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Title: Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy

Abstract

The third Sandia Fracture Challenge illustrated the geometric and material uncertainties presented by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Particularly, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This method allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.

Authors:
ORCiD logo [1];  [1];  [1]; ORCiD logo [1];  [1];  [1]; ORCiD logo [1];  [1]
  1. Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Publication Date:
Research Org.:
Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1559548
Report Number(s):
SAND-2018-11774J
Journal ID: ISSN 0376-9429; 669291; TRN: US2000366
Grant/Contract Number:  
AC04-94AL85000; NA0003525
Resource Type:
Accepted Manuscript
Journal Name:
International Journal of Fracture
Additional Journal Information:
Journal Volume: 218; Journal Issue: 1-2; Journal ID: ISSN 0376-9429
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Ductile failure; Finite element modeling; Additive manufacturing; Direct metal laser sintering (DMLS); 316L stainless steel; Material calibration; Plastic anisotropy

Citation Formats

Karlson, Kyle N., Alleman, Coleman, Foulk III, James W., Manktelow, Kevin L., Ostien, Jakob T., Stender, Michael E., Stershic, Andrew J., and Veilleux, Michael G. Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy. United States: N. p., 2019. Web. doi:10.1007/s10704-019-00365-x.
Karlson, Kyle N., Alleman, Coleman, Foulk III, James W., Manktelow, Kevin L., Ostien, Jakob T., Stender, Michael E., Stershic, Andrew J., & Veilleux, Michael G. Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy. United States. doi:10.1007/s10704-019-00365-x.
Karlson, Kyle N., Alleman, Coleman, Foulk III, James W., Manktelow, Kevin L., Ostien, Jakob T., Stender, Michael E., Stershic, Andrew J., and Veilleux, Michael G. Tue . "Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy". United States. doi:10.1007/s10704-019-00365-x. https://www.osti.gov/servlets/purl/1559548.
@article{osti_1559548,
title = {Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy},
author = {Karlson, Kyle N. and Alleman, Coleman and Foulk III, James W. and Manktelow, Kevin L. and Ostien, Jakob T. and Stender, Michael E. and Stershic, Andrew J. and Veilleux, Michael G.},
abstractNote = {The third Sandia Fracture Challenge illustrated the geometric and material uncertainties presented by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Particularly, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This method allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.},
doi = {10.1007/s10704-019-00365-x},
journal = {International Journal of Fracture},
number = 1-2,
volume = 218,
place = {United States},
year = {2019},
month = {7}
}

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Works referenced in this record:

Nonlocal Integral Formulations of Plasticity and Damage: Survey of Progress
journal, November 2002


A void–crack nucleation model for ductile metals
journal, November 1999


The Sandia Fracture Challenge: blind round robin predictions of ductile tearing
journal, January 2014

  • Boyce, B. L.; Kramer, S. L. B.; Fang, H. E.
  • International Journal of Fracture, Vol. 186, Issue 1-2
  • DOI: 10.1007/s10704-013-9904-6

The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal
journal, July 2019

  • Kramer, Sharlotte L. B.; Jones, Amanda; Mostafa, Ahmed
  • International Journal of Fracture, Vol. 218, Issue 1-2
  • DOI: 10.1007/s10704-019-00361-1

Intergranular fracture during power-law creep under multiaxial stresses
journal, August 1980


The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading
journal, March 2016

  • Boyce, B. L.; Kramer, S. L. B.; Bosiljevac, T. R.
  • International Journal of Fracture, Vol. 198, Issue 1-2
  • DOI: 10.1007/s10704-016-0089-7

A multivariate Kolmogorov-Smirnov test of goodness of fit
journal, October 1997


As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting
journal, May 2011

  • Vilaro, T.; Colin, C.; Bartout, J. D.
  • Metallurgical and Materials Transactions A, Vol. 42, Issue 10
  • DOI: 10.1007/s11661-011-0731-y

Nonlocal Damage Theory
journal, October 1987


Monocrystal-Polycrystal Elastic Constants of a Stainless Steel
journal, September 1984


A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling
journal, May 2018


Sandia fracture challenge 2: Sandia California’s modeling approach
journal, March 2016

  • Karlson, Kyle N.; Foulk, James W.; Brown, Arthur A.
  • International Journal of Fracture, Vol. 198, Issue 1-2
  • DOI: 10.1007/s10704-016-0090-1

A Criterion for Ductile Fracture by the Growth of Holes
journal, June 1968

  • McClintock, F. A.
  • Journal of Applied Mechanics, Vol. 35, Issue 2
  • DOI: 10.1115/1.3601204

