Effect of microsegregation behaviors on solidification microstructure of IC10 superalloy fabricated by directed energy deposition

Due to the solidification process and thermal history, the microstructure and properties along the deposition direction are generally inhomogeneous in components fabricated by the directed energy deposition technique. By developing a microsegregation model, this study gives an innovative understanding of the elemental segregation behavior of an as-deposited IC10 superalloy along the different heights and its influence on the microstructure. Results indicate that the gamma-gamma ' eutectic-free microstructure is only obtained at the initial deposition layer, and as the deposition height increases, eutectic phases gradually appear in interdendritic regions. By taking account of the nonequilibrium solidification and dendritic tip undercooling, the new microsegregation model can well explain the segregation behavior of the alloy at different deposition heights. Compared to the back diffusion coefficient, the partition coefficient plays a major role in microsegregation behavior under rapid solidification conditions, especially for the elements with a high diffusion coefficient in solid, such as Ti and Al. Moreover, microstructure transformation is dependent on varying solidification processes due to the change in micro-segregation. Limited by the heat transfer efficiency as the increased deposition heights, the temperature gradient and solidification rate decrease, which exacerbates the enrichment of Al and Ti at interdendritic regions and promotes the eutectic phase nucleation. Restricted by the diffusion rate of alloying elements, the eutectic re-action rate slows down, gamma and gamma ' lamellae thickness increase, and finally the petal-like eutectic phases form.