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Cross-Scale Simulation Research on the Macro/Microstructure of TC4 Alloy Wire Laser Additive Manufacturing

A cross-scale model of macro-micro coupling is established for the wire laser additive manufacturing process of the TC4 titanium alloy. The model reproduces the dynamic evolution process of the molten pool shape, reveals the temperature change law in the molten pool, and simulates the microstructure and morphology of different regions of the molten pool. Finally, the model is used to quantitatively analyze the effects of process parameters (laser power, scanning speed) on the growth morphology of dendrites during solidification. The research shows that with the increase in laser power and the decrease in scanning speed, the peak temperature of the molten pool increases rapidly, and the size of the molten pool increases gradually. When the laser scanning speed is greater than 5 mm/s, the molten pool length decreases significantly. After solidification, an asymmetrically distributed equiaxed grain structure is formed at the upper part of the molten pool, the bottom of the molten pool is made up of slender columnar crystals, and the columnar-to-equiaxed transition (CET) occurs in the middle of the molten pool. With the decrease in laser power and the increase in scanning speed, the growth rate of dendrites becomes faster, the arm spacing and the overall morphology of dendrites become smaller, and the arrangement of columnar crystals have a tighter microstructure.