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CALPHAD-guided interlayer design for crack-free additive manufacturing of copper C18150 – Inconel 625 bimetallic structures.

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Bibliographic Details
Title: CALPHAD-guided interlayer design for crack-free additive manufacturing of copper C18150 – Inconel 625 bimetallic structures.
Authors: Wang, Liyi, Ladinos Pizano, Luis Fernando, Klecka, Michael A., Neely, Kelsay, Xiong, Wei
Source: Science & Technology of Advanced Materials; Dec2025, Vol. 26 Issue 1, p1-16, 16p
Subject Terms: COPPER alloys, PHASE separation, INCONEL, THREE-dimensional printing, CRACK formation in solids, SOLIDIFICATION, METALLIC composites
Abstract: Additive manufacturing (AM) of bimetallic structures combining copper alloys and Ni-based superalloys is critical for extreme environmental applications. However, interface cracking during fabrication persists due to thermophysical property mismatches. By implementing a CALPHAD-based ICME framework (CALPHAD: Calculation of Phase Diagrams; ICME: Integrated Computational Materials Engineering), we decode nonequilibrium solidification and phase stability to predict cracking susceptibility. Liquid phase separation emerges as the dominant mechanism, altering solute redistribution and thermal stress accumulation – a previously underexplored factor in bimetallic systems. Experiments using wire arc additive manufacturing (WAAM) validate model prediction: crack-free interfaces between C18150 and In625 require intermediate layers with 65 wt.% In625. This composition mitigates cracking with the lowest cracking susceptibility coefficient (CSC). Importantly, we establish a quantitative correlation between phase separation and CSC, proposing a way to analyze systems exhibiting these microstructural features. This work uses ICME methodologies by linking thermochemical modeling to process optimization, offering new principles for designing defect-resistant bimetallic components in extreme environments such as rocket engine nozzles. IMPACT STATEMENT: CALPHAD-based ICME framework reveals liquid phase separation drives bimetallic interface cracking, establishing a quantitative cracking susceptibility correlation to enable predictive defect-resistant design in functionally graded materials by additive manufacturing. [ABSTRACT FROM AUTHOR]
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Database: Complementary Index
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Abstract:Additive manufacturing (AM) of bimetallic structures combining copper alloys and Ni-based superalloys is critical for extreme environmental applications. However, interface cracking during fabrication persists due to thermophysical property mismatches. By implementing a CALPHAD-based ICME framework (CALPHAD: Calculation of Phase Diagrams; ICME: Integrated Computational Materials Engineering), we decode nonequilibrium solidification and phase stability to predict cracking susceptibility. Liquid phase separation emerges as the dominant mechanism, altering solute redistribution and thermal stress accumulation – a previously underexplored factor in bimetallic systems. Experiments using wire arc additive manufacturing (WAAM) validate model prediction: crack-free interfaces between C18150 and In625 require intermediate layers with 65 wt.% In625. This composition mitigates cracking with the lowest cracking susceptibility coefficient (CSC). Importantly, we establish a quantitative correlation between phase separation and CSC, proposing a way to analyze systems exhibiting these microstructural features. This work uses ICME methodologies by linking thermochemical modeling to process optimization, offering new principles for designing defect-resistant bimetallic components in extreme environments such as rocket engine nozzles. IMPACT STATEMENT: CALPHAD-based ICME framework reveals liquid phase separation drives bimetallic interface cracking, establishing a quantitative cracking susceptibility correlation to enable predictive defect-resistant design in functionally graded materials by additive manufacturing. [ABSTRACT FROM AUTHOR]
ISSN:14686996
DOI:10.1080/14686996.2025.2587393