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Title: Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects

Abstract

We describe an approach to predict failure in a complex, additively-manufactured stainless steel part as defined by the third Sandia Fracture Challenge. A viscoplastic internal state variable constitutive model was calibrated to fit experimental tension curves in order to capture plasticity, necking, and damage evolution leading to failure. Defects such as gas porosity and lack of fusion voids were represented by overlaying a synthetic porosity distribution onto the finite element mesh and computing the elementwise ratio between pore volume and element volume to initialize the damage internal state variables. These void volume fraction values were then used in a damage formulation accounting for growth of these existing voids, while new voids were allowed to nucleate based on a nucleation rule. Blind predictions of failure are compared to experimental results. The comparisons indicate that crack initiation and propagation were correctly predicted, and that an initial porosity field superimposed as higher initial damage may provide a path forward for capturing material strength uncertainty. Here, the latter conclusion was supported by predicted crack face tortuosity beyond the usual mesh sensitivity and variability in predicted strain to failure; however, it bears further inquiry and a more conclusive result is pending compressive testing of challenge-builtmore » coupons to de-convolute materials behavior from the geometric influence of significant porosity.« less

Authors:
ORCiD logo [1];  [1];  [1];  [1];  [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:
1570251
Report Number(s):
[SAND-2019-10227J]
[Journal ID: ISSN 0376-9429; 678949]
Grant/Contract Number:  
[AC04-94AL85000]
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; Additive manufacturing; Failure; Plasticity; Porosity; Sandia fracture challenge; Fracture

Citation Formats

Johnson, Kyle L., Emery, John M., Hammetter, Chris I., Brown, Judith Alice, Grange, Spencer J., Ford, Kurtis Ross, and Bishop, Joseph E. Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects. United States: N. p., 2019. Web. doi:10.1007/s10704-019-00368-8.
Johnson, Kyle L., Emery, John M., Hammetter, Chris I., Brown, Judith Alice, Grange, Spencer J., Ford, Kurtis Ross, & Bishop, Joseph E. Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects. United States. doi:10.1007/s10704-019-00368-8.
Johnson, Kyle L., Emery, John M., Hammetter, Chris I., Brown, Judith Alice, Grange, Spencer J., Ford, Kurtis Ross, and Bishop, Joseph E. Wed . "Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects". United States. doi:10.1007/s10704-019-00368-8.
@article{osti_1570251,
title = {Predicting the reliability of an additively-manufactured metal part for the third Sandia fracture challenge by accounting for random material defects},
author = {Johnson, Kyle L. and Emery, John M. and Hammetter, Chris I. and Brown, Judith Alice and Grange, Spencer J. and Ford, Kurtis Ross and Bishop, Joseph E.},
abstractNote = {We describe an approach to predict failure in a complex, additively-manufactured stainless steel part as defined by the third Sandia Fracture Challenge. A viscoplastic internal state variable constitutive model was calibrated to fit experimental tension curves in order to capture plasticity, necking, and damage evolution leading to failure. Defects such as gas porosity and lack of fusion voids were represented by overlaying a synthetic porosity distribution onto the finite element mesh and computing the elementwise ratio between pore volume and element volume to initialize the damage internal state variables. These void volume fraction values were then used in a damage formulation accounting for growth of these existing voids, while new voids were allowed to nucleate based on a nucleation rule. Blind predictions of failure are compared to experimental results. The comparisons indicate that crack initiation and propagation were correctly predicted, and that an initial porosity field superimposed as higher initial damage may provide a path forward for capturing material strength uncertainty. Here, the latter conclusion was supported by predicted crack face tortuosity beyond the usual mesh sensitivity and variability in predicted strain to failure; however, it bears further inquiry and a more conclusive result is pending compressive testing of challenge-built coupons to de-convolute materials behavior from the geometric influence of significant porosity.},
doi = {10.1007/s10704-019-00368-8},
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:

Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS
journal, December 2017

  • Johnson, Kyle L.; Rodgers, Theron M.; Underwood, Olivia D.
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Validation of a model for static and dynamic recrystallization in metals
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The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal
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Intergranular fracture during power-law creep under multiaxial stresses
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The second Sandia Fracture Challenge: predictions of ductile failure under quasi-static and moderate-rate dynamic loading
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Fatigue behavior and failure mechanisms of direct laser deposited Ti–6Al–4V
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Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures
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Predicting laser weld reliability with stochastic reduced-order models: PREDICTING LASER WELD RELIABILITY
journal, May 2015

  • Emery, John M.; Field, Richard V.; Foulk, James W.
  • International Journal for Numerical Methods in Engineering, Vol. 103, Issue 12
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Metal Additive Manufacturing: A Review
journal, April 2014


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

The mechanisms of ductile rupture
journal, December 2018


    Works referencing / citing this record:

    Predicting laser weld reliability with stochastic reduced-order models: PREDICTING LASER WELD RELIABILITY
    journal, May 2015

    • Emery, John M.; Field, Richard V.; Foulk, James W.
    • International Journal for Numerical Methods in Engineering, Vol. 103, Issue 12
    • DOI: 10.1002/nme.4935

    Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS
    journal, December 2017

    • Johnson, Kyle L.; Rodgers, Theron M.; Underwood, Olivia D.
    • Computational Mechanics, Vol. 61, Issue 5
    • DOI: 10.1007/s00466-017-1516-y

    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 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

    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

    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

    Metal Additive Manufacturing: A Review
    journal, April 2014


    Mesh effects in the analysis of dynamic ductile crack growth
    journal, January 1994


    The mechanisms of ductile rupture
    journal, December 2018


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


    Microstructural and texture development in direct laser fabricated IN718
    journal, March 2014


    Fatigue behavior and failure mechanisms of direct laser deposited Ti–6Al–4V
    journal, February 2016

    • Sterling, Amanda J.; Torries, Brian; Shamsaei, Nima
    • Materials Science and Engineering: A, Vol. 655
    • DOI: 10.1016/j.msea.2015.12.026

    Corroborating tomographic defect metrics with mechanical response in an additively manufactured precipitation-hardened stainless steel
    conference, January 2018

    • Madison, Jonathan D.; Underwood, Olivia D.; Swiler, Laura P.
    • 44TH ANNUAL REVIEW OF PROGRESS IN QUANTITATIVE NONDESTRUCTIVE EVALUATION, VOLUME 37, AIP Conference Proceedings
    • DOI: 10.1063/1.5031506

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