A sensitivity analysis of the columnar-to-equiaxed transition for Ni-based superalloys in electron beam additive manufacturing

Solidification conditions experienced during Selective-Electron Beam Melting (S-EBM) of Nickel-Base superalloys generally lead to epitaxial grain growth from previous layers, resulting in highly textured columnar grain structures, and consequently, highly anisotropic mechanical properties. However, in recent work, researchers have been able to produce equiaxed grain structures by changing the scan strategy to influence the solidification conditions, thereby obtaining isotropic properties. The competition between columnar and equiaxed grain formation is governed by both the local thermal conditions and alloy thermodynamics. The above examples demonstrate successful manipulation of the thermal conditions through changes in process parameters. However, there is no guarantee that process conditions that encourage the formation of equiaxed grains for a given alloy will coincide with the production of defect free material. The goal of this work is therefore to understand the influence of alloy composition on the columnar-to-equiaxed transition (CET) so that alloys may be designed such that grain structure control is accessible to a wider range of S-EBM process conditions. A CET model originally developed by Hunt and extended by Gaumann was used to relate processing conditions to resulting microstructure. A sensitivity analysis of the CET model was performed using the Element Effects Methods. The results lead to a comparison of the relative effects of various alloying additions on the CET, as well as an assessment of other model parameters, including, most significantly, the nucleation density of equiaxed grains.