Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties

doi:10.1007/s11837-019-03808-x

Title: Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties

Abstract

Metal additive manufacturing (AM) allows for the freeform creation of complex parts. However, AM microstructures are highly sensitive to the process parameters used. Resulting microstructures vary significantly from typical metal alloys in grain morphology distributions, defect populations and crystallographic texture. AM microstructures are often anisotropic and possess three-dimensional features. These microstructural features determine the mechanical properties of AM parts. Here, we reproduce three “canonical” AM microstructures from the literature and investigate their mechanical responses. Stochastic volume elements are generated with a kinetic Monte Carlo process simulation. A crystal plasticity-finite element model is then used to simulate plastic deformation of the AM microstructures and a reference equiaxed microstructure. Results demonstrate that AM microstructures possess significant variability in strength and plastic anisotropy compared with conventional equiaxed microstructures.

Authors:

^[1]; Lim, Hojun ^[1]; Brown, Judith Alice ^[2]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States). Dept. of Computational Materials and Data Science
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States). Dept. of Fluid and Reactive Processes

Publication Date:: 2019-10-30

Research Org.:: Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Org.:: USDOE National Nuclear Security Administration (NNSA)

OSTI Identifier:: 1574438

Report Number(s):: SAND-2019-12098J
Journal ID: ISSN 1047-4838; 680146

Grant/Contract Number:: AC04-94AL85000

Resource Type:: Accepted Manuscript

Journal Name:: JOM. Journal of the Minerals, Metals & Materials Society

Additional Journal Information:: Journal Volume: 72; Journal Issue: 1; Journal ID: ISSN 1047-4838

Publisher:: Springer

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; additive manufacturing; crystal plasticity; texture; mechanical properties

Citation Formats


                    Rodgers, Theron M., Lim, Hojun, and Brown, Judith Alice. Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties.  United States: N. p., 2019. 
        Web.  doi:10.1007/s11837-019-03808-x.

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                    Rodgers, Theron M., Lim, Hojun, & Brown, Judith Alice. Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties.  United States.  doi:10.1007/s11837-019-03808-x.

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                    Rodgers, Theron M., Lim, Hojun, and Brown, Judith Alice. Wed .  
        "Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties".  United States.  doi:10.1007/s11837-019-03808-x.  https://www.osti.gov/servlets/purl/1574438.

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@article{osti_1574438,

  title        = {Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties},

  author       = {Rodgers, Theron M. and Lim, Hojun and Brown, Judith Alice},

  abstractNote = {Metal additive manufacturing (AM) allows for the freeform creation of complex parts. However, AM microstructures are highly sensitive to the process parameters used. Resulting microstructures vary significantly from typical metal alloys in grain morphology distributions, defect populations and crystallographic texture. AM microstructures are often anisotropic and possess three-dimensional features. These microstructural features determine the mechanical properties of AM parts. Here, we reproduce three “canonical” AM microstructures from the literature and investigate their mechanical responses. Stochastic volume elements are generated with a kinetic Monte Carlo process simulation. A crystal plasticity-finite element model is then used to simulate plastic deformation of the AM microstructures and a reference equiaxed microstructure. Results demonstrate that AM microstructures possess significant variability in strength and plastic anisotropy compared with conventional equiaxed microstructures.},

  doi          = {10.1007/s11837-019-03808-x},

  journal      = {JOM. Journal of the Minerals, Metals & Materials Society},

  number       = 1,

  volume       = 72,

  place        = {United States},

  year         = {2019},

  month        = {10}

}

Copy to clipboard

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Title: Three-Dimensional Additively Manufactured Microstructures and Their Mechanical Properties

Abstract

Citation Formats

On the fatigue crack growth behavior in 316L stainless steel manufactured by selective laser melting journal, April 2014

Effect of manufacturing parameters on mechanical properties of 316L stainless steel parts fabricated by selective laser melting: A computational framework journal, December 2016

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

Functionally graded Inconel 718 processed by additive manufacturing: Crystallographic texture, anisotropy of microstructure and mechanical properties journal, January 2017

A multi-scale, multi-physics modeling framework to predict spatial variation of properties in additive-manufactured metals journal, January 2019

An analysis of nonuniform and localized deformation in ductile single crystals journal, June 1982

High-throughput stochastic tensile performance of additively manufactured stainless steel journal, March 2017

Modeling process-structure-property relationships for additive manufacturing journal, February 2018

Evolution of solidification texture during additive manufacturing journal, November 2015

Heterogeneous random medium plasticity and fracture model of additively-manufactured Ti-6Al-4V journal, April 2018

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

Incorporating grain-level residual stresses and validating a crystal plasticity model of a two-phase Ti-6Al-4 V alloy produced via additive manufacturing journal, December 2018

Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures journal, June 2018

Quantitative comparison between experimental measurements and CP-FEM predictions of plastic deformation in a tantalum oligocrystal journal, March 2015

Strengthening mechanisms in directed energy deposited austenitic stainless steel journal, February 2019

Mean-field polycrystal plasticity modeling with grain size and shape effects for laser additive manufactured FCC metals journal, May 2017

Bounds and Self-Consistent Estimates for Creep of Polycrystalline Materials journal, February 1976

