Laser metal deposition (LMD) offers a unique combination of process flexibility, time savings, and reduced cost in producing titanium alloy components. The current challenge in processing titanium alloys using LMD methods is understanding the complex microstructure evolution as a part is fabricated layer by layer. The current work focuses on the characterization, thermal, and microstructural modeling of multilayered Ti-6Al-4V deposits. A thermal model has been developed using finite difference techniques to predict the thermal history of LMD processes. A microstructure model that predicts the alpha phase fraction and morphology evolution was constructed to quantify the effect of thermal cycling on the as-deposited microstructure evolution. Alpha dissolution and growth are modeled assuming one-dimensional plate dissolution according to a parabolic rate law, and a Johnson-Mehl-Avrami-Kolmorgorov (JMAK) nucleation and growth model, respectively. Alpha morphology (colony-alpha and basketweave-alpha) evolution is tracked using a simplistic approach. Characterization of the deposit has shown that a complex microstructure evolves consisting of a two distinct regions: a transient region of undeveloped microstructure and a characteristic layer that is periodically repeated throughout the deposit. The transient region contains a fine basketweave and colony-alpha morphology. The characteristic layer contains a two phase mixture of alpha+beta, with the alpha phase exhibits regions of colony-alpha (layer band) and basketweave-alpha morphology. The different regions of microstructural contrast in the deposit are associated with thermal cycling. The thermal model results show that a heat affected zone defined by the beta transus extends approximately 3 layers into the deposit. The phase fraction model predicts the greatest variation in microstructural evolution to occur in a layer n after the deposition of layer n+3. The results of the morphology model show that increased amounts of colony-alpha form near the top of a characteristic layer. It follows that a layer band (colony-alpha region) forms as a result of heating a region of material to a peak temperature just below the beta transus, where a large amount of primary-alpha dissolves. Upon cooling, colony-alpha forms intragranularly. The coupled thermal and microstructure models offer a way to quantitatively map microstructure during LMD processing of Ti-6Al-4V. / Ph. D.

A numerical model was developed to evaluate the performance of detailed solid oxide fuel cell (SOFC) anode microstructures obtained from experimental reconstruction techniques or generated from synthetic computational techniques. The model is also capable of identifying the linear triple phase boundary (TPB) reaction sites and evaluating the effective transport within the detailed structures, allowing a comparison between the structural properties and performance to be conducted. To simulate the cell performance, a novel numerical coupling technique was developed in OpenFOAM and validated. The computational grid type and mesh properties were also evaluated to establish appropriate mesh resolutions to employ when studying the performance. The performance of a baseline synthetic electrode structure was evaluated using the model and under the applied conditions it was observed that the ionic potential had the largest influence over the performance. The model was used in conjunction with a computational synthetic electrode manufacturing algorithm to conduct a numerical powder to power parametric study investigating the effects of the manufacturing properties on the performance. An improvement in the overall performance was observed in structures which maximized the number of reaction sites and had well established transport networks in the ion phase. From the manufacturing parameters studied a performance increase was observed in structures with low porosity and ionic solid volume fractions near the percolation threshold, and when the anodes were manufactured from small monosized particles or binary mixtures comprising of smaller oxygen ion conductive particles. Insight into the anode thickness was also provided and it was observed that the current distribution within the anode was a function of the applied overpotential and an increase in the overpotential resulted in the majority of the current production to increase and shift closer to the electrode-electrolyte interface. / Thesis (Master, Mechanical and Materials Engineering) -- Queen's University, 2013-10-01 09:41:47.617