ICME framework to simulate microstructure evolution during laser powder bed fusion of Haynes 282 nickel-based superalloy

Haynes 282 is a creep-resistant, γ′ strengthened nickel-based superalloy with excellent weldability. Additive manufacturing, especially laser powder bed fusion (LPBF), of Haynes 282 is being researched for its potential applications in aerospace and power generation sectors. LPBF enables us to achieve desired properties via microstructure control through process parameter optimization. Integrated computational materials engineering (ICME) approach can be used to tune the process parameters to obtain desired microstructure, instead of trial-and-error methods. In this report, ICME framework has been established to simulate microstructural evolution during LPBF and post-processing of Haynes 282. A dimensionless number was used to optimize the process parameters with minimal porosity. Thermal modelling was performed using a semi-analytical model and the obtained thermal data was used to simulate solidification during LPBF. The corresponding cell spacing obtained matched closely with the experimental data. The segregation pattern extracted from the phase-field model was used as input for homogenization simulation. The γ′ precipitate evolution was predicted using Langer–Schwartz theory and Kampmann–Wagner-Numerical (KWN) approach. The predicted values agreed with the experimentally measured values. The room temperature yield strength of as-built samples was comparable and that of heat-treated samples were superior to the aged wrought material.