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Monte Carlo simulations of solidification and solid-state phase transformation during directed energy deposition additive manufacturing

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Abstract

Both solidification and phase transformation play key roles in determining the final mechanical properties of Ti–6Al–4V parts fabricated by directed energy deposition (DED) additive manufacturing (AM). A cross-sectional Monte Carlo model is proposed to simulate both solidification and solid-state phase transformations on the cross section of DED parts. Results indicate that the simulated prior β and α grains are both well correlated with experimental observations. An increase in the build height leads to an increase in the grain length during solidification, and α embryos are generated on the boundaries of the formed β grains. The phase transformation is completed between 950 and 800 °C during cooling. The numerical results of the phase transformation agree well with the experimental observations.

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Data availability

The raw/processed data required to reproduce these findings cannot be shared at this time because of technical or time limitations.

Code availability

Not applicable (numerical simulations are calculated by commercial finite-element software and user subroutines).

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Funding

This article was funded by Natural Science Foundation of Liaoning Province (Grant No: 2019-KF-05-07, Zhao Zhang).

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Authors and Affiliations

  1. State Key Laboratory of Structural Analysis for Industrial Equipment, Department of Engineering Mechanics, Faculty of Vehicle Engineering and Mechanics, Dalian University of Technology, Dalian, 116024, China

    Z. Zhang, P. Ge & J. Y. Li

  2. College of Civil Engineering and Architecture, Henan University of Technology, Zhengzhou, 450000, China

    P. Ge

  3. School of Automotive Engineering, Dalian University of Technology, Dalian, 116024, China

    D. X. Ren

  4. Institute of Materials Engineering, University of Kassel, Mönchebergstr 3, 34125, Kassel, Germany

    T. Wu

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  1. Z. Zhang
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  5. T. Wu
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Contributions

ZZ: writing (original draft preparation), project administration, and reviewing and editing (final draft). PG: experimental and numerical work, data processing, and mapping. JYL: XRD experiment. DR: XRD experiment. TW: XRD and microstructure analyses.

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Correspondence to Z. Zhang.

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Zhang, Z., Ge, P., Li, J.Y. et al. Monte Carlo simulations of solidification and solid-state phase transformation during directed energy deposition additive manufacturing. Prog Addit Manuf 7, 671–682 (2022). https://doi.org/10.1007/s40964-021-00253-8

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  • DOI: https://doi.org/10.1007/s40964-021-00253-8

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