Microstructure refinement was observed in the fusion zone of AZ31 magnesium (Mg) alloy resistance spot welds when an inoculant was added, either Ti, Al8Mn5, or Mn. The dependence of inoculant potency on the lattice disregistry between inoculants and matrix, and on the liquid cooling rate was studied. Microstructural characterization was performed via optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Thin foils containing the interface of the inoculant particles and Mg matrix were prepared using a focused ion beam (FIB) technique. Columnar dendritic structures in the vicinity of the fusion boundary and equiaxed dendritic structures in the central area were observed in the fusion zone of welds in the SA and SB AZ31Mg alloys from different suppliers. However, the columnar dendritic zone (CDZ) was well restricted, and the width of the CDZ and the diameters of equiaxed dendrites were much smaller in the SA alloy than those in the SB alloy due to the earlier columnar-equiaxed-transition (CET) in the SA alloy. The refined microstructure in the fusion zone of the SA alloy welds is attributed to the pre-existence of the larger Al8Mn5 particles of 4-10 microns in length in the SA alloy which act as an inoculant for alpha-Mg heterogeneous nucleation. Fatigue life and dislocation substructure were compared between the SA and SB welds. The SA welds with the refined microstructure displayed an enhanced fatigue resistance compared to the SB welds, when the interfacial failure took place across the fusion zone. The increased number and dispersion of slip systems in the fine-grained SA welds contributed to the improvement of fatigue life. The well-developed columnar dendritic grains were successfully restricted and the coarse equiaxed dendritic grains were efficiently refined by intentionally adding Ti or Mn inoculant particles into the as-received SB alloy welds. The Ti and Mn particles of about 8μm diameter were observed to promote the nucleation of alpha-Mg grains during welding. TEM examinations showed the existence of local orientation relationships between the respective inoculants Ti, Mn, and Al8Mn5 with the Mg matrix. The further lattice matching was observed between the Al8Mn5 particles and Mg. The diameter of the added inoculant should be larger than 1.8 microns to make it a potent inoculant based on the thermodynamic calculation. Microstructural examinations of samples with different inoculant additions and under different cooling rates showed that the inoculant potency was high for the Ti inoculant, medium for the Al8Mn5, but low for the Mn, when the cooling rate was low. This order in the decrease of grain refinement efficiency is inversely proportional with the order of crystallographic lattice disregistry between inoculants and matrix, which is calculated based on a crystallographic matching model. This implies that the lattice disregistry determines the potency of inoculants at the low cooling rates. In comparison, the lattice disregistry did not influence the heterogeneous nucleation, when the cooling rate was high. It could be inferred that an extremely high cooling rate produces a large supercooling, and provides a sufficient driving force for heterogeneous nucleation.

Magnésio e suas ligas têm adquirido importância cada vez mais significativa como material estrutural de peso leve despertando um singular interesse pela indústria uma vez que oferece a melhor relação peso/resistência entre os metais. Os campos mais conhecidos de sua aplicação consistem na construção de veículos, na aeronáutica, manipulação industrial (robôs, automatização) e tecnologia de comunicação. Em particular, a indústria automobilística tem crescentemente ampliado a utilização de ligas de magnésio na produção de peças que vão desde caixas de câmbio até aros de rodas. As principais razões para este desenvolvimento são: mudanças na legislação ambiental, as exigências de cliente, e objetivos corporativos que requerem veículos mais leves diminuindo o consumo de combustível. O uso do magnésio para aplicações estruturais em altas temperaturas é limitado devido a sua baixa resistência à fluência. Isso se deve ao enfraquecimento do contorno de grão a partir da precipitação descontínua da fase b-Mg17Al12 de baixo ponto de fusão. Dentre as ligas de magnésio desenvolvidas para resistência à fluência, as ligas do sistema Mg-Al-RE-Ca oferecem ótimo desempenho com resultados similares à liga de alumínio ADC12. Muitos trabalhos sobre o sistema de ligas Mg-Al-RE-Ca foram realizados visando compreender a relação entre microestruturas e propriedades mecânicas. Entretanto, poucos estudos relacionaram a influência das variáveis de solidificação na formação das microestruturas. O presente trabalho tem como objetivo realizar um estudo em uma liga Mg-4%Al-3%La-1%Ca analisando a influência das variáveis térmicas tais como taxas de resfriamento, velocidade da isoterma liquidus e gradientes de temperatura, na formação de