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In fusion‐based metal additive manufacturing (MAM), the high‐intensity energy input leads to serious evaporation, but how evaporation induces composition evolution and variation and further impacts microstructure and mechanical properties remain a knowledge gap. Here a model integrating composition evolution with molten pool dynamics is developed to reproduce temperature‐ and composition‐dependent evaporative losses and subsequent transport during laser melting. Together with comprehensive experimental characterizations and tests, the simulation results illustrate varying evaporation rates of different elements altering compositions, resulting in a 3D cirrus‐shaped concentration distribution, which significantly impacts the mechanical properties. The simulations reproduce the detailed composition evolution from surface evaporation to molten pool transport and reveal underlying mechanisms relating the composition, temperature, fluid flow, and cracking, which is challenging to observe experimentally. This study elucidates the critical role of evaporation‐induced composition evolution in determining microstructure and mechanical properties. In future alloy design for MAM, integrating initial composition and manufacturing parameters is imperative, where composition evolution simulation offers valuable guidance. [ABSTRACT FROM AUTHOR]

The C4F7N/CO2 mixed gas is most expected to replace SF6 in high-voltage power equipment, and the generation of free metal particles in gas-insulated equipment is unavoidable and highly susceptible to inducing insulation failures. In this paper, the effects of flaky, spherical, and mixed shape aluminum particle defects on the breakdown characteristics of C4F7N/CO2 mixed gas are investigated and compared to those of SF6 under the same conditions. The experimental results show that the effect of particle defects on the insulating properties of C4F7N/CO2 gas mixtures is visualized by the fact that particle defects reduce the breakdown voltage of C4F7N/CO2 gas mixtures, increase their stochasticity, and reduce the enhancement of the insulating properties of C4F7N/CO2 gas mixtures by increasing the air pressure. The greater the number of particles, the greater is the degree of influence. Comparison of the SF6 and C4F7N/CO2 gas mixtures reveals that, in the case of flake defects, increasing the air pressure improves the insulation performance of the SF6 gas better than that of the C4F7N/CO2 gas mixture. Under the condition of the same number of particles, the larger the proportion of spherical particles in the hybrid particles, the smaller is the influence of metal particles on the C4F7N/CO2 mixed gas and on SF6 gas. [ABSTRACT FROM AUTHOR]

One of the most essential tasks in probabilistic damage tolerance assessment is to describe the scatter in crack growth accurately. This study proposes a stochastic model of the crack growth rate, which calculates the critical parameters of a random distribution accurately by combining the Markov chain and data fitting algorithms. The proposed method is validated by the crack growth test data of Ni‐based superalloy GH4710Li at 550°C. The validation results show that the proposed method is a robust and efficient stochastic model for the crack growth rate. [ABSTRACT FROM AUTHOR]