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Meeting 2027 TMS Annual Meeting & Exhibition
Symposium Algorithms Development in Materials Science and Engineering
Presentation Title Quantitative Phase-Field Benchmarking of Eutectic Fraction in Laser-Deposited Hypoeutectic Al–Si
Author(s) Husam M. Alrehaili
On-Site Speaker (Planned) Husam M. Alrehaili
Abstract Scope Predictive computational approaches to microstructure evolution in additive manufacturing (AM) still require experimental benchmarking, and the effect of rapid solidification on non-equilibrium phase selection remains incompletely understood. In laser metal deposition of hypoeutectic Al-Si, measured eutectic fractions deviate from equilibrium predictions, variously attributed to solute trapping, kinetic shift of the eutectic point, or solute supersaturation of alpha-Al; mechanisms not yet discriminated against a common physics-based reference. This work establishes a quantitative phase-field model (Echebarria-Folch-Karma-Plapp formulation) driven by process-derived thermal gradients and solidification velocities across 3.5-7.5 wt.% Si, with eutectic fractions extracted by composition thresholding mirroring SEM analysis. Simulated and measured fractions agree within 5% at 3.5 wt.% Si but diverge by 20-23% at higher silicon; this divergence is decomposed into α-Al supersaturation (1.3-1.4x equilibrium solubility) and quantification contributions. A velocity sensitivity study identifies growth conditions consistent with experiments, establishing phase-field simulation as a verification-and-validation benchmark for AM microstructure quantification.
Proceedings Inclusion? Planned:
Keywords Phase Transformations, Aluminum, Additive Manufacturing

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