder bed fusion additive manufacturing.

metals

Non- and Quasi-Equilibrium Multi-Phase Field Methods Coupled with CALPHAD Database for Rapid-Solidification Microstructural Evolution in Laser Powder Bed Additive Manufacturing Condition