A multi-scale multi-physics modeling framework has been developed to predict solidification cracking susceptibility (SCS) during welding. The framework integrates a thermo-mechanical finite element model to simulate temperature and strain rate profiles during welding, a cellular automata model to simulate the solidified microstructure in the weld pool, and a granular model to calculate the pressure drop in the mushy zone. Verification was achieved by comparing the model’s predictions with welding experiments on two steels, demonstrating its capability to accurately capture the effects of process parameters, grain refinement, and alloy composition on SCS. Results indicate that increasing welding velocity, while maintaining a constant power-to-velocity ratio, extends the size of the mushy zone and increases the maximum pressure drop in the mushy zone, leading to higher SCS. Grain refinement decreases separation velocities and the permeability of liquid channels, which increases SCS, but it also raises the coalescence temperature, resulting in an overall reduction in SCS. Alloy composition impacts SCS through thermal diffusivity and segregation. Lower thermal diffusivity or stronger segregation tends to elongate the mushy zone, resulting in an increase in SCS. This framework provides a robust tool for understanding the mechanisms of solidification cracking, optimizing welding parameters to prevent its occurrence, and comparing SCS of different compositions during alloy design.@en

A cellular automata (CA) model has been developed for solidification simulation considering the kinetic undercooling at the interface. The state-of-the-art model incorporates a decentered growth algorithm to suppress the grid anisotropy and a generalized height function method to calculate the curvature accurately. To develop a CA model which is independent of the mesh size, a new diffusion term is proposed to handle the diffusion between the interface cells and liquid cells. The developed CA model is employed to simulate the single-dendritic solidification of an Al–3Cu (wt pct) alloy. The simulated tip velocities agree with the prediction of the Kurz–Giovanola–Trivedi (KGT) model. Further studies show that the developed CA model converges to an equilibrium model with increasing kinetic mobility values. Moreover, it is found that the virtual liquid cell assumption which is commonly used in existing CA models may lead to a deviation in the mass balance. The mass balance error has been resolved by redistributing solutes from neighboring liquid cells in each time step. The developed CA model could be potentially used in solidification simulations with a high undercooling, which is common in welding and additive manufacturing.

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Additive manufacturing offers a significant potential for producing metallic parts with distinctly localised microstructures and mechanical properties, commonly known as functional grading. While functional grading is generally accomplished through compositional variations or in-situ thermo-mechanical treatments, variation of process parameters during additive manufacturing can offer a promising alternative approach. Focusing on the electric arc-based additive manufacturing process, this work focuses on the functional grading of high-strength steel (S690 grade) by adjusting the travel speed and inter-pass temperature. Through a combination of thermal simulations and experimental measurements on single bead-on-plate depositions, it is shown that the microstructure and the mechanical properties of parts can be controlled through the rational adjustment of process parameters. A rectangular block was fabricated to demonstrate functional grading using a constant wire feed rate and varying travel speed. The rectangular block consisted of a low heat input (LHI) region deposited between high heat input (HHI) zones. A graded microstructure was obtained with the HHI zones composed of a mixture of polygonal ferrite, acicular ferrite, and bainite, while the LHI region was primarily composed of martensite. The hardness and profilometry-based indentation plastometry measurements indicated that the LHI region exhibited higher hardness (32%) and strength (50%), but lower uniform elongation (80%), compared to the HHI zones. The present study demonstrates the potential to achieve functional grading by adjusting process parameters in electric arc-based additive manufacturing, providing opportunities for tailor-made properties in parts.

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The absorptivity of a material is a major uncertainty in numerical simulations of laser welding and additive manufacturing, and its value is often calibrated through trial-and-error exercises. This adversely affects the capability of numerical simulations when predicting the process behaviour and can eventually hinder the exploitation of fully digitised manufacturing processes, which is a goal of “industry 4.0”. In the present work, an enhanced absorption model that takes into account the effects of laser characteristics, incident angle, surface temperature, and material composition is utilised to predict internal heat and fluid flow in laser melting of stainless steel 316L. Employing such an absorption model is physically more realistic than assuming a constant absorptivity and can reduce the costs associated with calibrating an appropriate value. High-fidelity three-dimensional numerical simulations were performed using both variable and constant absorptivity models and the predictions compared with experimental data. The results of the present work unravel the crucial effect of absorptivity on the physics of internal flow in laser material processing. The difference between melt-pool shapes obtained using fibre and CO2 laser sources is explained, and factors affecting the local energy absorption are discussed.@en

