Solute segregation in a rapidly solidified Hastelloy-X Ni-based superalloy during laser powder bed fusion investigated by phase-field and computational thermal-fluid dynamics simulations

Solute segregation significantly affects material properties and is a critical issue in the laser powder-bed fusion (LPBF) additive manufacturing (AM) of Ni-based superalloys. In this study, we demonstrated a computational thermal-fluid dynamics (CtFD) simulation coupled multi-phase-field (MPF) simulation with a multicomponent-composition model of Ni-based superalloy to predict solute segregation under solidification conditions in LPBF. Solute segregation at the various interfacial regions of Ni-based multicomponent alloys could be predicted by the conventional MPF simulation. The design of crack-free Ni-based superalloys can be expedited by MPF simulations of a broad range of element combinations and their concentrations in multicomponent Ni-based superalloys.