estruturas, na transição colunarequiaxial e espaçamento dendrítico durante o processo de solidificação. A previsão das distintas estruturas, tais como zona colunar e equiaxial é de grande interesse para avaliação e projeção das propriedades mecânicas dos fundidos. Dessa forma, a liga estudada foi submetida à solidificação unidirecional vertical ascendente e análise térmica. Foram realizadas análises metalográficas nos lingotes solidificados. Os resultados colaboram para uma melhor compreensão do fenômeno de solidificação da liga e serve como ferramenta no desenvolvimento de modelos de previsões de formação de micro e macroestruturas que influenciam diretamente nas propriedades mecânicas. / Due to their superior weight/resistance relation, magnesium and its alloys have been acquiring a great deal of importance in the modern industry, specially as lightweight structural materials in the fields of vehicle construction, aeronautics, industrial robotics, automation, and communication technologies. In particular, the automotive industry has been increasingly expanding the use of magnesium alloys in the production of auto-parts, ranging from gearbox housings to steering wheels. The main reasons for this developments are changes in environmental legislations, new customer requirements, and corporate policies regarding fuel consumption and weight/power relations. The use of magnesium alloys for structural applications at high temperatures is limited due to the precipitation of the discontinuous phase b-Mg17Al12, which in fact, weakens the grain boundary during service resulting in a low creep resistance. Among the magnesium alloys developed for creep resistance, the alloys of the system Al-Mg-RE-Ca offer optimum performance with results similar to the ADC12 aluminum alloy. Many studies on the Al-Mg-RE-Ca system alloys were aimed to understand the relationship between microstructure and mechanical properties. However, few studies undertake the influence of the solidification variables in the microstructure formation. This work aims to study the influence of some thermal variables such as temperature gradients, solidification and growth tip rate on the formation of microstructures, the columnar/equiaxial transition and dendrite arm spacing, during the solidification process of a Mg-4%Al-3%La- 1%Ca alloy. The prediction of the different structures, such as the columnar and the equiaxial regions is of great interest for the assessment and projection of the mechanical properties of the casts. Therefore, the alloy studied in this work were submitted to thermal analysis during an unidirectional vertical ascending solidification, as well as optical and scanning electron microscopy characterization. The results contribute to a better understanding of the solidification phenomena of the magnesium alloys, as well as a tool in the development of numerical models for the prediction of structures which directly influence the mechanical properties of the parts.

Magnésio e suas ligas têm adquirido importância cada vez mais significativa como material estrutural de peso leve despertando um singular interesse pela indústria uma vez que oferece a melhor relação peso/resistência entre os metais. Os campos mais conhecidos de sua aplicação consistem na construção de veículos, na aeronáutica, manipulação industrial (robôs, automatização) e tecnologia de comunicação. Em particular, a indústria automobilística tem crescentemente ampliado a utilização de ligas de magnésio na produção de peças que vão desde caixas de câmbio até aros de rodas. As principais razões para este desenvolvimento são: mudanças na legislação ambiental, as exigências de cliente, e objetivos corporativos que requerem veículos mais leves diminuindo o consumo de combustível. O uso do magnésio para aplicações estruturais em altas temperaturas é limitado devido a sua baixa resistência à fluência. Isso se deve ao enfraquecimento do contorno de grão a partir da precipitação descontínua da fase b-Mg17Al12 de baixo ponto de fusão. Dentre as ligas de magnésio desenvolvidas para resistência à fluência, as ligas do sistema Mg-Al-RE-Ca oferecem ótimo desempenho com resultados similares à liga de alumínio ADC12. Muitos trabalhos sobre o sistema de ligas Mg-Al-RE-Ca foram realizados visando compreender a relação entre microestruturas e propriedades mecânicas. Entretanto, poucos estudos relacionaram a influência das variáveis de solidificação na formação das microestruturas. O presente trabalho tem como objetivo realizar um estudo em uma liga Mg-4%Al-3%La-1%Ca analisando a influência das variáveis térmicas tais como taxas de resfriamento, velocidade da isoterma liquidus e gradientes de temperatura, na formação de estruturas, na transição colunarequiaxial e espaçamento dendrítico durante o processo de solidificação. A previsão das distintas estruturas, tais como zona colunar e equiaxial é de grande interesse para avaliação e projeção das propriedades mecânicas dos fundidos. Dessa forma, a liga estudada foi submetida à solidificação unidirecional vertical ascendente e análise térmica. Foram realizadas análises metalográficas nos lingotes solidificados. Os resultados colaboram para uma melhor compreensão do fenômeno de solidificação da liga e serve como ferramenta no desenvolvimento de modelos de previsões de formação de micro e macroestruturas que influenciam diretamente nas propriedades mecânicas. / Due to their superior weight/resistance relation, magnesium and its alloys have been acquiring a great deal of importance in the modern industry, specially as lightweight structural materials in the fields of vehicle construction, aeronautics, industrial robotics, automation, and communication technologies. In particular, the automotive industry has been increasingly expanding the use of magnesium alloys in the production of auto-parts, ranging from gearbox housings to steering wheels. The main reasons for this developments are changes in environmental legislations, new customer requirements, and corporate policies regarding fuel consumption and weight/power relations. The use of magnesium alloys for structural applications at high temperatures is limited due to the precipitation of the discontinuous phase b-Mg17Al12, which in fact, weakens the grain boundary during service resulting in a low creep resistance. Among the magnesium alloys developed for creep resistance, the alloys of the system Al-Mg-RE-Ca offer optimum performance with results similar to the ADC12 aluminum alloy. Many studies on the Al-Mg-RE-Ca system alloys were aimed to understand the relationship between microstructure and mechanical properties. However, few studies undertake the influence of the solidification variables in the microstructure formation. This work aims to study the influence of some thermal variables such as temperature gradients, solidification and growth tip rate on the formation of microstructures, the columnar/equiaxial transition and dendrite arm spacing, during the solidification process of a Mg-4%Al-3%La- 1%Ca alloy. The prediction of the different structures, such as the columnar and the equiaxial regions is of great interest for the assessment and projection of the mechanical properties of the casts. Therefore, the alloy studied in this work were submitted to thermal analysis during an unidirectional vertical ascending solidification, as well as optical and scanning electron microscopy characterization. The results contribute to a better understanding of the solidification phenomena of the magnesium alloys, as well as a tool in the development of numerical models for the prediction of structures which directly influence the mechanical properties of the parts.

The aluminium alloys for electrical conductivity applications are generally not grain refinedsince the addition of grain refiners drops the electrical conductivity by introducing impuritiesinto the melt. Non-grain refined aluminium may lead to bar fracture and cracks during themetalworking process. The present study focuses to find an optimum balance between the grain refiner addition andthe electrical conductivity of commercial EC grade 1070 aluminium alloy for electricalapplication. In order to reach this goal, the electrical conductivity and the macrostructure ofcommercial EC grade 1070 aluminium (commercial pure aluminium) have been studiedunder a series of controlled lab scale trails. Specific addition levels of different grain refiners(TiBloy, Al-5Ti-1B, Al-3Ti-0.15C, and Al-3Ti-1B) were added to the metal melt and sampleswere taken at specific time intervals. The collected samples were sectioned, ground andmacro-etched. Thereafter, the macrostructure was analysed by the use of a digital camera andthe electrical conductivity was measured at temperature. The obtained result was expressed asa percentage of the International Annealed Copper Standard (IACS %). The macro-structuralanalysis showed that TiBloy, Al-5Ti-1B, and Al-3Ti-1B, with the maximum addition level of0.1%, cannot grin refine commercial pure aluminium. However, at higher grain refiner levelsthe number of columnar grains increased and their size decreased. The Al-3Ti-0.15C master alloy, with the same addition level as the once chosen for the othergrain refiners (up to 0.1%), showed significantly better grain refining. By the addition of0.1% of this grain refiner the macrostructure became very equiaxed already after 30 minutesof grain refiner addition. The fading of the Al-3Ti-0.15 master alloy was, however, observedfor samples with a long holding time. Nevertheless, by maximum addition level (0.1%) and a90 minutes holding time the macrostructure remained as equiaxed grains. The electrical conductivity results showed that none of the applied grain refiners (TiBloy, Al-5Ti-1B, Al-3Ti-0.15C, and Al-3Ti-1B), with the maximum addition level of 0.1%, decreasedthe electrical conductivity of commercial pure aluminium.

