Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach
In this study, laser-material interactions during laser-powder bed fusion of WE43 magnesium alloy were characterized through numerical and experimental analyses. Various melting modes (i.e., conduction, transition, and keyhole) were induced through deposition of laser tracks at powers ranging from 8...
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| Language: | English |
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Elsevier
2025-05-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525003454 |
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| author | Francesco D’Elia Mohammad Hoseini-Athar Satya Chaitanya Vaddamanu Mikael Ersson Peter Hedström Cecilia Persson |
| author_facet | Francesco D’Elia Mohammad Hoseini-Athar Satya Chaitanya Vaddamanu Mikael Ersson Peter Hedström Cecilia Persson |
| author_sort | Francesco D’Elia |
| collection | DOAJ |
| description | In this study, laser-material interactions during laser-powder bed fusion of WE43 magnesium alloy were characterized through numerical and experimental analyses. Various melting modes (i.e., conduction, transition, and keyhole) were induced through deposition of laser tracks at powers ranging from 80 to 130 W, and used as input parameters for a thermo-fluid model. Results of microscopy demonstrated good agreement between numerical and experimental measurements of melt pool depth, as well as a strong correlation between melt pool microstructure and the thermo-fluid conditions predicted by the model. Specifically, for conduction mode at 80 W, a predominance of cellular subgrains within the melt pool was consistent with the predicted steep thermal gradients, while for keyhole mode at 130 W, low thermal gradients correlated with high presence of equiaxed dendrites. Moreover, convection currents attributed to high recoil pressure in keyhole melt pools, were in agreement with locations of numerous subgrain boundaries having non-uniform morphologies, while under conduction, outward Marangoni flow led to a unique alignment of cellular subgrains and fewer subgrain boundaries. This study demonstrates the interplay among processing, thermal history, fluid flow and microstructure in WE43, and provides a basis for future design of microstructures for improved material properties. |
| format | Article |
| id | doaj-art-dfddc79ebaa24d84b2bcc469b7135f5c |
| institution | OA Journals |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-dfddc79ebaa24d84b2bcc469b7135f5c2025-08-20T02:38:30ZengElsevierMaterials & Design0264-12752025-05-0125311392510.1016/j.matdes.2025.113925Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approachFrancesco D’Elia0Mohammad Hoseini-Athar1Satya Chaitanya Vaddamanu2Mikael Ersson3Peter Hedström4Cecilia Persson5Department of Materials Science and Engineering, Division of Biomedical Engineering, Uppsala University, Uppsala, Sweden; Corresponding author.Department of Materials Science and Engineering, KTH Royal Institute of Technology, Stockholm, SwedenDepartment of Materials Science and Engineering, Division of Biomedical Engineering, Uppsala University, Uppsala, SwedenDepartment of Materials Science and Engineering, KTH Royal Institute of Technology, Stockholm, SwedenDepartment of Materials Science and Engineering, KTH Royal Institute of Technology, Stockholm, SwedenDepartment of Materials Science and Engineering, Division of Biomedical Engineering, Uppsala University, Uppsala, SwedenIn this study, laser-material interactions during laser-powder bed fusion of WE43 magnesium alloy were characterized through numerical and experimental analyses. Various melting modes (i.e., conduction, transition, and keyhole) were induced through deposition of laser tracks at powers ranging from 80 to 130 W, and used as input parameters for a thermo-fluid model. Results of microscopy demonstrated good agreement between numerical and experimental measurements of melt pool depth, as well as a strong correlation between melt pool microstructure and the thermo-fluid conditions predicted by the model. Specifically, for conduction mode at 80 W, a predominance of cellular subgrains within the melt pool was consistent with the predicted steep thermal gradients, while for keyhole mode at 130 W, low thermal gradients correlated with high presence of equiaxed dendrites. Moreover, convection currents attributed to high recoil pressure in keyhole melt pools, were in agreement with locations of numerous subgrain boundaries having non-uniform morphologies, while under conduction, outward Marangoni flow led to a unique alignment of cellular subgrains and fewer subgrain boundaries. This study demonstrates the interplay among processing, thermal history, fluid flow and microstructure in WE43, and provides a basis for future design of microstructures for improved material properties.http://www.sciencedirect.com/science/article/pii/S0264127525003454Laser-powder bed fusionMagnesium alloysComputational modelingMelt poolMicrostructureSolidification |
| spellingShingle | Francesco D’Elia Mohammad Hoseini-Athar Satya Chaitanya Vaddamanu Mikael Ersson Peter Hedström Cecilia Persson Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach Materials & Design Laser-powder bed fusion Magnesium alloys Computational modeling Melt pool Microstructure Solidification |
| title | Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach |
| title_full | Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach |
| title_fullStr | Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach |
| title_full_unstemmed | Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach |
| title_short | Influence of melting mode on melt pool dynamics and microstructure in WE43 Mg alloy: A combined computational and experimental approach |
| title_sort | influence of melting mode on melt pool dynamics and microstructure in we43 mg alloy a combined computational and experimental approach |
| topic | Laser-powder bed fusion Magnesium alloys Computational modeling Melt pool Microstructure Solidification |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525003454 |
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