Modelling of Marangoni effects in electron beam melting

Restricted accessMoreSectionsView PDF ToolsAdd to favoritesDownload CitationsTrack Citations ShareShare onFacebookTwitterLinked InRedditEmail Cite this article 1998Modelling of Marangoni effects in electron beam meltingPhil. Trans. R. Soc. A.3561027–1043http://doi.org/10.1098/rsta.1998.0207SectionRestricted accessModelling of Marangoni effects in electron beam melting Published:15 April 1998https://doi.org/10.1098/rsta.1998.0207AbstractElectron beam melting processes exhibit large thermal gradients in the region where the electron beam intercepts the melt; this leads to variations in the surface energy of the melt close to the beam inducing thermocapillary (Marangoni) flow. During melt processing of many materials the Marangoni contribution can dominate the fluid flow, influencing the trajectories of inclusions within the melt and providing a potential mechanism for controlling the removal and/or distribution of inclusions. A model of the macroscopic fluid flow and heat transfer, incorporating Marangoni effects, during electron beam melting has been developed and validated against surface flow observations during the electron beam button melting (EBBM) of IN718. The model indicates, and experimental observation confirms, that fluid flow in the molten pool is dominated by thermocapillary (Marangoni) forces, for the scale and operating conditions of the EBBM process. It is, therefore, possible to reverse the fluid flow through modification of the surface energy.The effect of altering the concentration of sulphur, which is a highly surface active element, upon the Marangoni flow was determined both experimentally and computationally. The implications of altering this concentration on the effectiveness of inclusion removal and final material quality are discussed. Previous ArticleNext Article VIEW FULL TEXT DOWNLOAD PDF FiguresRelatedReferencesDetailsCited by Siao Y and Wen C (2021) Thermal analysis of anisotropic heat conduction model with experimental validation on molten pool during selective laser melting, Materials Today Communications, 10.1016/j.mtcomm.2021.102425, 27, (102425), Online publication date: 1-Jun-2021. Niu S, Zhao L, You X, Wang Y and Tan Y (2021) Evaporation for element Al in K417 Ni-based superalloy during electron beam remelting, Vacuum, 10.1016/j.vacuum.2021.110073, 187, (110073), Online publication date: 1-May-2021. Imbrogno S, Alhuzaim A and Attallah M (2021) Influence of the laser source pulsing frequency on the direct laser deposited Inconel 718 thin walls, Journal of Alloys and Compounds, 10.1016/j.jallcom.2020.158095, 856, (158095), Online publication date: 1-Mar-2021. Siao Y and Wen C (2021) Influence of process parameters on heat transfer of molten pool for selective laser melting, Computational Materials Science, 10.1016/j.commatsci.2021.110388, 193, (110388), Online publication date: 1-Jun-2021. Siao Y and Wen C (2021) Examination of molten pool with Marangoni flow and evaporation effect by simulation and experiment in selective laser melting, International Communications in Heat and Mass Transfer, 10.1016/j.icheatmasstransfer.2021.105325, 125, (105325), Online publication date: 1-Jun-2021. Arjunan A, Demetriou M, Baroutaji A and Wang C (2020) Mechanical performance of highly permeable laser melted Ti6Al4V bone scaffolds, Journal of the Mechanical Behavior of Biomedical Materials, 10.1016/j.jmbbm.2019.103517, 102, (103517), Online publication date: 1-Feb-2020. Morciano M, Fasano M, Boriskina S, Chiavazzo E and Asinari P (2020) Solar passive distiller with high productivity and Marangoni effect-driven salt rejection, Energy & Environmental Science, 10.1039/D0EE01440K, 13:10, (3646-3655) Gruber H, Luchian C, Hryha E and Nyborg L (2020) Effect of Powder Recycling on Defect Formation in Electron Beam Melted Alloy 718, Metallurgical and Materials Transactions A, 10.1007/s11661-020-05674-8, 51:5, (2430-2443), Online publication date: 1-May-2020. Polonsky A, Raghavan N, Echlin M, Kirka M, Dehoff R and Pollock T (2020) 3D Characterization of the Columnar-to-Equiaxed Transition in Additively Manufactured Inconel 718 Superalloys 2020, 10.1007/978-3-030-51834-9_97, (990-1002), . Temmler A, Pirch