No description available.

L’augmentation des températures de fonctionnement des turboréacteurs est un axe de développement privilégié dans l’industrie aéronautique. Une solution est l’amélioration des systèmes barrières thermiques. Ce travail de thèse s’intéresse au procédé de projection plasma de suspensions (SPS) qui permet d’envisager une amélioration significative des performances pour les prochaines générations de barrières thermiques, comparé au procédé d’évaporation sous faisceau d’électrons (EB-PVD). Le procédé SPS a en effet démontré une capacité à générer des microstructures colonnaires qui présentent un intérêt pour l’accommodation des contraintes thermo-mécaniques. Une étude microstructurale a conduit à l’identification des paramètres influant sur les variations de morphologies des revêtements (taille de colonnes, distribution de taille, compacité). Deux nuances optimisées en zircone yttriée (YSZ), nommées colonnaire et colonnaire compacte, ont été caractérisées de façon approfondie afin de déterminer les bénéfices du procédé SPS. Ces nuances se caractérisent par une conductivité thermique inférieure à 1 W.m-1.K-1, sur une plage de température allant de 25 à 1100 °C, soit des valeurs avantageuses par rapport à celles des revêtements EB-PVD (1,3 – 1,5 W.m-1.K-1). La durée de vie des dépôts SPS, estimée par cyclage thermique, est au moins équivalente à un dépôt YSZ réalisé par EB-PVD et cyclé en même temps. Le résultat le plus élevé obtenu, supérieur à 2000 cycles, est particulièrement prometteur. La capacité de fonctionnalisation du procédé SPS a par ailleurs permis la réalisation de systèmes multifonctionnels comprenant un dépôt colonnaire YSZ et un dépôt homogène Gd2Zr2O7 en surface. Cette architecture bicouche a pour objectif de pallier les infiltrations chimiques de type CMAS (CaO–MgO–Al2O3–SiO2) qui constituent un frein pour l’augmentation de la température de fonctionnement. Le caractère anti-CMAS du matériau Gd2Zr2O7 mis en forme par SPS a été évalué jusqu’à 1300 °C. / The increase of operating temperature of gas turbine engines is an issue of interest for the aeronautic industry. A solution is the enhancement of thermal insulation properties of thermal barrier coatings (TBCs). The present work is related to suspension plasma spraying process (SPS) that allows to consider significant improvements for the next generation of TBC systems, compared to the currently used process, namely electron beam physical vapor deposition (EB-PVD). Indeed, SPS process can produce columnar microstructures able to provide high thermo-mechanical compliance. A microstructural study led to identify parameters which impacted the coating morphology (column size, distribution, and compaction). Two optimized yttria-stabilized zirconia (YSZ) microstructures were carefully characterized to highlight SPS process advantages. Low thermal conductivities (< 1 W.m-1.K-1) were obtained within a large temperature range (25 °C – 1100 °C), compared to EB-PVD YSZ coatings (1,3 – 1,5 W.m-1.K-1). Thermal lifetime was estimated thanks to thermal cyclic fatigue tests. A similar level of thermal lifetime was reached with SPS coatings compared to EB-PVD one. Some SPS columnar coatings even showed more than 2000 cycles to failure. The ability of SPS to perform multifunctional systems, including a YSZ columnar structure with a homogeneous Gd2Zr2O7 coating on the top, was investigated. This architecture must provide a chemical protection to CMAS (CaO–MgO–Al2O3–SiO2) aggressions. These contaminants would impede the increase of temperature in next generation of gas turbine engines. The anti-CMAS behavior was assessed for SPS Gd2Zr2O7 coatings until 1300 °C.

