Numerical modeling of microstructure evolution during laser additive manufacturing of a nickel-based superalloy

A multi-scale model that combines the finite element method and stochastic analysis is developed to simulate the evolution of the microstructure of an Nb-bearing nickel-based superalloy during laser additive manufacturing solidification. Through the use of this model, the nucleation and growth of dendrites, the segregation of niobium (Nb) and the formation of Laves phase particles during the solidification are investigated to provide the relationship between the solidification conditions and the resultant microstructure, especially in the morphology of Laves phase particles. The study shows that small equiaxed dendrite arm spacing under a high cooling rate and low temperature gradient to growth rate (G/R) ratio is beneficial for forming discrete Laves phase particles. In contrast, large columnar dendrite arm spacing under a low cooling rate and high G/R ratio tends to produce continuously distributed coarse Laves phase particles, which are known to be detrimental to mechanical properties. In addition, the improvement of hot cracking resistance by controlling the morphology of Laves phase particles is discussed by analyzing the cracking pattern and microstructure in the laser deposited material. This work provides valuable understanding of solidification microstructure development in Nb-bearing nickel-based superalloys, like IN 718, during laser additive manufacturing and constitutes a fundamental basis for controlling the microstructure to minimize the formation of deleterious Laves phase particles.