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

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Názov: CALPHAD-guided interlayer design for crack-free additive manufacturing of copper C18150 – Inconel 625 bimetallic structures.
Autori: Wang, Liyi, Ladinos Pizano, Luis Fernando, Klecka, Michael A., Neely, Kelsay, Xiong, Wei
Zdroj: Science & Technology of Advanced Materials; Dec2025, Vol. 26 Issue 1, p1-16, 16p
Predmety: COPPER alloys, PHASE separation, INCONEL, THREE-dimensional printing, CRACK formation in solids, SOLIDIFICATION, METALLIC composites
Abstrakt: 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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  Label: Title
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  Data: CALPHAD-guided interlayer design for crack-free additive manufacturing of copper C18150 – Inconel 625 bimetallic structures.
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  Data: <searchLink fieldCode="AR" term="%22Wang%2C+Liyi%22">Wang, Liyi</searchLink><br /><searchLink fieldCode="AR" term="%22Ladinos+Pizano%2C+Luis+Fernando%22">Ladinos Pizano, Luis Fernando</searchLink><br /><searchLink fieldCode="AR" term="%22Klecka%2C+Michael+A%2E%22">Klecka, Michael A.</searchLink><br /><searchLink fieldCode="AR" term="%22Neely%2C+Kelsay%22">Neely, Kelsay</searchLink><br /><searchLink fieldCode="AR" term="%22Xiong%2C+Wei%22">Xiong, Wei</searchLink>
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  Data: Science & Technology of Advanced Materials; Dec2025, Vol. 26 Issue 1, p1-16, 16p
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22COPPER+alloys%22">COPPER alloys</searchLink><br /><searchLink fieldCode="DE" term="%22PHASE+separation%22">PHASE separation</searchLink><br /><searchLink fieldCode="DE" term="%22INCONEL%22">INCONEL</searchLink><br /><searchLink fieldCode="DE" term="%22THREE-dimensional+printing%22">THREE-dimensional printing</searchLink><br /><searchLink fieldCode="DE" term="%22CRACK+formation+in+solids%22">CRACK formation in solids</searchLink><br /><searchLink fieldCode="DE" term="%22SOLIDIFICATION%22">SOLIDIFICATION</searchLink><br /><searchLink fieldCode="DE" term="%22METALLIC+composites%22">METALLIC composites</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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]
– Name: Abstract
  Label:
  Group: Ab
  Data: <i>Copyright of Science & Technology of Advanced Materials is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1080/14686996.2025.2587393
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      – Code: eng
        Text: English
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        PageCount: 16
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      – SubjectFull: COPPER alloys
        Type: general
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      – SubjectFull: INCONEL
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      – SubjectFull: THREE-dimensional printing
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      – SubjectFull: METALLIC composites
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              M: 12
              Text: Dec2025
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              Y: 2025
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