Aujourd’hui, la fabrication additive de pièces métalliques par le procédé EBM (fusion sélective par faisceau d’électrons) concerne essentiellement les alliages de titane et les alliages cobalt-chrome. Une forte demande du secteur aéronautique pousse à étudier la possibilité d'étendre les champs d’application de ce nouveau procédé d'élaboration à d'autres matériaux à haute valeur ajoutée, notamment les superalliages base Nickel.Après la caractérisation des poudres et la description des particularités du procédé EBM (mise en œuvre, paramètres, thermique…), ce travail s'est attaché à développer une méthodologie permettant de structurer l’utilisation d’un nouveau matériau par EBM. Cette méthodologie a dans un premier temps été validée sur un superalliage base Nickel soudable: l'inconel 625.La mise en œuvre d’un superalliage non-soudable a révélé une problématique de fissuration à chaud. Une partie du travail de thèse a été consacrée à la compréhension de l'origine de la fissuration à partir de caractérisations microstructurales multi-échelles. L'étude de la genèse des microstructures et des défauts hérités de la fabrication a permis de proposer des règles de fabrication afin de limiter, et même d'éviter complètement la fissuration. Une adaptation des paramètres opératoires et des stratégies de fusion lors du procédé EBM est utilisée pour générer des microstructures présentant des structures de grains différentes allant de structures équiaxes jusqu'à la fabrication de monocristaux en passant par des structures colonnaires de différentes tailles.Le couplage entre un modèle de solidification prédisant la transition colonnaire-équiaxe et des simulations éléments finis permettant de quantifier les gradients thermiques et les vitesses de solidification a permis d’établir des liens entre les paramètres procédé et les microstructures résultantes. / Over the last decade, new processing routes based on additive manufacturing (AM) have emerged. Among the AM processes, Electron Beam Melting (EBM) was mainly dedicated to the fabrication of components made of titanium or chromium-cobalt alloys. Aeronautic industry has been a driving force to investigate the possibility to extend the EBM process to other materials and in particular to Ni-based superalloys.The first objective of this work was to develop a methodology to rationalize the use of a new material in the EBM machine. This can be achieved by studying the main characteristics of the EBM process: powder requirements, melting parameters and strategies, thermal aspects.... The methodology was first validated on a weldable Ni-based superalloy: the Inconel 625 grade.The methodology was then extended to the fabrication of a non-weldable Ni-based superalloy, i.e. a grade containing a large fraction of the γ' strengthening phase. Processing such non-weldable superalloys by EBM usually induced cracks in the fabricated components. The microstructures were characterized in order to identify the mechanism at the origin of the cracks. Understanding the mechanism responsible for the development of cracks has allowed to propose new melting strategies limiting or completely avoiding the formation of cracks.Adjusting melting parameters and strategies turns out to be an efficient way for tailoring the grain structure. Equiaxed grains, columnar grains with different sizes as well as single crystals can thus be generated with suitable process parameters.Finally, coupling a solidification model predicting the equiaxed/columnar transition and finite element calculations quantifying the magnitude of the thermal gradient and solidification velocity allowed to establish some links between microstructures and EBM melting parameters.

