Emergence of rapid solidification microstructure in additive manufacturing of a Magnesium alloy

IF 1.9 4区 材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY Modelling and Simulation in Materials Science and Engineering Pub Date : 2024-05-13 DOI:10.1088/1361-651x/ad4576
Damien Tourret, Rouhollah Tavakoli, Adrian D Boccardo, Ahmed K Boukellal, Muzi Li and Jon Molina-Aldareguia
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Abstract

Bioresorbable Mg-based alloys with low density, low elastic modulus, and excellent biocompatibility are outstanding candidates for temporary orthopedic implants. Coincidentally, metal additive manufacturing (AM) is disrupting the biomedical sector by providing fast access to patient-customized implants. Due to the high cooling rates associated with fusion-based AM techniques, they are often described as rapid solidification processes. However, conclusive observations of rapid solidification in metal AM—attested by drastic microstructural changes induced by solute trapping, kinetic undercooling, or morphological transitions of the solid-liquid interface—are scarce. Here we study the formation of banded microstructures during laser powder-bed fusion (LPBF) of a biomedical-grade Magnesium-rare earth alloy, combining advanced characterization and state-of-the-art thermal and phase-field modeling. Our experiments unambiguously identify microstructures as the result of an oscillatory banding instability known from other rapid solidification processes. Our simulations confirm that LPBF-relevant solidification conditions strongly promote the development of banded microstructures in a Mg–Nd alloy. Simulations also allow us to peer into the sub-micrometer nanosecond-scale details of the solid–liquid interface evolution giving rise to the distinctive banded patterns. Since rapidly solidified Mg alloys may exhibit significantly different mechanical and corrosion response compared to their cast counterparts, the ability to predict the emergence of rapid solidification microstructures (and to correlate them with local solidification conditions) may open new pathways for the design of bioresorbable orthopedic implants, not only fitted geometrically to each patient, but also optimized with locally-tuned mechanical and corrosion properties.
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快速凝固微结构在镁合金添加剂制造中的出现
可生物吸收的镁基合金具有低密度、低弹性模量和良好的生物相容性,是临时骨科植入物的理想候选材料。无独有偶,金属快速成型技术(AM)正在颠覆生物医学领域,为患者提供快速定制植入物。由于基于熔融的快速成型技术具有较高的冷却速度,因此通常被称为快速凝固工艺。然而,有关金属 AM 快速凝固的确凿观察结果却很少,这些观察结果表明,溶质截留、动力学过冷或固液界面形态转变会诱发微观结构的剧烈变化。在这里,我们结合先进的表征技术和最先进的热场与相场建模技术,研究了生物医学级镁稀土合金在激光粉末床熔融(LPBF)过程中形成的带状微结构。我们的实验明确确定了微结构是其他快速凝固过程中已知的振荡带状不稳定性的结果。我们的模拟证实,与 LPBF 相关的凝固条件强烈促进了 Mg-Nd 合金中带状微结构的发展。模拟还使我们能够窥探到导致独特带状图案的固液界面演变的亚微米纳秒级细节。由于快速凝固的镁合金与铸造的镁合金相比,在机械性能和腐蚀反应方面可能会有很大不同,因此预测快速凝固微结构的出现(并将其与局部凝固条件相关联)的能力可能会为生物可吸收骨科植入物的设计开辟新的途径。
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来源期刊
CiteScore
3.30
自引率
5.60%
发文量
96
审稿时长
1.7 months
期刊介绍: Serving the multidisciplinary materials community, the journal aims to publish new research work that advances the understanding and prediction of material behaviour at scales from atomistic to macroscopic through modelling and simulation. Subject coverage: Modelling and/or simulation across materials science that emphasizes fundamental materials issues advancing the understanding and prediction of material behaviour. Interdisciplinary research that tackles challenging and complex materials problems where the governing phenomena may span different scales of materials behaviour, with an emphasis on the development of quantitative approaches to explain and predict experimental observations. Material processing that advances the fundamental materials science and engineering underpinning the connection between processing and properties. Covering all classes of materials, and mechanical, microstructural, electronic, chemical, biological, and optical properties.
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