Predicting Residual Stress and Microstructural Equiaxed-to-Columnar Grain Transition in 304L Stainless Steel LENS Parts
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Sintering is a component fabrication process in which powder is compacted by pressing or some other means and then held at elevated temperature for a period of hours. The powder grains bond with each other, leading to the formation of a solid component with much lower porosity, and therefore higher density and higher strength, than the original powder compact. In this project, we investigated a new way of computationally modeling sintering at the length scale of grains. The model uses a high-fidelity, three-dimensional representation with a few hundred nodes per grain. The numerical model solves the peridynamic equations, in which nonlocal forces allow representation of the attraction, adhesion, and mass diffusion between grains. The deformation of the grains is represented through a viscoelastic material model. The project successfully demonstrated the use of this method to reproduce experimentally observed features of material behavior in sintering, including densification, the evolution of microstructure, and the occurrence of random defects in the sintered solid.
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This memo derives a particular use of a rate-dependent, perfectly plastic Von Mises Plasticity constitutive model that represents a Newtonian (or Bingham) fluid. Only two parameters are needed: the viscosity and bulk modulus to complete the model parameterization. Under certain deformations, the model exactly represents a Newtonian fluid. Under others, the model shear thins. A Newtonian fluid representation may be used in confined flow applications in which a fluid-solid interaction is desired but code coupling is not.
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