Data-driven phase-field modeling for additively manufactured Inconel 617: Transformative insights for small modular reactors

This study examines the microstructural evolution and thermal-fluid behavior of Inconel 617 during laser-directed energy deposition additive manufacturing, focusing on temperature distribution, surface tension, and melt pool dynamics. A monolithic phase-field model, integrated with CALPHAD-informed thermodynamic data, is developed to predict solidification processes and surface tension variations. Results indicate that laser power critically influences thermal gradients, melt pool stability, and defect formation. Higher laser power increases thermal gradients, reducing surface tension and expanding melt pools, while lower laser power results in more stable surface tension and reduced defect risks. The temperature field is analyzed along and perpendicular to the laser movement, highlighting vaporization thresholds and melt pool geometry in governing material behavior. Surface tension consistently decreases near the laser interaction region, influenced by local thermal gradients. These findings contribute to process optimization—ensuring defect-free, corrosion-resistant Inconel 617 components with optimized microstructure and minimal residual stress for high-temperature applications, including small modular reactors.