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Abstract The far-from-equilibrium solidification during additive manufacturing often creates large residual stresses that induce solid-state cracking. Here we present a strategy to suppress solid-state cracking in an additively manufactured AlCrFe2Ni2high-entropy alloy via engineering phase transformation pathway. We investigate the solidification microstructures formed during laser powder-bed fusion and directed energy deposition, encompassing a broad range of cooling rates. At high cooling rates (104−106 K/s), we observe a single-phase BCC/B2 microstructure that is susceptible to solid-state cracking. At low cooling rates (102−104 K/s), FCC phase precipitates out from the BCC/B2 matrix, resulting in enhanced ductility (~10 %) and resistance to solid-state cracking. Site-specific residual stress/strain analysis reveals that the ductile FCC phase can largely accommodate residual stresses, a feature which helps relieve residual strains within the BCC/B2 phase to prevent cracking. Our work underscores the value of exploiting the toolbox of phase transformation pathway engineering for material design during additive manufacturing.
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Experimental, Computational, and Machine Learning Methods for Prediction of Residual Stresses in Laser Additive Manufacturing: A Critical Review
In recent decades, laser additive manufacturing has seen rapid development and has been applied to various fields, including the aerospace, automotive, and biomedical industries. However, the residual stresses that form during the manufacturing process can lead to defects in the printed parts, such as distortion and cracking. Therefore, accurately predicting residual stresses is crucial for preventing part failure and ensuring product quality. This critical review covers the fundamental aspects and formation mechanisms of residual stresses. It also extensively discusses the prediction of residual stresses utilizing experimental, computational, and machine learning methods. Finally, the review addresses the challenges and future directions in predicting residual stresses in laser additive manufacturing.
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- Award ID(s):
- 1937128
- PAR ID:
- 10542291
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Materials
- Volume:
- 17
- Issue:
- 7
- ISSN:
- 1996-1944
- Page Range / eLocation ID:
- 1498
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.3390/ma17071498
