Analysis of the Effect of Magnetic Field on Solidification of Stainless Steel in Laser Surface Processing and Additive Manufacturing
Abstract
:1. Introduction
2. Experimental Methodology and Microstructure Assessment
- (1)
- Comparison of the histograms in Figure 5a–d, respectively, shows that the microstructure under the effect of magnetic fields is more homogeneous, and the spread in grain sizes is smaller with EMAT turned on than with EMAT turned off. The fraction of grains with an area of less than 2 µm2 or more than 15 µm2 become smaller. Presumably, the reason for this is alignment of the flow conditions near the solidification front under the influence of an electromagnetic field. Random oscillations of the convective currents from uneven laser exposure are excluded that impacts on the spatial distribution of chemical components and microsegregation.
- (2)
- The initial microstructure was characterized by an average grain area of ~30 µm2 and a median grain area of ~20 µm2. With a single laser pass, no statistically significant differences between the modes with EMAT turned off/on were detected: the average areas were 6.5 and 7.4 µm2, respectively, while the median areas were 4.5 and 5.6 µm2, respectively.
- (3)
- With five laser passes, the effect of magnetic fields leads to reduction of the number of large grains. A shift to the left (toward smaller grain areas) is clearly visible in the histograms in Figure 5c,d, respectively, when exposed to an EM field.
3. Relevant Physical Phenomena and Quantitative Estimation of the EM Field Effect
4. Effect of the Alternating EM Field on the Molten Pool
5. Effect of the Permanent Magnetic Field
6. Conclusions
- (1)
- It is confirmed experimentally that the EM field with the frequency of 100 kHz has a minor effect on the microstructure of stainless AISI 321H samples in comparison with ultrasound treatment induced by modulated laser processing.
- (2)
- The industrial parts produced by additive manufacturing techniques typically have lower plasticity in contrast to casted parts. We have received that additional EM treatment performed simultaneously with laser treatment yields a decrease of the grain’s area S (where an estimate of the grain size is related to S as d~√S) between 10% and 15%. At the same time, the histogram exhibits that the distribution becomes more narrow, i.e., the range of grain areas is smaller. The revealed effect is similar to microstructure homogenization known in heat treatment processing. The revealed new effect can facilitate the improvement of material performance owing to improvement of its plasticity.
- (3)
- The alternating magnetic field with the frequency up to 100 kHz is characterized by a skin penetration thickness in the range between 1 and 5 mm. Consequently, application of this additional exposure is more effective in laser annealing where the molten pool is sufficiently large and has the size of L ≥ 1 mm. This explains the physical background in the positive effect of applied electromagnetic fields during welding, which is noted in numerous studies available in the literature.
- (4)
- The alternating magnetic field results in the formation of the inhomogeneous Lorence force field that has a minor impact on convection in the molten pool in comparison with other physical factors of laser annealing. In the performed laboratory experiments, this effect is registered at the susceptibility threshold. The registered small modification of grain sizes can only be explained by the magnetic field effect, which is substantially mitigated by other physical phenomena in the molten pool.
- (5)
- According to the literature, the thermoelectrical Seebeck effect provides a meaningful impact on solidification of aluminum alloys owing to the intensification of convection in the zone of dendritic growth. For the case of stainless steel, it has been shown that this effect is small. It happens due to the following factors. First, the sensitivity Seebeck coefficient, which defines generation of thermoelectromotive force, is small for stainless steels. Second, the relaxation time of electromotive force is few orders of magnitude smaller than the time interval required for temperature stabilization in the molten pool.
Author Contributions
Funding
Informed Consent Statement
Conflicts of Interest
References
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Parameter | Symbol | Value | Units |
---|---|---|---|
Density of the solid phase | |||
Density of the melt | |||
Specific heat of the solid phase | J/kg | ||
Specific heat of the melt | J/kg | ||
Thermal conductivity of the solid phase | W/(K m) | ||
Thermal conductivity of the melt | W/(K m) | ||
Melting temperature | K | ||
Viscosity of the melt | Pa s | ||
Viscosity of the solid phase | Pa s | ||
Thermocapillary coefficient | |||
Velocity of the laser beam | m/s |
Magnetic Flux Density, T | Mean Temperature in the Molten Pool, K | Time-Averaged Maximum Flow Velocity in the Molten Pool, m/s | Spatially Averaged Flow Velocity in the Molten Pool, m/s |
---|---|---|---|
0 | 1949 | 1.879 | 0.378 |
0.1 | 1949 | 1.878 | 0.378 |
1 | 1949 | 1.879 | 0.377 |
10 | 1994 | 1.818 | 0.354 |
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Gruzd, S.A.; Lomaev, S.L.; Simakov, N.N.; Gordeev, G.A.; Bychkov, A.S.; Gapeev, A.A.; Cherepetskaya, E.B.; Krivilyov, M.D.; Ivanov, I.A. Analysis of the Effect of Magnetic Field on Solidification of Stainless Steel in Laser Surface Processing and Additive Manufacturing. Metals 2022, 12, 1540. https://doi.org/10.3390/met12091540
Gruzd SA, Lomaev SL, Simakov NN, Gordeev GA, Bychkov AS, Gapeev AA, Cherepetskaya EB, Krivilyov MD, Ivanov IA. Analysis of the Effect of Magnetic Field on Solidification of Stainless Steel in Laser Surface Processing and Additive Manufacturing. Metals. 2022; 12(9):1540. https://doi.org/10.3390/met12091540
Chicago/Turabian StyleGruzd, Svetlana A., Stepan L. Lomaev, Nikolay N. Simakov, Georgii A. Gordeev, Anton S. Bychkov, Artem A. Gapeev, Elena B. Cherepetskaya, Mikhail D. Krivilyov, and Ivan A. Ivanov. 2022. "Analysis of the Effect of Magnetic Field on Solidification of Stainless Steel in Laser Surface Processing and Additive Manufacturing" Metals 12, no. 9: 1540. https://doi.org/10.3390/met12091540