Journal Article

PUBDB-2025-03879

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Phase-Separation-Driven Cracking in Additive Manufacturing of Ni-Cu Alloy Systems

Özsoy, A.Extern* ; Gaudez, S.Extern* ; Hearn, W. A.Extern* ; Baganis, A.Extern* ; Hegedüs, Z.DESY* ; Chen, Y.Extern* ; Rack, A.Extern* ; Logé, R. E. ; Van Petegem, S. (Corresponding author)Extern*

2025
Elsevier Amsterdam [u.a.]

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Please use a persistent id in citations: doi:10.1016/j.addma.2025.104950  doi:10.3204/PUBDB-2025-03879

Abstract: This study investigates the cracking mechanism in additive manufacturing of Ni-Cu multi-material combinations using operando X-ray diffraction and imaging experiments during laser powder-bed fusion (L-PBF) of CuCrZr and IN625. It is shown that liquid immiscibility between the two alloy systems stems from the interaction between Cu and the alloying elements in IN625, causing both Cu-rich and Ni-rich liquids to form with different freezing ranges. Consequently, solidification cracking takes place due to the large solidification range where the Ni-rich solid and Cu-rich liquid co-exist. Guided by thermodynamic calculations, it was identified that the highest crack susceptibility occurs between 20 and 40 wt% CuCrZr-IN625, which was further validated by printing mixtures of the two alloys in different ratios. Operando X-ray imaging and scanning electron microscopy characterization revealed that the cracking occurred during the terminal stage of solidification. It was observed that the columnar grains of the Ni-rich primary solid separate into cracks, where Cu-rich liquid regions persist over a wide temperature range as the solidification of these regions begin significantly later. It was concluded that the mechanism of cracking explained in this study could be extended to other Cu-Ni alloy combinations containing elements that induce immiscibility when mixed with Cu during fusion-based processing methods.

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Contributing Institute(s):

1. DOOR-User (DOOR ; HAS-User)
2. PETRA-D (FS-PETRA-D)

Research Program(s):

1. 632 - Materials – Quantum, Complex and Functional Materials (POF4-632) (POF4-632)
2. 6G3 - PETRA III (DESY) (POF4-6G3) (POF4-6G3)
3. PSI-FELLOW-III-3i - International, Interdisciplinary & Intersectoral Postdoctoral Fellowships at the Paul Scherrer Institut (884104) (884104)
4. FS-Proposal: I-20230515 EC (I-20230515-EC) (I-20230515-EC)

Experiment(s):

1. PETRA Beamline P21.2 (PETRA III)

Appears in the scientific report 2025

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Database coverage:
; ; ; Clarivate Analytics Master Journal List ; Current Contents - Engineering, Computing and Technology ; Essential Science Indicators ; IF >= 10 ; JCR ; SCOPUS ; Science Citation Index Expanded ; Web of Science Core Collection

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