Molten metal melt pools are characterised by highly non-linear responses, which are very sensitive to imposed boundary conditions. Temporal and spatial variations in the energy flux distribution are often neglected in numerical simulations of melt pool behaviour. Additionally, thermo-physical properties of materials are commonly changed to achieve agreement between predicted melt-pool shape and experimental post-solidification macrograph. Focusing on laser spot melting in conduction mode, we investigated the influence of dynamically adjusted energy flux distribution and changing thermo-physical material properties on melt pool oscillatory behaviour using both deformable and non-deformable assumptions for the gas-metal interface. Our results demonstrate that adjusting the absorbed energy flux affects the oscillatory fluid flow behaviour in the melt pool and consequently the predicted melt-pool shape and size. We also show that changing the thermo-physical material properties artificially or using a non-deformable surface assumption lead to significant differences in melt pool oscillatory behaviour compared to the cases in which these assumptions are not made.

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Additive manufacturing (AM) is now recognised as a viable alternative to processes such as casting, forging, and subtractive technologies such as machining. Wire arc additive manufacturing (WAAM) has emerged as a cost-effective AM approach for component fabrication and a considerable body of literature on the subject has become available over the last 30 years. This review references the published work in a critical manner. It traces the development of WAAM, the principles of operation, materials considerations, process options, process physics, numerical simulation, process control, the current status and future research needs.

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Oxide dispersion-strengthened (ODS) Eurofer steel was laser welded using a short pulse duration and a designed pattern to minimise local heat accumulation. With a laser power of 2500 W and a duration of more than 3 ms, a full penetration can be obtained in a 1 mm thick plate. Material loss was observed in the fusion zone due to metal vaporisation, which can be fully compensated by the use of filler material. The solidified fusion zone consists of an elongated dual phase microstructure with a bimodal grain size distribution. Nano-oxide particles were found to be dispersed in the steel. Electron backscattered diffraction (EBSD) analysis shows that the microstructure of the heat-treated joint is recovered with substantially unaltered grain size and lower misorientations in different regions. The experimental results indicate that joints with fine grains and dispersed nano-oxide particles can be achieved via pulsed laser beam welding using filler material and post heat treatment. @en

Development, optimisation and qualification of welding and additive manufacturing procedures to date have largely been undertaken on an experimental trial and error basis, which imposes significant costs. Numerical simulations are acknowledged as a promising alternative to experiments, and can improve the understanding of the complex process behaviour. In the present work, we propose a simulation-based approach to study and characterise molten metal melt pool oscillatory behaviour during arc welding. We implement a high-fidelity three-dimensional model based on the finite-volume method that takes into account the effects of surface deformation on arc power-density and force distributions. These factors are often neglected in numerical simulations of welding and additive manufacturing. Utilising this model, we predict complex molten metal flow in melt pools and associated melt-pool surface oscillations during both steady-current and pulsed-current gas tungsten arc welding (GTAW). An analysis based on a wavelet transform was performed to extract the time-frequency content of the displacement signals obtained from numerical simulations. Our results confirm that the frequency of oscillations for a fully penetrated melt pool is lower than that of a partially penetrated melt pool with an abrupt change from partial to full penetration. We find that during transition from partial to full penetration state, two dominant frequencies coexist in the time-frequency spectrum. The results demonstrate that melt-pool oscillations profoundly depend on melt-pool shape and convection in the melt pool, which in turn is influenced by process parameters and material properties. The present numerical simulations reveal the unsteady evolution of melt pool oscillatory behaviour that are not predictable from published theoretical analyses. Additionally, using the proposed simulation-based approach, the need of triggering the melt-pool oscillations is expendable since even small surface displacements are detectable, which are not sensible to the current measurement devices employed in experiments.
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Internal flow behaviour and melt-pool surface oscillations during arc welding are complex and not yet fully understood. In the present work, high-fidelity numerical simulations are employed to describe the effects of welding position, sulphur concentration (60-300 ppm) and travel speed (1.25-5 mms-1) on molten metal flow dynamics in fully-penetrated melt-pools. A wavelet transform is implemented to obtain time-resolved frequency spectra of the oscillation signals, which overcomes the shortcomings of the Fourier transform in rendering time resolution of the frequency spectra. Comparing the results of the present numerical calculations with available analytical and experimental datasets, the robustness of the proposed approach in predicting melt-pool oscillations is demonstrated. The results reveal that changes in the surface morphology of the pool resulting from a change in welding position alter the spatial distribution of arc forces and power-density applied to the molten material, and in turn affect flow patterns in the pool. Under similar welding conditions, changing the sulphur concentration affects the Marangoni flow pattern, and increasing the travel speed decreases the size of the pool and increases the offset between top and bottom melt-pool surfaces, affecting the flow structures (vortex formation) on the surface. Variations in the internal flow pattern affect the evolution of melt-pool shape and its surface oscillations.

