Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(Z...Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(ZCASW filler material,a novel filler)coupled with an oscillating laser-arc hybrid welding process,and we investigated the solidification cracking susceptibility(SCS)and cracking behavior of AA2024 weld fabricated with different filler materials.The cracking inhibition mechanism of the weld fabricated with ZCASW filler material was elucidated by combined experiments and phase-field simulation.The results show that the effectiveness of filler materials in reducing the SC gradually improves in the order of ER2319 filler material<ER4043 filler material<ZCASW filler material.The main cracking(when using the ER2319 filler material)branches and the micro cracking branches interact with each other to produce cracking coalescence,which aggravates the cracking propagation.The formation of the Al_(3) Zr phase(when using the ZCASW filler material)promotes heterogeneous nucleation of α-Al,thereby resulting in finer and equiaxed non-dendrite structures,which shortens the liquid phase channels and decreases cracking susceptibility index|d T/d(f_(s))^(1/2)|(T is temperature and f_(s) is solidification fraction)at final solidification.A higher proportion(7.65%area fraction)of inter-dendrite phase with spherical distribution state,a shorter(8.6 mm liquid channel length)inter-dendrite phase coupled with round non-dendrite structure(6μm dendrite size)effectively inhibit the SC.The present study can be a useful database for welding and additive manufacturing of AA2024.展开更多
In this study,a novel multi-physics multi-scale model with the dilute multicomponent phase-field method in three-dimensional(3D)space was developed to investigate the complex microstructure evolu-tion in the molten po...In this study,a novel multi-physics multi-scale model with the dilute multicomponent phase-field method in three-dimensional(3D)space was developed to investigate the complex microstructure evolu-tion in the molten pool during laser welding of Al-Li alloy.To accurately compute mass data within both two and three-dimensional computational domains,three efficient computing methods,including central processing unit parallel computing,adaptive mesh refinement,and moving-frame algorithm,were uti-lized.Emphasis was placed on the distinctive equiaxed-to-columnar-to-equiaxed transition phenomenon that occurs during the entire solidification process of Al-Li alloy laser welding.Simulation results indi-cated that the growth distance of columnar grains that epitaxially grew from the base metal(BM)de-creased as the nucleation rate increased.As the nucleation rate increased,the morphology of the newly formed grains near the fusion boundary(FB)changed from columnar to equiaxed,and newly formed equiaxed grains changed from having high-order dendrites to no obvious dendrite structure.When the nucleation rate was sufficiently high,non-dendritic equiaxed grains could directly form near the FB,and there was nearly no epitaxial growth from the BM.Additionally,simulation results illustrated the com-petition among multiple grains with varying orientations that grow in 3D space near the FB.Finally,how equiaxed grain bands develop was elucidated.The equiaxed band not only hindered the growth of early columnar grains but also some of its grains could grow epitaxially to form new columnar grains.These predicted results were in good agreement with experimental measurements and observations.展开更多
基金financially supported by the National Natural Science Foundation of China under Grant Nos.52305467,52188102,U22A20196,and 52075201the Guangdong Basic and Applied Basic Research Foundation Nos.2023A1515010081 and 2022B1212020003the Fundamental Research Funds for the Central Universities under Grant No.YCJJ20230360.
文摘Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(ZCASW filler material,a novel filler)coupled with an oscillating laser-arc hybrid welding process,and we investigated the solidification cracking susceptibility(SCS)and cracking behavior of AA2024 weld fabricated with different filler materials.The cracking inhibition mechanism of the weld fabricated with ZCASW filler material was elucidated by combined experiments and phase-field simulation.The results show that the effectiveness of filler materials in reducing the SC gradually improves in the order of ER2319 filler material<ER4043 filler material<ZCASW filler material.The main cracking(when using the ER2319 filler material)branches and the micro cracking branches interact with each other to produce cracking coalescence,which aggravates the cracking propagation.The formation of the Al_(3) Zr phase(when using the ZCASW filler material)promotes heterogeneous nucleation of α-Al,thereby resulting in finer and equiaxed non-dendrite structures,which shortens the liquid phase channels and decreases cracking susceptibility index|d T/d(f_(s))^(1/2)|(T is temperature and f_(s) is solidification fraction)at final solidification.A higher proportion(7.65%area fraction)of inter-dendrite phase with spherical distribution state,a shorter(8.6 mm liquid channel length)inter-dendrite phase coupled with round non-dendrite structure(6μm dendrite size)effectively inhibit the SC.The present study can be a useful database for welding and additive manufacturing of AA2024.
基金supported by the National Natural Science Foundation of China(Grant Nos.52075201,U22A20196,52188102)GuangDong Basic and Applied Basic Research Foundation(No.2023A1515010081).
文摘In this study,a novel multi-physics multi-scale model with the dilute multicomponent phase-field method in three-dimensional(3D)space was developed to investigate the complex microstructure evolu-tion in the molten pool during laser welding of Al-Li alloy.To accurately compute mass data within both two and three-dimensional computational domains,three efficient computing methods,including central processing unit parallel computing,adaptive mesh refinement,and moving-frame algorithm,were uti-lized.Emphasis was placed on the distinctive equiaxed-to-columnar-to-equiaxed transition phenomenon that occurs during the entire solidification process of Al-Li alloy laser welding.Simulation results indi-cated that the growth distance of columnar grains that epitaxially grew from the base metal(BM)de-creased as the nucleation rate increased.As the nucleation rate increased,the morphology of the newly formed grains near the fusion boundary(FB)changed from columnar to equiaxed,and newly formed equiaxed grains changed from having high-order dendrites to no obvious dendrite structure.When the nucleation rate was sufficiently high,non-dendritic equiaxed grains could directly form near the FB,and there was nearly no epitaxial growth from the BM.Additionally,simulation results illustrated the com-petition among multiple grains with varying orientations that grow in 3D space near the FB.Finally,how equiaxed grain bands develop was elucidated.The equiaxed band not only hindered the growth of early columnar grains but also some of its grains could grow epitaxially to form new columnar grains.These predicted results were in good agreement with experimental measurements and observations.
