Effects of melt-pool geometry on crystal growth and microstructure development in laser surface-melted superalloy single crystals: Mathematical modeling of single-crystal growth in a melt pool (part I)
Abstract The effects of melt-pool geometrical parameters on crystal growth and microstructure development during laser surface melting of single-crystal alloys were studied by means of mathematical modeling and experiments. A mathematical model was developed for the three-dimensional (3-D) melt-pool geometry and single-crystalline melt-pool solidification in laser surface melting. The 3-D melt-pool geometry corresponding to the solidification interface is described by four geometrical parameters ( w , l , h , α ). The model was used to study the effects of variations in the geometrical parameters on crystal growth and microstructure development in the melt pool. Laser surface melting experiments with single-crystal nickel-base superalloys were conducted to verify the computational results of microstructure development in the melt pool. Results indicate that the melt-pool geometrical parameters have profound influences on the dendrite growth velocity and growth pattern in the melt pool. For the (0 0 1)/[1 0 0] substrate orientation, variations in l / w and α can influence both the number and the relative sizes of growth regions while the variation in h / w can only influence the relative sizes of the growth regions. Unidirectional dendrite growth along the [0 0 1] crystallographic direction can be achieved for an α value of 45° or below. The maximum ratio of dendrite-growth velocity to the beam velocity in the melt pool is related to α and l / w . Experimental microstructure observations agreed well with the computational results. These findings show that the desired dendrite growth velocity and microstructure can be obtained through proper control of the 3-D melt-pool geometry.
Laser-beam and photon-assisted processed materials and their microstructures
Laser processing is a relatively new technique for modifying the near-surface region of materials without altering the in-bulk characteristics. A single laser can perform several functions by manipulating processing conditions such as laser power, beam diameter, and traverse speed. Lasers have shown attractive applications, such as cutting, welding, glazing, alloying, and cladding. A laser glazing process has demonstrated an improvement in the microstructure of vacuum plasma-coated copper-based alloys containing cavities, unmelted particles, and segregation. Laser glazing has also been shown to restore the degraded microstructure of components and make them equivalent to, or better than, the original wrought alloy. The laser cladding concept was used to develop nickel-based alloys for high-temperature applications that exhibited higher thermal stability than the nickel-based Rene-95 alloy. Rapid melting and quenching occurred during the laser glazing, alloying, and cladding processes resulting in a fine-grained microstructure, metastable phases and extended solid solubility of alloying additions in the matrix.Photon-assisted processing of material is a relatively new technique being explored to synthesize new materials from various substrates (solid, liquid, and gas). This process is successfully used to fabricate high-quality thin films for electronic industries. Thin films of multicomponents can be deposited with stoichiometric composition. Diamond thin films have been synthesized from liquid hydrocarbon (Benzene, C6H6) by laser-liquid hydrocarbon-substrate interaction. A laser-assisted physical vapour deposition process was found to be very successful in depositing stoichiometric compositions of multilayered thin films such as superconducting YBa2Cu3O7, ferroelectric Pb0.52Zr0.48TiO3 and other coatings such as TiN and CoSi2. This review reports some of the major advances in the understanding and engineering of new materials for electronic industries and high-temperature applications in the auto, aerospace, and turbine industries.
The microscale obstacle-resolving meteorological model MITRAS v2.0: model theory
Abstract. This paper describes the developing theory and underlying
processes of the microscale obstacle-resolving model MITRAS version 2. MITRAS
calculates wind, temperature, humidity, and precipitation fields, as well as
transport within the obstacle layer using Reynolds averaging. It explicitly
resolves obstacles, including buildings and overhanging obstacles, to
consider their aerodynamic and thermodynamic effects. Buildings are
represented by impermeable grid cells at the building positions so that the
wind speed vanishes in these grid cells. Wall functions are used to calculate
appropriate turbulent fluxes. Most exchange processes at the obstacle
surfaces are considered in MITRAS, including turbulent and radiative
processes, in order to obtain an accurate surface temperature. MITRAS is also
able to simulate the effect of wind turbines. They are parameterized using
the actuator-disk concept to account for the reduction in wind speed. The
turbulence generation in the wake of a wind turbine is parameterized by
adding an additional part to the turbulence mechanical production term in the
turbulent kinetic energy equation. Effects of trees are considered
explicitly, including the wind speed reduction, turbulence production, and
dissipation due to drag forces from plant foliage elements, as well as the
radiation absorption and shading. The paper provides not only
documentation of the model dynamics and numerical framework but also a solid
foundation for future microscale model extensions.