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One of the challenges for development, qualification and optimisation of arc welding processes lies in characterising the complex melt-pool behaviour which exhibits highly non-linear responses to variations of process parameters. The present work presents a computational model to describe the melt-pool behaviour in root-pass gas metal arc welding (GMAW). Three-dimensional numerical simulations have been performed using an enhanced physics-based computational model to unravel the effect of groove shape on complex unsteady heat and fluid flow in GMAW. The influence of surface deformations on the magnitude and distribution of the heat input and the forces applied to the molten material were taken into account. Utilising this model, the complex thermal and fluid flow fields in melt pools were visualised and described for different groove shapes. Additionally, experiments were performed to validate the numerical predictions and the robustness of the present computational model is demonstrated. The model can be used to explore the physical effects of governing fluid flow and melt-pool stability during gas metal arc root welding. @en

Oxide dispersion strengthened (ODS) steels are leading candidates for structural materials in nuclear fission and fusion power plants. Understanding the nature of nano-oxide particles in ODS steels is vital for a better control of the microstructure and mechanical properties to further their applications. In this study, electron microscopy and atom probe tomography (APT) have been used to investigate the nanocluster features in ODS Eurofer steel. With the addition of V and Ta in ODS Eurofer, the nanoclusters exhibit a higher number density with a decreased average diameter, indicating that V and Ta are beneficial for the formation of small clusters. Irrespective of the composition of the base material, the smaller particles have a variable stoichiometry while the larger particles are likely to have Y₂O₃ stoichiometry. The nanoclusters were found to have a core/shell structure, where Y, O and Ta are enriched in the core and Cr and V are predominant in the shell. The formation of the complex structure is possibly the result of a competing effect between Ta, Y, V and Cr binding with O. It is deduced that Ta tends to combine with O in the core (Y₂O₃) of the clusters due to a higher affinity, and pushes V and Cr to the surrounding shell during the formation of nanoclusters.

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The present work deals with oxide dispersion strengthened (ODS) Eurofer steel fabricated by powder metallurgy involving mechanical alloying and spark plasma sintering. A heat treatment route including normalising and tempering was applied to the as-produced steel, based on differential scanning calorimetry (DSC) measurement. The microstructure was characterised by scanning electron microscopy (SEM), electron backscattered diffraction (EBSD), electrolytic extraction, X-ray diffraction (XRD) and transmission electron microscopy (TEM). Thermodynamic calculations conducted using Thermo-Calc software were used to determine the precipitation conditions. The results show that the Vickers microhardness of the sample after the designed heat treatment is more uniform compared to the as-produced condition. A dual phase and bimodal microstructure is formed in the as-produced and tempered steels. M₂₃C₆ and M₆C carbides were found in the as-produced sample while only M₂₃C₆ carbides were observed in the tempered sample. The carbides dissolve and reprecipitate during the heat treatment, preferably at the grain boundaries. Nanosized Y₂O₃ particles were found to be homogenously distributed in the steel matrix, which is crucial for the mechanical properties. The dislocation density in the material is decreased significantly after the normalising and tempering treatment. A yield strength model was developed that includes the strengthening contributions of solid solutes, grain size, dislocation density and nanoparticles. Good agreement is obtained between the experimentally measured and theoretically calculated strength of the as-produced and tempered steels.

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Oxide dispersion strengthened (ODS) steels are considered to be one of the candidate structural materials for advanced nuclear applications due to their high elevated-temperature strength, corrosion resistance, and radiation tolerance. Joining of ODS steels by traditional fusion joining techniques is not applicable, because the melting process results in the coarsening of fine grains and agglomeration of nanosized oxide particles, and consequently a significant loss of strength. Spark plasma sintering (SPS) has recently been employed as a novel joining technique, which could be beneficial for joining ODS steels considering the solid state characteristic. A powder metallurgy prepared ODS Eurofer steel was successfully joined using SPS. The microstructure and mechanical properties of the joints were investigated. An almost defect-free joint was obtained at the selected processing condition. The tensile properties of the joints are comparable to the base material. Fracture analysis shows an intergranular fracture in the as-joined sample, while a ductile fracture with well-defined dimples is found in the tempered sample.

