About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing of Metals: Multiscale and Non-Equilibrium Solidification Fundamentals
|
| Presentation Title |
Multilayer CFD Simulation and Crack Susceptibility Analysis in Graded Inconel 718–SS 316 DED Builds |
| Author(s) |
Tishta Das, Sourav Goswami, Shyamprasad Karagadde |
| On-Site Speaker (Planned) |
Tishta Das |
| Abstract Scope |
This work presents CFD-based thermal simulation framework to analyze temperature evolution and crack susceptibility during multi-material Directed Energy Deposition (DED) of IN 718 and SS 316. Multi-layer builds, up to six layers, were simulated for two compositionally graded systems: IN 718-rich (85% IN 718 + 15% SS 316) and SS-rich (15% IN 718 + 85% SS 316), using Goldak’s double-ellipsoidal heat source and process parameters (1100 W laser power, 7.5 mm/s scan speed). Temperature gradients and cooling rates were extracted from spatially resolved thermal profiles. Single-layer simulations were validated with thermocouple measurements. Crack-prone regions were predicted using the RDG-Kous Critical Solidification Indicator (CSI) method. Results reveal that IN 718-rich compositions exhibit higher thermal gradients and cooling rates, resulting in increased crack susceptibility near the melt pool boundary under low energy densities. This study provides a multiscale, physics-informed approach to optimize material combinations and process strategies in dissimilar alloy DED applications. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Solidification |