Le système Ti-Al est prometteur pour la substitution aux superalliages base-Ni aéronautiques. Dans la gamme de compositions d’intérêt pour ces applications, la solidification de ces alliages débute par la phase ß (structure cubique centrée) suivie d’une transition péritectique ß + L → α (structure hexagonale). En fonction de la teneur en Al, les proportions des phases ß et α au cours de la solidification varient, et le procédé de coulée centrifuge pour fabriquer des aubes de turbine pour l’aéronautique introduit d’autres variations structurales. Le présent travail explore l’influence de la teneur en Al et de la centrifugation sur la solidification de ces alliages. Des expériences de refusion en creuset froid sous induction, de solidification dirigée en centrifugeuse de grand diamètre et de coulée centrifuge sont présentées et caractérisées. Des mécanismes potentiels pour les différences structurales observées sont proposés. Une fragmentation assistée par une teneur en Al plus élevée est observée dans les essais en creuset froid, et une réaction péritectique démarrant plus tôt est associée à une fragmentation plus efficace pour provoquer la transition colonnaire-équiaxe (TCE). Une compétition entre la convection et la sédimentation est observée lors des essais de solidification dirigée sous centrifugation, et la refusion des bras secondaires est responsable de la TCE. En coulée centrifuge, des structures hétérogènes en « ailes de mouette » à faibles teneurs en Al dépendent de la cinétique de refroidissement et de la convection. Un comportement différent sous les mêmes conditions est constaté à plus fortes teneurs en Al, transition qui semble coïncider avec le péritectique / The Ti-Al system is a promising substitute for Ni-based aeronautical superalloys. In the composition range of interest for these applications, the solidification of these alloys begins with a ß phase (body-centered cubic structure) followed by a peritectic transition ß + L → α (hexagonal close-packed structure). As a function of Al content, the proportions of ß and α phases over the course of solidification change, and the centrifuge casting process for aeronautical turbine blade fabrication introduces other structural variations. The present work explores the influence of Al content and centrifugation on the solidification process in these alloys. Remelting experiments in a cold-crucible induction furnace, directional solidification experiments in a large-diameter centrifuge and centrifuge casting experiments are presented and characterized. Potential mechanisms for the observed structural differences are proposed. Fragmentation assisted by a higher Al content is observed in cold crucible casting, and an early onset of the peritectic reaction is associated with fragmentation that more effectively provokes a columnar-to-equiaxed transition (CET). Competition between convection and sedimentation is observed in directional solidification under centrifugation, and secondary arm remelting is responsible for CET. In centrifuge casting, heterogeneous “seagull wing” structures for low Al contents depend on cooling rates and convection. A different behavior under the same conditions is noted for higher Al contents, and the transition seems to coincide with the peritectic

Des structures prismées sont fréquemment observées dans les coulées de lave comme la Chaussée des Géants (Irlande). Plusieurs théories existent pour expliquer ces formations, dont la plus répandue est celle de la contraction thermique. Or cette théorie permet difficilement de comprendre certaines observations de terrain comme la séparation fréquente des coulées en plusieurs niveaux. Afin de mieux comprendre la structuration au sein des coulées basaltiques, nous avons procédé à une étude pluridisciplinaire basée sur les propriétés magnétiques, les variations structurales et géochimiques de deux coulées prismées du Massif Central (La Palisse, Ardèche et Saint-Arcons-d’Allier, Haute-Loire). Notre approche permet de montrer que les fabriques cristallographiques et magnétiques sont gouvernées par l’écoulement de la lave. L’orientation du plagioclase contrôle la distribution des titanomagnétites à l’origine des fabriques magnétiques. Notre étude montre également que l’utilisation de l’ASM est un outil fiable pour déterminer l’orientation de l’écoulement à condition d’être contrôlée par des mesures de fabriques cristallographiques. Les mesures de la quantité d’eau et les analyses isotopiques (H et O) montrent que l’effet de l’altération météorique est faible et que l’eau contenue dans la roche est essentiellement de l'eau de constitution. De plus, à l’échelle du prisme, des variations de deuxième ordre sont observées comme celle des paramètres d’hystérésis qui indique des tailles de grains de titanomagnétites plus importantes vers le centre. Ces variations au sein du prisme semblent difficilement compatibles avec une structuration des coulées par la simple contraction thermique. / Columnar jointing is frequently observed in lava flows, as in the Giant Causeway (Ireland). The most common theory explaining the formation of prisms is by the thermal contraction. However, this theory hardly explains some field observations such as the frequent existence of three parts within the lavas flows, from the base to the top. To complete our understanding of the structuring lava flows, we carried out a multidisciplinary study based on the magnetic properties, structural and geochemical characterization of two basaltic flows from the French Massif Central (La Palisse, Ardèche and Saint-Arcons-d'Allier, Haute-Loire). Our approach shows that crystallographic and magnetic fabrics are governed by the flow. The distribution of titanomagnetite grains carrying the magnetic fabrics is mainly controlled by the plagioclase orientation. Our study also shows that the use of the AMS to determine the flow direction is a reliable tool, provided punctual control by measurements of crystallographic fabrics are performed. Measurements of the water content and isotopic analyses (H and O) show a limited weathering effect in the studied areas: rock water is mostly primary water in equilibrium with the magma. Moreover, second order changes are noted across the prism section such as hysteresis parameters associated to grain size variation of titanomagnetite (larger grains in the center). The variations of magnetic properties across the prism section suggest a gradient of the crystallization rate from the center to the edge of the prism, which seems difficult to reconcile with the structuring of the flow by thermal contraction only.