Anisotropic high cycle fatigue behavior of Ti–6Al–4V obtained by powder bed laser fusion
journal, January 2017


An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel
journal, September 2014

  • Wu, Amanda S.; Brown, Donald W.; Kumar, Mukul
  • Metallurgical and Materials Transactions A, Vol. 45, Issue 13
  • DOI: 10.1007/s11661-014-2549-x

Modification of the Gurson Model for shear failure
journal, January 2008


The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading
text, January 2016


Validation of a model for static and dynamic recrystallization in metals
journal, May 2012


Fatigue life of additively manufactured Ti–6Al–4V in the very high cycle fatigue regime
journal, January 2017


On the ductile enlargement of voids in triaxial stress fields∗
journal, June 1969


A class of variational strain-localization finite elements
journal, January 2005

  • Yang, Q.; Mota, A.; Ortiz, M.
  • International Journal for Numerical Methods in Engineering, Vol. 62, Issue 8
  • DOI: 10.1002/nme.1199

A return mapping algorithm for isotropic and anisotropic plasticity models using a line search method
journal, April 2017


Effects of Defects in Laser Additive Manufactured Ti-6Al-4V on Fatigue Properties
journal, January 2014


    Works referencing / citing this record:

    Effects of Defects in Laser Additive Manufactured Ti-6Al-4V on Fatigue Properties
    journal, January 2014


    A void–crack nucleation model for ductile metals
    journal, November 1999


    Modification of the Gurson Model for shear failure
    journal, January 2008


    Monocrystal-Polycrystal Elastic Constants of a Stainless Steel
    journal, September 1984


    Fatigue life of additively manufactured Ti–6Al–4V in the very high cycle fatigue regime
    journal, January 2017


    Intergranular fracture during power-law creep under multiaxial stresses
    journal, August 1980


    Validation of a model for static and dynamic recrystallization in metals
    journal, May 2012


    On the ductile enlargement of voids in triaxial stress fields∗
    journal, June 1969


    A return mapping algorithm for isotropic and anisotropic plasticity models using a line search method
    journal, April 2017


    Nonlocal Integral Formulations of Plasticity and Damage: Survey of Progress
    journal, November 2002


    Sandia fracture challenge 2: Sandia California’s modeling approach
    journal, March 2016

    • Karlson, Kyle N.; Foulk, James W.; Brown, Arthur A.
    • International Journal of Fracture, Vol. 198, Issue 1-2
    • DOI: 10.1007/s10704-016-0090-1

    A multivariate Kolmogorov-Smirnov test of goodness of fit
    journal, October 1997


    The Sandia Fracture Challenge: blind round robin predictions of ductile tearing
    journal, January 2014

    • Boyce, B. L.; Kramer, S. L. B.; Fang, H. E.
    • International Journal of Fracture, Vol. 186, Issue 1-2
    • DOI: 10.1007/s10704-013-9904-6

    A Criterion for Ductile Fracture by the Growth of Holes
    journal, June 1968

    • McClintock, F. A.
    • Journal of Applied Mechanics, Vol. 35, Issue 2
    • DOI: 10.1115/1.3601204

    As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting
    journal, May 2011

    • Vilaro, T.; Colin, C.; Bartout, J. D.
    • Metallurgical and Materials Transactions A, Vol. 42, Issue 10
    • DOI: 10.1007/s11661-011-0731-y

    An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel
    journal, September 2014

    • Wu, Amanda S.; Brown, Donald W.; Kumar, Mukul
    • Metallurgical and Materials Transactions A, Vol. 45, Issue 13
    • DOI: 10.1007/s11661-014-2549-x

    A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling
    journal, May 2018


    The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading
    journal, March 2016

    • Boyce, B. L.; Kramer, S. L. B.; Bosiljevac, T. R.
    • International Journal of Fracture, Vol. 198, Issue 1-2
    • DOI: 10.1007/s10704-016-0089-7

    Anisotropic high cycle fatigue behavior of Ti–6Al–4V obtained by powder bed laser fusion
    journal, January 2017


    Nonlocal Damage Theory
    journal, October 1987


    A class of variational strain-localization finite elements
    journal, January 2005

    • Yang, Q.; Mota, A.; Ortiz, M.
    • International Journal for Numerical Methods in Engineering, Vol. 62, Issue 8
    • DOI: 10.1002/nme.1199

    The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal
    journal, July 2019

    • Kramer, Sharlotte L. B.; Jones, Amanda; Mostafa, Ahmed
    • International Journal of Fracture, Vol. 218, Issue 1-2
    • DOI: 10.1007/s10704-019-00361-1