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Meeting TMS Specialty Congress 2025
Symposium 8th World Congress on Integrated Computational Materials Engineering (ICME 2025)
Presentation Title Computational Investigation on the Combined Effect of Surface Roughness and Pore Attributes on Strain Concentrators in Metal Additively Manufactured Materials
Author(s) Erick Ramirez, George Weber, Saikumar Yeratapally, Kenji Shimada
On-Site Speaker (Planned) Erick Ramirez
Abstract Scope Metal additive manufacturing (AM) provides a pathway for creating highly optimized components. However, porosity and surface roughness (SR) continue to be prevalent issues for fatigue performance despite best efforts in optimizing process parameters and postprocessing techniques. This work uses finite element analysis to conduct a parametric study to link various pore attributes (i.e., size, aspect ratio, orientation, and location) to strain concentration factors (SCFs) in the presence of SR under elastic/plastic deformation during uniaxial loading. Keyhole and lack-of-fusion pores are idealized by prolate and oblate ellipsoids, respectively, while SR is reconstructed from high-resolution X-ray computed tomography images of an AM tensile specimen. Each simulation of the parametric study assumes a single pore in a Ti-6Al-4V material, modeled with J2-plasticity. This investigation reveals how isolated porosity increases SCF at the rough surface and how variability in SR geometry results in variability in SCF at the pore.
Proceedings Inclusion? Undecided

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