This study aims to improve the Additive Manufacturing (AM) design space for the popular multi-component Ni alloy Inconel 625 (IN625) thorough investigating the microstructural evolution, namely the solidification microstructure and the solid-state phase transformations during the Laser Powder Bed Fusion (LPBF) process. Highly non-equilibrium solidification and the complex reheating conditions during the LPBF process result in the formation of various types of solidification microstructures and grain morphologies which consequently lead to a wide range of mechanical properties. Understanding the melt’s thermal conditions, alloy chemistry, and thermodynamics during the rapid solidification and solid-state phase transformation in AM process will help to control material properties and even produce a material with specific microstructural features suited to a given application. This research helps to better understand the process-microstructure-property relationships of LPBF IN625. First, a set of simple but effective analytical solidification models were employed to evaluate their ability to predict the solidification microstructure in AM applications. As a case study, Solidification Microstructure Selection (SMS) maps were created to predict the solidification growth mode and grain morphology of a ternary Al-10Si-0.5Mg alloy manufactured by the LPBF process. The resulting SMS maps were validated against the experimentally obtained LPBF microstructure available in the literature for this alloy. The challenges, limitations, and potential of the SMS map method to predict the microstructural features in AM were comprehensively discussed. Second, The SMS map method was implemented to predict the solidification microstructure and grain morphology in an LPBF-built multi-component IN625 alloy. A single-track LPBF experiment was performed utilizing the EOSINT M280 machine to evaluate the SMS map predictions. The resulting microstructure was characterized both qualitatively and quantitatively in terms of the solidification microstructure, grain morphology, and Primary Dendrite Arm Spacing (PDAS). Comparing the experimentally obtained solidification microstructure to the SMS map prediction, it was found that the solidification mode and grain morphology were correctly predicted by the SMS maps. Although the formation of precipitates was predicted using the CALculation of PHAse Diagrams (CALPHAD) approach, it was not anticipated from the analytical solution results. Third, to further investigate the microsegregation and precipitation in IN625, Scanning Transmission Electron Microscopy (STEM) using Energy-Dispersive X-ray Spectroscopy (EDS), High-Angle Annular Dark-Field Scanning Transmission Electron Microscopy (HAADF-STEM), Scheil-Gulliver (with solute trapping) model, and DIffusion-Controlled TRAnsformations (DICTRA) method were employed. It was found that the microstructural morphology mainly consists of the Nickel-Chromium (gamma-FCC) dendrites and a small volume fraction of precipitates embedded into the interdendritic regions. The precipitates predicted with the computational method were compared with the precipitates identified via HAADF-STEM analysis inside the interdendritic region. The level of elemental microsegregation was overestimated in DICTRA simulations compared to the STEM-EDS results; however, a good agreement was observed between the Scheil and STEM-EDS microsegregation estimations. Finally, the spatial variations in mechanical properties and the underlying microstructural heterogeneity of a multi-layer as-built LPBF part were investigated to complete the process-structure-properties relationships loop of LPBF IN625. Towards this end, numerical thermal simulation, electron microscopy, nano hardness test, and a CALPHAD approach were utilized to investigate the mechanical and microstructural heterogeneity in terms of grain size and morphology, PDAS, microsegregation pattern, precipitation, and hardness along the build direction. It was found that the as-built microstructure contained mostly columnar (Nickel–Chromium) dendrites were growing epitaxially from the substrate along the build direction. The hardness was found to be minimum in the middle and maximum in the bottom layers of the build’s height. Smaller melt pools, grains, and PDAS and higher thermal gradients and cooling rates were observed in the bottom layers compared to the top layers. Microsegregation patterns in multiple layers were also simulated using DICTRA, and the results were compared with the STEM-EDS results. The mechanism of the formation of precipitates in different regions along the build direction and the precipitates’ corresponding effects on the mechanical properties were also discussed. / Thesis / Doctor of Philosophy (PhD)