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Title: Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures

Abstract

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. Here, 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.

Authors:
ORCiD logo [1];  [1];  [1]
  1. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Publication Date:
Research Org.:
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1459990
Report Number(s):
SAND2018-5362J
Journal ID: ISSN 0965-0393; 663276
Grant/Contract Number:  
AC04-94AL85000
Resource Type:
Accepted Manuscript
Journal Name:
Modelling and Simulation in Materials Science and Engineering
Additional Journal Information:
Journal Volume: 26; Journal Issue: 5; Journal ID: ISSN 0965-0393
Publisher:
IOP Publishing
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; additive manufacturing; Potts Monte Carlo; SPPARKS; direct numerical simulation

Citation Formats

Rodgers, Theron M., Bishop, Joseph E., and Madison, Jonathan D. Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures. United States: N. p., 2018. Web. doi:10.1088/1361-651X/aac616.
Rodgers, Theron M., Bishop, Joseph E., & Madison, Jonathan D. Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures. United States. doi:10.1088/1361-651X/aac616.
Rodgers, Theron M., Bishop, Joseph E., and Madison, Jonathan D. Thu . "Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures". United States. doi:10.1088/1361-651X/aac616. https://www.osti.gov/servlets/purl/1459990.
@article{osti_1459990,
title = {Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures},
author = {Rodgers, Theron M. and Bishop, Joseph E. and Madison, Jonathan D.},
abstractNote = {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. Here, 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.},
doi = {10.1088/1361-651X/aac616},
journal = {Modelling and Simulation in Materials Science and Engineering},
number = 5,
volume = 26,
place = {United States},
year = {2018},
month = {6}
}

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