A comprehensive study of how solidification and cooling rate change in melt pool dynamics affect oxide growth and distribution in Additively Manufactured Ferritic 14YWT samples produced using Gas Atomization Reaction Synthesis Precursor Powder

Thermally and mechanically stable nano oxide dispersoid spread throughout the matrix in a Fe-Cr Oxide Dispersion Strengthened (ODS) ferritic steel offers excellent creep, fatigue, and improved radiation resistance at high temperatures. Recent progress in novel powder production in Gas Atomization Reaction Synthesis (GARS) technique has shown that rapid solidification of a Cr rich matrix resulted in the formation of stable Y-containing intermetallic Y2Fe17 on the interior of the powder, and a stable Cr-rich oxide surface. This study builds upon the fundamentals of previously established research into processing conditions for AM samples produced using GARS under different reactive atmospheres. In this study, we establishment transient FEA and Heat transfer model process using a multi-physical field model of the melt pool. Using simulation tools, we are predicting how changes in melt pool depth (caused by change in scanning speed and layer thickness which affect the peak temperature and solidification and cooliding gradient) and powder size individually affect the thermo physical properties which in turn formation of oxide and distribution in as fabricated sample. These oxides are characterized and analyzed using TEM.