| About this Abstract |
| Meeting |
2025 TMS Annual Meeting & Exhibition
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| Symposium
|
Microstructural Evolution and Material Properties Due to Manufacturing Processes: A Symposium in Honor of Anthony Rollett
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| Presentation Title |
Predicting Spatial Variability of Mechanical Properties in Additively Manufactured Metals Using a Process-Structure-Property Modeling Framework |
| Author(s) |
Ashley D. Spear, Wenda Tan |
| On-Site Speaker (Planned) |
Ashley D. Spear |
| Abstract Scope |
Professor Rollett’s implementation of the parallelized Micromechanical Analysis of Stress-Strain Inhomogeneities with fast Fourier transforms (MASSIF) code has enabled micromechanical simulations of real and realistic 3D microstructures with unprecedented computational efficiency. Serendipitously, the implementation of MASSIF coincided with growing needs to simulate microstructure-dependent mechanical responses of additively manufactured (AM) metals, which notoriously depend on process conditions and spatially dependent thermal history. Recognizing the tremendous potential of MASSIF for solving this previously unresolved need for AM metals, we integrated MASSIF into a physics-based process-structure-property framework to predict location- and microstructure-dependent mechanical properties throughout AM build domains. Additionally, a grain-boundary strengthening mechanism was incorporated into the MASSIF framework to account for grain-size effects in polycrystalline metals. The entire process-structure-property framework was then used to predict, in succession: thermal history under specific laser-based AM processing conditions; evolution of grain structure, accounting for competitive grain growth; micromechanical response of microstructural subvolumes throughout the simulated build domains; and homogenized (upscaled) values of yield strength, visualized as heat maps. Recently, we extended the framework to predict location-dependent fatigue properties for AM metals. Back stress was incorporated into MASSIF, along with computation of fatigue indicator parameters (FIP) based on a well-established Fatemi-Socie metric. Estimates of fatigue severity based on FIP values computed over thousands of loading cycles can now be visualized as 3D heat maps, providing a powerful tool to assist with qualification of AM metals in fatigue-critical applications. Overall, the generation of such mechanical property maps for meaningful volumes of AM build domains requires high-throughput (O(1000)) micromechanical simulations—a task made tractable by MASSIF. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Computational Materials Science & Engineering, Modeling and Simulation |