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Pulsed laser beam welding was used successfully to join the oxide dispersion-strengthened (ODS) Eurofer steel. The joining was conducted with a laser power of 2500 W and a pulsed duration of 4 ms. With the filler material being used, a minor material loss and microvoids were observed in the joint. The microstructure of the fusion zone consists of dual phase elongated structures. The heat-affected zone has a width of around 0.06 mm with finer grains. The transmission electron microscopy observation reveals that nanoprecipitates are finely distributed in the fusion zone. The tensile strength, yield strength and elongation of the joint are slightly inferior to the base material. The fractography results reveal a typical ductile fracture. The experimental results indicate a reasonable joint from the perspective of both the microstructure and mechanical behaviour.

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The high degree of uncertainty and conflicting literature data on the value of the permeability coefficient (also known as the mushy zone constant), which aims to dampen fluid velocities in the mushy zone and suppress them in solid regions, is a critical drawback when using the fixed-grid enthalpy-porosity technique for modelling non-isothermal phase-change processes. In the present study, the sensitivity of numerical predictions to the value of this coefficient was scrutinised. Using finite-volume based numerical simulations of isothermal and non-isothermal melting and solidification problems, the causes of increased sensitivity were identified. It was found that depending on the mushy-zone thickness and the velocity field, the solid–liquid interface morphology and the rate of phase-change are sensitive to the permeability coefficient. It is demonstrated that numerical predictions of an isothermal phase-change problem are independent of the permeability coefficient for sufficiently fine meshes. It is also shown that sensitivity to the choice of permeability coefficient can be assessed by means of an appropriately defined Péclet number.
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This paper studies the joining of an oxide dispersion strengthened (ODS) steel without destroying the microstructure and thereby deteriorating the mechanical performance. ODS Eurofer was successfully joined by spark plasma sintering (SPS) at 1373 K with a heating rate of 100 K/min and a pressure of 80 MPa. An almost defect-free joint was obtained with a holding time of 40 min and a powder layer between the steel disks. The fine-grained microstructure and homogeneously distributed nanoparticles in the material show no significant change after the joining process. The tensile properties of the joint material are comparable to the base material. SPS has been proven to be a promising technique to join ODS steels due to the good mechanical properties of the joints.

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Oxide dispersion strengthened (ODS)Eurofer steel was prepared via mechanical alloying (MA)and spark plasma sintering (SPS). Different combinations of MA and SPS parameters were adopted in order to optimise the fabrication process. The experimental results show that the sample milled for 30 h, sintered at 1373 K at a pressure of 60 MPa has the highest density and microhardness among all the results obtained. As-produced ODS Eurofer shows a bimodal microstructure with homogeneously dispersed nanoscale Y ₂ O ₃ , that is beneficial for the mechanical properties. The yield and tensile strengths are higher while the elongation is lower in the top and bottom surfaces compared to the middle area of the sample. This is due to the presence of a larger number of M ₂₃ C ₆ carbides, resulting from carbon diffusion from the mould material. As-produced samples were also subjected to a heat treatment. A good balance is achieved between the strength and ductility of the heat-treated material. Yielding properties comparable to hot isostatic pressing or hot extrusion as reported in the literature, the processing route presented by this study shows potential to produce high performance ODS Eurofer.

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Heat and fluid flow in low Prandtl number melting pools during laser processing of materials are sensitive to the prescribed boundary conditions, and the responses are highly nonlinear. Previous studies have shown that fluid flow in melt pools with surfactants can be unstable at high Marangoni numbers. In numerical simulations of molten metal flow in melt pools, surface deformations and its influence on the energy absorbed by the material are often neglected. However, this simplifying assumption may reduce the level of accuracy of numerical predictions with surface deformations. In the present study, we carry out three-dimensional numerical simulations to realise the effects of surface deformations on thermocapillary flow instabilities in laser melting of a metallic alloy with surfactants. Our computational model is based on the finite-volume method and utilises the volume-of-fluid (VOF) method for gas-metal interface tracking. Additionally, we employ a dynamically adjusted heat source model and discuss its influence on numerical predictions of the melt pool behaviour. Our results demonstrate that including free surface deformations in numerical simulations enhances the predicted flow instabilities and, thus, the predicted solid-liquid interface morphologies.@en