Thermo-Calc 2024a Available Now
Webinar on Thermo-Calc 2024a Release
New Keyhole Model
A keyhole model has been introduced in the AM Module. In additive manufacturing, when the laser beam intensity is high, which is often done to increase productivity, evaporation of liquid metal creates a recoil pressure that pushes down the liquid to form a cavity, which is called a keyhole. You can see this demonstrated on the right side of the image below.
A representation of the additive manufacturing process comparing the effects of low and high laser beam intensity. High energy (right) creates a recoil pressure that pushes down the liquid to form a cavity, which is called a keyhole.
The Additive Manufacturing Module now includes a model that computes the keyhole shape and corresponding mesh that is used for the steady-state simulation. The model also includes the effect of multiple reflections of the laser beam on the keyhole walls.
From example AM_06b, this Steady-state temperature distribution around the melt pool for SS316L with P = 80 W and scanning speed = 400 mm/s using the calibrated Gaussian heat source with the keyhole model. A keyhole can also be seen formed just below the location of the heat source.
Calibrate Volume Heat Source Parameters Using Experimental Melt Pool Data
A Heat source calibration option has been added to the AM Module in order to improve the ability to predict the melt pool size under various process conditions. This new feature allows users to import experimental melt pool data for a range of processing parameters.
A screenshot from the AM Module in Thermo-Calc showing imported experimental melt pool data for the new Heat source calibration feature.
Users can calibrate the heat source parameters to match the experimental data for your material and processing conditions. Once you have finished the optimization, you can plot the Heat calibration parameters and the Melt pool dimensions as a function of energy density (power/scan speed) and select a function for each heat source parameter.
Heat calibration parameters for a double ellipsoidal calculation.
One of the plot results from example PM_G_15 where the CET curves for a Ni-26Al-9Cr alloy are plotted compared to experimental data. In this example, the nickel demo databases are used, which are available to all users.
New Parallel Coordinates Plot Type
For those working with Materials Design, a new Parallel Coordinates plot type is introduced in the Property Model Calculator.
Screenshot of the new Parallel Coordinates plot type is introduced in the Property Model Calculator.
New Scheil Property Model
A new Scheil Property Model is available for all users of Thermo-Calc. This new Property Model is essentially the same as the Scheil Calculator already included in the software, but implementing Scheil as a Property Model allows users to benefit from the additional calculation types available in the Property Model Calculator, including multi-axis Grid, Min/Max, Uncertainty, and Batch.
A heat map of the Freezing range from a Scheil calculation for an Al-1Si-1Mn-0.7Mg-0.6Fe-0.1Cu alloy using the new Scheil Property Model with the grid calculation type.
Crack Susceptibility Coefficient Property Model Improved
The Crack Susceptibility Coefficient Property Model received two new models in this release. In addition to the original Clyne and Davies model, you can now select Kou or Easton models.
Screenshot of the settings in the Crack Susceptibility Coefficient Property Model, showing all the models including the new Kou and Easton models.
The Model also received additional Scheil settings. For example, users can now select Scheil with Back Diffusion in Primary Phase or Scheil with Solute Trapping, in addition to Classic Scheil. The Advanced Scheil Options have also been expanded in the Property Model.
Yield Strength Model Improved
The intrinsic strength model has been completely overhauled in order to improve the Yield Strength Model. Previously, intrinsic strength was only calculated per element and only for FCC, BCC, and HCP. Now, the model formulation corresponds to a surface of reference with end-members.
The plot shows how the intrinsic strength of FCC_A1#2 (in this case TiC) is accurately calculated with increasing volume fraction.
The plot shows the tempering temperature compared to the total hardness of three tempered AISI steels (1030, 1095 1144) compared to handbook data from Penha, et al. (2013), calculated using the new Martensitic Steel Strength Property Model.
Parallel plot of the SAC risk factor along with experimental and calculated solvus of γ’ for the three alloys compared in [2020Zho], calculated using the new Strain-Age Cracking Property Model.
This figure illustrates the two-dimensional cross section obtained from sectioning a three-dimensional dispersion of spheres, relevant to Scanning Electron and Optical micrographs taken of material with second phase precipitates.
To learn more, you can read the release notes or the help, which both go into detail about this new feature.
A new example is included in the release demonstrating this new feature: