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Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures

Modelling and Simulation in Materials Science and Engineering

Rodgers, Theron R.; Bishop, Joseph E.; Madison, Jonathan D.

Additive manufacturing (AM) processes for metals can yield as-built microstructures that vary significantly from their cast or wrought counterparts. These microstructural variations can in turn, have profound effects on the properties of a component. Here, a modeling methodology is presented to investigate microstructurally-influenced mechanical response in additively manufactured structures via direct numeral simulation. Three-dimensional, synthetic voxelized microstructures are generated by kinetic Monte Carlo (kMC) additive manufacturing process simulations performed at four scan speeds to create a thin-wall cylindrical geometry notionally constructed using a concentric-pathed directed energy deposition AM process. The kMC simulations utilize a steady-state molten pool geometry that is held constant throughout the study. Resultant microstructures are mapped onto a highly-refined conformal finite-element mesh of a part geometry. A grain-scale anisotropic crystal elasticity model is then used to represent the constitutive response of each grain. The response of the structure subjected to relatively simple load conditions is studied in order to provide understanding of both the influence of AM processing on microstructure as well as the microstructure's influence on the macroscale mechanical response.

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TYPE Journal Article YEAR 2018
DOIOSTIScopus

Modeling of additive manufacturing processes for metals: Challenges and opportunities

Current Opinion in Solid State and Materials Science

Francois, M.M.; Sun, Amy C.; King, W.E.; Henson, N.J.; Bronkhorst, C.A.; Carlson, N.N.; Newman, C.K.; Haut, T.; Bakosi, J.; Gibbs, J.W.; Livescu, V.; Vander Wiel, S.A.; Clarke, A.J.; Schraad, M.W.; Blacker, Ted D.; Lim, Hojun L.; Rodgers, Theron R.; Owen, Steven J.; Abdeljawad, Fadi F.; Madison, Jonathan D.; Anderson, A.T.; Fattebert, J.L.; Ferencz, R.M.; Hodge, N.E.; Khairallah, S.A.; Walton, O.

Researchers review the challenges and opportunities that we are facing in the modeling and simulation of additive manufacturing processes for metals and the predictive representation of their mechanical performance at the different scales. They highlight the current modeling efforts taking place at the US Department of Energy National Nuclear Security Administration (NNSA) Laboratories, such as process modeling, microstructure modeling, properties modeling, performance and topology and process optimization. All these various modeling developments at different scales and regimes are necessary to move toward an integrated computational approach of process-structure-properties-performance that will ultimately enable the engineering and optimization of materials to specific performance requirements. Truchas, a continuum thermo-mechanical modeling tool originally designed for the simulation of casting processes, is being extended to simulate directed energy deposition additive manufacturing processes.

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TYPE Journal Article YEAR 2017
DOIOSTIScopus
Results 51–75 of 166
Results 51–75 of 166