Phase-field simulation of solidification morphology in laser powder deposition of Ti–Nb alloys

A phase-field model of alloy solidification is coupled to a new heat transfer finite element model of the laser powder deposition process. The robustness and accuracy of the coupled model is validated by studying spacing evolution under the directional solidification conditions in laser powder deposition of Ti–Nb alloys. Experimental Ti–Nb samples reveal the microstructure on a longitudinal section with significant change in the size of the dendrites across the sample. Quantitative phase-field simulations of directional solidification under local steady-state conditions extracted from the results of the finite element thermal model confirmed this behavior. Specifically, the phase-field simulations agree with the results of the analytical model of Hunt in predicting a minimum spacing value, which is due to the mutual effects of the increasing temperature gradient and decreasing solidification velocity towards the bottom of the microstructure. This work demonstrates the potential of coupling the phase-field method to complex heat transfer conditions necessary to simulate topologically complex microstructure morphologies present in laser powder deposition and other industrially relevant casting conditions.