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Engineering    2017, Vol. 3 Issue (5) : 685 -694
Research |
A Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and Solidification Microstructure of Inconel 718 Products Made by Laser Powder-Bed Fusion
Patcharapit Promoppatum1,Shi-Chune Yao1(),P. Chris Pistorius2,Anthony D. Rollett2
1. Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA
2. Department of Materials Science and Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA

The finite-element (FE) model and the Rosenthal equation are used to study the thermal and microstructural phenomena in the laser powder-bed fusion of Inconel 718. A primary aim is to comprehend the advantages and disadvantages of the Rosenthal equation (which provides an analytical alternative to FE analysis), and to investigate the influence of underlying assumptions on estimated results. Various physical characteristics are compared among the FE model, Rosenthal equation, and experiments. The predicted melt pool shapes compared with reported experimental results from the literature show that both the FE model and the analytical (Rosenthal) equation provide a reasonably accurate estimation. At high heat input, under conditions leading to keyholing, the reported melt width is narrower than predicted by the analytical equation. Moreover, a sensitivity analysis based on choices of the absorptivity is performed, which shows that the Rosenthal approach is more sensitive to absorptivity, compared with the FE approach. The primary reason could be the effect of radiative and convective losses, which are assumed to be negligible in the Rosenthal equation. In addition, both methods predict a columnar solidification microstructure, which agrees well with experimental reports, and the primary dendrite arm spacing (PDAS) predicted with the two approaches is comparable with measurements.

Keywords Additive manufacturing      Finite-element modeling      Rosenthal equation      Microstructure      Thermal behavior      Inconel 718     
Corresponding Authors: Shi-Chune Yao   
Online First Date: 03 November 2017    Issue Date: 08 November 2017
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Patcharapit Promoppatum
Shi-Chune Yao
P. Chris Pistorius
Anthony D. Rollett
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Patcharapit Promoppatum,Shi-Chune Yao,P. Chris Pistorius, et al. A Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and Solidification Microstructure of Inconel 718 Products Made by Laser Powder-Bed Fusion[J]. Engineering, 2017, 3(5): 685 -694 .
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