Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations

Okugawa, Masayuki; Saito, Kenji; Yoshima, Haruki; Sawaizumi, Katsuhiko; Nomoto, Sukeharu; Watanabe, Makoto; Nakano, Takayoshi; Koizumi, Yuichiro

doi:https://doi.org/10.1016/j.addma.2024.104079

Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations

Okugawa, Masayuki; Saito, Kenji; Yoshima, Haruki et al.

Additive Manufacturing, 2024, 84, 104079

Number of Access:668（2025-08-15 01:10 Counts）

Identifier to cite or link to this item: https://hdl.handle.net/11094/95650

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Title	Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations
Creator	NRID 1000070847160 1000070847160 ORCID 0000-0002-6844-6856 0000-0002-6844-6856 researchmap permalink masayuki.okugawa masayuki.okugawa Scopus Author ID 57202824128 57202824128 CreatorName Okugawa, Masayuki
	CreatorName Saito, Kenji
	CreatorName Yoshima, Haruki
	CreatorName Sawaizumi, Katsuhiko
	CreatorName Nomoto, Sukeharu
	CreatorName Watanabe, Makoto
	NRID 1000030243182 1000030243182 ORCID 0000-0001-8052-1698 0000-0001-8052-1698 researchmap permalink read0013987 read0013987 Scopus Author ID 7403896013 7403896013 CreatorName Nakano, Takayoshi
	NRID 1000010322174 1000010322174 ORCID 0000-0001-7061-7135 0000-0001-7061-7135 researchmap permalink YuichiroKoizumi YuichiroKoizumi Scopus Author ID 57202772340 57202772340 CreatorName Koizumi, Yuichiro
Subject	Computational thermal-fluid dynamics simulation
	Hastelloy-X nickel-based superalloy
	Laser powder-bed fusion
	Phase-field method
	Solute element segregation
Description	Okugawa M., Saito K., Yoshima H., et al. Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations. Additive Manufacturing 84, 104079 (2024); https://doi.org/10.1016/j.addma.2024.104079.
Abstract	Solute segregation significantly affects material properties and is a critical issue in the laser powder-bed fusion (LPBF) additive manufacturing (AM) of Ni-based superalloys. To the best of our knowledge, this is the first study to demonstrate a computational thermal-fluid dynamics (CtFD) simulation coupled multi-phase-field (MPF) simulation with a multicomponent-composition model of Ni-based superalloy to predict solute segregation under solidification conditions in LPBF. The MPF simulation of the Hastelloy-X superalloy reproduced the experimentally observed submicron-sized cell structure. Significant solute segregations were formed within interdendritic regions during solidification at high cooling rates of up to 1.6 × 106 K s−1, a characteristic feature of LPBF. Solute segregation caused a decrease in the solidus temperature (TS), with a reduction of up to 38.4 K, which increases the risk of liquation cracks during LPBF. In addition, the segregation triggers the formation of carbide phases, which increases the susceptibility to ductility dip cracking. Conversely, we found that the decrease in TS is suppressed at the melt-pool boundary regions, where re-remelting occurs during the stacking of the layer above. Controlling the re-remelting behavior is deemed to be crucial for designing crack-free alloys. Thus, we demonstrated that solute segregation at the various interfacial regions of Ni-based multicomponent alloys can be predicted by the conventional MPF simulation. The design of crack-free Ni-based superalloys can be expedited by MPF simulations of a broad range of element combinations and their concentrations in multicomponent Ni-based superalloys.
Publisher	Elsevier B.V.
Source Title	Additive Manufacturing
Volume (Issue)	84
Page	104079
Date of Issued	2024-03-25
Language	English
Handle URL	https://hdl.handle.net/11094/95650
eISSN	22148604
Relation.isIdenticalTo	DOI (Publisher Version) https://doi.org/10.1016/j.addma.2024.104079
Access Rights	open access
CopyRight	This article is licensed under a Creative Commons Attribution 4.0 International License.
oaire:version	Version of Record
Category	学術雑誌論文 Journal Article

Resource Type	journal article
Local Type	Journal Article
DCMI Type	Text
DCTERMS.bibliographicCitation	Additive Manufacturing. 2024, 84, p. 104079
DC.title	Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations
DC.creator	Okugawa, Masayuki
	Saito, Kenji
	Yoshima, Haruki
	Sawaizumi, Katsuhiko
	Nomoto, Sukeharu
	Watanabe, Makoto
	Nakano, Takayoshi
	Koizumi, Yuichiro
DC.publisher	Elsevier B.V.
DC.language' scheme='DCTERMS.RFC1766	English
DC.type' scheme='DCTERMS.DCMIType	Text
DCTERMS.issued' scheme='DCTERMS.W3CDTF	2024-03-25
DC.identifier	https://doi.org/10.1016/j.addma.2024.104079
DC.subject	Computational thermal-fluid dynamics simulation
	Hastelloy-X nickel-based superalloy
	Laser powder-bed fusion
	Phase-field method
	Solute element segregation
DC.description	Okugawa M., Saito K., Yoshima H., et al. Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations. Additive Manufacturing 84, 104079 (2024); https://doi.org/10.1016/j.addma.2024.104079.
DCTERMS.abstract	Solute segregation significantly affects material properties and is a critical issue in the laser powder-bed fusion (LPBF) additive manufacturing (AM) of Ni-based superalloys. To the best of our knowledge, this is the first study to demonstrate a computational thermal-fluid dynamics (CtFD) simulation coupled multi-phase-field (MPF) simulation with a multicomponent-composition model of Ni-based superalloy to predict solute segregation under solidification conditions in LPBF. The MPF simulation of the Hastelloy-X superalloy reproduced the experimentally observed submicron-sized cell structure. Significant solute segregations were formed within interdendritic regions during solidification at high cooling rates of up to 1.6 × 106 K s−1, a characteristic feature of LPBF. Solute segregation caused a decrease in the solidus temperature (TS), with a reduction of up to 38.4 K, which increases the risk of liquation cracks during LPBF. In addition, the segregation triggers the formation of carbide phases, which increases the susceptibility to ductility dip cracking. Conversely, we found that the decrease in TS is suppressed at the melt-pool boundary regions, where re-remelting occurs during the stacking of the layer above. Controlling the re-remelting behavior is deemed to be crucial for designing crack-free alloys. Thus, we demonstrated that solute segregation at the various interfacial regions of Ni-based multicomponent alloys can be predicted by the conventional MPF simulation. The design of crack-free Ni-based superalloys can be expedited by MPF simulations of a broad range of element combinations and their concentrations in multicomponent Ni-based superalloys.
DC.rights	This article is licensed under a Creative Commons Attribution 4.0 International License.
DC.format	95650
citation_title	Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations
citation_author	Okugawa, Masayuki
	Saito, Kenji
	Yoshima, Haruki
	Sawaizumi, Katsuhiko
	Nomoto, Sukeharu
	Watanabe, Makoto
	Nakano, Takayoshi
	Koizumi, Yuichiro
citation_publisher	Elsevier B.V.
citation_language	English
citation_date	2024-03-25
citation_journal_title	Additive Manufacturing
citation_volume	84
citation_firstpage	104079
citation_doi	https://doi.org/10.1016/j.addma.2024.104079
citation_public_url	https://hdl.handle.net/11094/95650

Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations

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