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About this Abstract
Meeting	2025 TMS Annual Meeting & Exhibition
Symposium	Verification, Calibration, and Validation Approaches in Modeling the Mechanical Performance of Metallic Materials
Presentation Title	Experiment and Crystal Plasticity Model-Based Investigation of Surface Roughness Influence in the Fatigue Life of Additive Manufactured Nickel-Supperalloys
Author(s)	Jiahao Cheng, Daniel Ryan, Patxi Fernandez-Zelaia, Brandon Kemerling, Sudhakar Bollapragada, Michael Kirka
On-Site Speaker (Planned)	Jiahao Cheng
Abstract Scope	Additive manufacturing (AM) offers the advantage of fabricating geometrically complex components. However, those components often present challenges in machining and typically have as-built rough surfaces. It is known that surface roughness will impact the material's fatigue properties by introducing surface-initiated cracks. A fully experimental approach to quantifying the fatigue behavior of rough AM samples is both costly and labor-intensive. This presentation introduces a two-scale crystal plasticity model incorporating a Chaboche-type fatigue damage model to simulate micro-crack formation from rough surfaces. The model is calibrated with experimental fatigue tests on both machined and as-built samples. Synthetic rough surfaces and microstructures with a wide range of surface characteristics are then generated to conduct Monte Carlo simulations for uncertainty quantification. The results are analyzed to investigate the role of different surface characteristics on the fatigue behavior and the interaction between surface roughness and near-surface microstructures.
Proceedings Inclusion?	Planned:
Keywords	Modeling and Simulation, Additive Manufacturing, Mechanical Properties

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