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<p>A multiscale numerical model integrating the Cellular Automaton (CA) and Finite Element Method (FEM) has been developed to investigate the microstructure evolution of Mg–Y–Sm–Zn–Zr rare-earth Mg alloys during Selective Laser Melting (SLM). This approach comprehensively accounts for heat conduction, nucleation behavior, solute redistribution, and dendritic growth kinetics. The influence of laser power and scanning speed on molten pool thermal behavior, geometry, and resulting microstructure was systematically examined. The simulation results reveal that an increase in laser power or a reduction in scanning speed leads to an enlarged molten pool, enhanced columnar grain growth, and diminished solute accumulation at the solid–liquid interface. Specifically, as the laser power increases from 50 to 80 W, the Primary Dendrite Arm Spacing (PDAS) rises from 1.02 to 1.4&#xa0;µm. In contrast, increasing the scanning speed from 200 to 400&#xa0;mm/s reduces the PDAS from 1.56 to 1.12&#xa0;µm. Comparative analysis demonstrates a relative deviation of approximately 7% between simulated and experimental results, indicating a strong consistency in microstructure distribution. These findings provide a theoretical basis for optimizing SLM process parameters and offer a cost-effective alternative to extensive experimental trials in the fabrication of rare-earth Mg alloys.</p>

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Prediction of microstructure evolution of rare-earth Mg alloy during selective laser melting based on cellular automaton method

  • 期刊论文

  • 发表日期：

    2026年3月8日

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  • Kefan Lei,
  • Wenli Wang,
  • Yafei Liu,
  • Chunhong Liu

摘要

A multiscale numerical model integrating the Cellular Automaton (CA) and Finite Element Method (FEM) has been developed to investigate the microstructure evolution of Mg–Y–Sm–Zn–Zr rare-earth Mg alloys during Selective Laser Melting (SLM). This approach comprehensively accounts for heat conduction, nucleation behavior, solute redistribution, and dendritic growth kinetics. The influence of laser power and scanning speed on molten pool thermal behavior, geometry, and resulting microstructure was systematically examined. The simulation results reveal that an increase in laser power or a reduction in scanning speed leads to an enlarged molten pool, enhanced columnar grain growth, and diminished solute accumulation at the solid–liquid interface. Specifically, as the laser power increases from 50 to 80 W, the Primary Dendrite Arm Spacing (PDAS) rises from 1.02 to 1.4 µm. In contrast, increasing the scanning speed from 200 to 400 mm/s reduces the PDAS from 1.56 to 1.12 µm. Comparative analysis demonstrates a relative deviation of approximately 7% between simulated and experimental results, indicating a strong consistency in microstructure distribution. These findings provide a theoretical basis for optimizing SLM process parameters and offer a cost-effective alternative to extensive experimental trials in the fabrication of rare-earth Mg alloys.