N, Luo J, Schleifenbaum J and Häfner C (2020) Numerical and experimental investigation on formation of surface structures in laser remelting for additive-manufactured Inconel 718, Surface and Coatings Technology, 10.1016/j.surfcoat.2020.126370, 403, (126370), Online publication date: 1-Dec-2020. Niu S, Yin K, You Q, You X, Wang Y and Tan Y (2019) The alloying elements dispersion and its mechanisms in a Ni-based superalloy during electron beam remelting, Vacuum, 10.1016/j.vacuum.2019.04.055, 166, (107-113), Online publication date: 1-Aug-2019. Ma T, Guzman-Pichardo J, Klein L, Jitianu A, Singer J, Račiukaitis G, Makimura T and Molpeceres C (2019) Focused laser spike (FLaSk) thermocapillary patterning of micro/nanostructures Laser Applications in Microelectronic and Optoelectronic Manufacturing (LAMOM) XXIV, 10.1117/12.2507662, 9781510624528, (39) Shi S, Li P, Sheng Z, Jiang D, Tan Y, Wang D, Wen S and Asghar H (2019) Energy efficiency improvement in electron beam purification of silicon by using graphite lining, Energy, 10.1016/j.energy.2019.07.038, 185, (102-110), Online publication date: 1-Oct-2019. Wei H, Knapp G, Mukherjee T and DebRoy T (2019) Three-dimensional grain growth during multi-layer printing of a nickel-based alloy Inconel 718, Additive Manufacturing, 10.1016/j.addma.2018.11.028, 25, (448-459), Online publication date: 1-Jan-2019. You Q, Yuan H, Zhao L, Li J, You X, Shi S, Tan Y and Ding X (2018) Removal of inclusions from nickel-based superalloy by induced directional solidification during electron beam smelting, Vacuum, 10.1016/j.vacuum.2018.07.014, 156, (39-47), Online publication date: 1-Oct-2018. You Q, Tan Y, Zhao L, Li P, Li H, Liu H, Li J and Ding X (2018) Effects of electron beam smelting on removal of inclusions in nickel-based superalloys, Journal of Physics: Conference Series, 10.1088/1742-6596/1089/1/012014, 1089, (012014), Online publication date: 1-Sep-2018. Song J, Chew Y, Bi G, Yao X, Zhang B, Bai J and Moon S (2018) Numerical and experimental study of laser aided additive manufacturing for melt-pool profile and grain orientation analysis, Materials & Design, 10.1016/j.matdes.2017.10.033, 137, (286-297), Online publication date: 1-Jan-2018. Singer J (2017) Thermocapillary approaches to the deliberate patterning of polymers, Journal of Polymer Science Part B: Polymer Physics, 10.1002/polb.24298, 55:22, (1649-1668), Online publication date: 15-Nov-2017. Rai A, Helmer H and Körner C (2017) Simulation of grain structure evolution during powder bed based additive manufacturing, Additive Manufacturing, 10.1016/j.addma.2016.10.007, 13, (124-134), Online publication date: 1-Jan-2017. Sarychev V, Gromov V, Nevskii S, Nizovskii A and Konovalov S (2017) Nanolayer formation during hydrodynamic instability under external stimuli, Steel in Translation, 10.3103/S0967091216100132, 46:10, (679-685), Online publication date: 1-Oct-2016. Rai A, Markl M and Körner C (2016) A coupled Cellular Automaton–Lattice Boltzmann model for grain structure simulation during additive manufacturing, Computational Materials Science, 10.1016/j.commatsci.2016.07.005, 124, (37-48), Online publication date: 1-Nov-2016. Lee Y and Farson D (2015) Surface tension-powered build dimension control in laser additive manufacturing process, The International Journal of Advanced Manufacturing Technology, 10.1007/s00170-015-7974-5, 85:5-8, (1035-1044), Online publication date: 1-Jul-2016. Sercombe T, Xu X, Challis V, Green R, Yue S, Zhang Z and Lee P (2015) Failure modes in high strength and stiffness to weight scaffolds produced by Selective Laser Melting, Materials & Design, 10.1016/j.matdes.2014.10.063, 67, (501-508), Online publication date: 1-Feb-2015. Sarychev V, Nevskii S, Konovalov S, Komissarova I and Chermushkina E (2015) Thermocapillary model of formation of surface nanostructure in metals at electron beam treatment, IOP Conference Series: Materials Science and Engineering, 10.1088/1757-899X/91/1/012028, 91, (012028), Online publication date: 14-Sep-2015. Yu H, Xu Y, Song J, Pu J, Zhao X and Yao G (2015) On-line monitor of hydrogen porosity based on arc spectral information in Al–Mg alloy pulsed gas tungsten arc welding, Optics & Laser Technology, 10.1016/j.optlastec.2015.01.010, 70, (30-38), Online publication date: 1-Jul-2015. Lee Y, Nordin M, Babu S and Farson D (2014) Effect of Fluid Convection on Dendrite Arm Spacing in Laser Deposition, Metallurgical and Materials Transactions B, 10.1007/s11663-014-0054-7, 45:4, (1520-1529), Online publication date: 1-Aug-2014. Tan Y, Wen S, Shi S, Jiang D, Dong W and Guo X (2013) Numerical simulation for parameter optimization of silicon purification by electron beam melting, Vacuum, 10.1016/j.vacuum.2013.02.002, 95, (18-24), Online publication date: 1-Sep-2013. Ou J, Chatterjee A, Reilly C, Maijer D and Cockcroft S (2012) Computational Modeling of the Dissolution of Alloying Elements Supplemental Proceedings, 10.1002/9781118356074.ch109, (871-878) Yuan L and Lee P (2010) Dendritic solidification under natural and forced convection in binary alloys: 2D versus 3D simulation, Modelling and Simulation in Materials Science and Engineering, 10.1088/0965-0393/18/5/055008, 18:5, (055008), Online publication date: 1-Jul-2010. Shevchenko D and Ward R (2008) Liquid Metal Pool Behavior during the Vacuum Arc Remelting of INCONEL 718, Metallurgical and Materials Transactions B, 10.1007/s11663-008-9206-y, 40:3, (263-270), Online publication date: 1-Jun-2009. Safdar S, Li L and Sheikh M (2007) Numerical analysis of the effects of non-conventional laser beam geometries during laser melting of metallic materials, Journal of Physics D: Applied Physics, 10.1088/0022-3727/40/2/039, 40:2, (593-603), Online publication date: 21-Jan-2007. Tin S, Lee P, Kermanpur A, McLean M and Rist M (2005) Integrated modeling for the manufacture of Ni-based superalloy discs from solidification to final heat treatment, Metallurgical and Materials Transactions A, 10.1007/s11661-005-0123-2, 36:9, (2493-2504), Online publication date: 1-Sep-2005. Ritchie M, Lee P, Mitchell A, Cockcroft S and Wang T (2003) X-ray-based measurement of composition during electron beam melting of AISI 316 stainless steel: Part II. Evaporative processes and simulation, Metallurgical and Materials Transactions A, 10.1007/s11661-003-0120-2, 34:3, (863-877), Online publication date: 1-Mar-2003. Quested, P, Brooks, R and Monaghan, B The Prediction of Thermophysical Properties for Modelling Solidification of Metallic Melts, High Temperature Materials and Processes, 10.1515/HTMP.2003.22.5-6.247, 22:5-6, (247-256) Ritchie M, Lee P, Mitchell A, Cockcroft S and Wang T (2003) X-ray-based measurement of composition during electron beam melting of AISI 316 stainless steel: Part II. Evaporative processes and simulation, Metallurgical and Materials Transactions A, 10.1007/s11661-003-1013-0, 34:13, (863-877), Online publication date: 1-Mar-2003. Goldstein R, Eckert E, Ibele W, Patankar S, Simon T, Kuehn T, Strykowski P, Tamma K, Bar-Cohen A, Heberlein J, Davidson J, Bischof J, Kulacki F, Kortshagen U and Garrick S (2001) Heat transfer: a review of 1998 literature, International Journal of Heat and Mass Transfer, 10.1016/S0017-9310(00)00117-4, 44:2, (253-366), Online publication date: 1-Aug-2001. Halali M, McLean M and West D (2013) Effects of flux additions on inclusion removal and microstructure in electron beam button melting of Udimet 720, Materials Science and Technology, 10.1179/026708300101508018, 16:4, (427-430), Online publication date: 1-Apr-2000. Clark S, Leung C, Chen Y, Sinclair L, Marussi S and Lee P (2020) Capturing Marangoni flow via synchrotron imaging of selective laser melting, IOP Conference Series: Materials Science and Engineering, 10.1088/1757-899X/861/1/012010, 861, (012010) Konovalov S, Chen X, Sarychev V, Nevskii S, Gromov V and Trtica M (2016) Mathematical Modeling of the Concentrated Energy Flow Effect on Metallic Materials, Metals, 10.3390/met7010004, 7:1, (4) This Issue15 April 1998Volume 356Issue 1739Discussion Meeting Issue ‘Marangoni and interfacial phenomena in materials processing’ organized by E. D. Hondros, M. McLean and K. C. Mills Article InformationDOI:https://doi.org/10.1098/rsta.1998.0207Published by:Royal SocietyPrint ISSN:1364-503XOnline ISSN:1471-2962History: Published online15/04/1998Published in print15/04/1998 License: Citations and impact Keywordssuperalloyssolidification modellingMarangoni flowelectron beam button melting