| Abstract Scope |
I will present our high-fidelity models of multi-component/material additive manufacturing with chemical reactions. The first scenario is oxidation, which is inevitable. Our high-fidelity model reproduces oxidation (also other gas-liquid metal reactions), oxygen mass transport, and the effect on molten pool flow. The second scenario is AM of mixed powders for particle-reinforced composites, and we developed high-fidelity models for both micro- and nano- particles considering size effects. The third scenario is AM of mixed powders for in-situ alloying, where our model enables synergistic design of alloy compositions and AM parameters. We developed phase field and cellular automaton models to simulate grain and dendrite evolutions, incorporating the effects of nano-particles, melt flow and locally varied solute concentration, providing guidance for the design of new AM alloys with intrinsic hot cracking resistance. Finally, we leveraged crystal plasticity simulation and in-situ tensile experiments to reveal how the heterogeneous structures impact mechanical properties. |