Developing anisotropic yield models of polycrystalline tantalum using crystal plasticity finite element simulations journal, July 2018

Dislocation network in additive manufactured steel breaks strength–ductility trade-off journal, May 2018

Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel Produced by Selective Laser Melting journal, August 2016

The laser additive manufacture of Ti-6Al-4V journal, September 2001

Additively manufactured hierarchical stainless steels with high strength and ductility journal, October 2017

Lattice Structures Manufactured by SLM: On the Effect of Geometrical Dimensions on Microstructure Evolution During Processing journal, May 2014

Energy input effect on morphology and microstructure of selective laser melting single track from metallic powder journal, April 2013

Mechanical behavior of selective laser melted 316L stainless steel journal, June 2017

An internal variable constitutive model for hot working of metals journal, January 1989

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder journal, March 2013

Defect distribution and microstructure heterogeneity effects on fracture resistance and fatigue behavior of EBM Ti–6Al–4V journal, January 2017

Texture control during laser deposition of nickel-based superalloy journal, September 2012

Hardened austenite steel with columnar sub-grain structure formed by laser melting journal, February 2015

Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo journal, July 2017

Three-dimensional Analysis and Reconstruction of Additively Manufactured Materials in the Cloud-Based BisQue Infrastructure journal, March 2019

Predicting Mesoscale Microstructural Evolution in Electron Beam Welding journal, March 2016

Crystallographic texture evolution in bulk deformation processing of FCC metals journal, January 1992

Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V journal, January 2017

Metal Additive Manufacturing: A Review of Mechanical Properties journal, July 2016

Extreme-Value Statistics Reveal Rare Failure-Critical Defects in Additive Manufacturing : Extreme-Value Statistics Reveal Rare Failure- Critical Defects… journal, April 2017

On the Anisotropic Mechanical Properties of Selective Laser-Melted Stainless Steel journal, September 2017

A Monte Carlo model for 3D grain evolution during welding journal, August 2017

Highly Anisotropic Steel Processed by Selective Laser Melting journal, May 2013

Defects and 3D structural inhomogeneity in electron beam additively manufactured Inconel 718 journal, September 2018

On the fatigue crack growth behavior in 316L stainless steel manufactured by selective laser melting
journal, April 2014

Effect of manufacturing parameters on mechanical properties of 316L stainless steel parts fabricated by selective laser melting: A computational framework
journal, December 2016

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

Functionally graded Inconel 718 processed by additive manufacturing: Crystallographic texture, anisotropy of microstructure and mechanical properties
journal, January 2017

A multi-scale, multi-physics modeling framework to predict spatial variation of properties in additive-manufactured metals
journal, January 2019

An analysis of nonuniform and localized deformation in ductile single crystals
journal, June 1982

High-throughput stochastic tensile performance of additively manufactured stainless steel
journal, March 2017

Modeling process-structure-property relationships for additive manufacturing
journal, February 2018

Evolution of solidification texture during additive manufacturing
journal, November 2015

Heterogeneous random medium plasticity and fracture model of additively-manufactured Ti-6Al-4V
journal, April 2018

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

Incorporating grain-level residual stresses and validating a crystal plasticity model of a two-phase Ti-6Al-4 V alloy produced via additive manufacturing
journal, December 2018

Direct numerical simulation of mechanical response in synthetic additively manufactured microstructures
journal, June 2018

Quantitative comparison between experimental measurements and CP-FEM predictions of plastic deformation in a tantalum oligocrystal
journal, March 2015

Strengthening mechanisms in directed energy deposited austenitic stainless steel
journal, February 2019

Mean-field polycrystal plasticity modeling with grain size and shape effects for laser additive manufactured FCC metals
journal, May 2017

Bounds and Self-Consistent Estimates for Creep of Polycrystalline Materials
journal, February 1976

Developing anisotropic yield models of polycrystalline tantalum using crystal plasticity finite element simulations
journal, July 2018

Dislocation network in additive manufactured steel breaks strength–ductility trade-off
journal, May 2018

Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel Produced by Selective Laser Melting
journal, August 2016

The laser additive manufacture of Ti-6Al-4V
journal, September 2001

Additively manufactured hierarchical stainless steels with high strength and ductility
journal, October 2017

Lattice Structures Manufactured by SLM: On the Effect of Geometrical Dimensions on Microstructure Evolution During Processing
journal, May 2014

Energy input effect on morphology and microstructure of selective laser melting single track from metallic powder
journal, April 2013

Mechanical behavior of selective laser melted 316L stainless steel
journal, June 2017

An internal variable constitutive model for hot working of metals
journal, January 1989

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder
journal, March 2013

Defect distribution and microstructure heterogeneity effects on fracture resistance and fatigue behavior of EBM Ti–6Al–4V
journal, January 2017

Texture control during laser deposition of nickel-based superalloy
journal, September 2012

Hardened austenite steel with columnar sub-grain structure formed by laser melting
journal, February 2015

Simulation of metal additive manufacturing microstructures using kinetic Monte Carlo
journal, July 2017

Three-dimensional Analysis and Reconstruction of Additively Manufactured Materials in the Cloud-Based BisQue Infrastructure
journal, March 2019

Predicting Mesoscale Microstructural Evolution in Electron Beam Welding
journal, March 2016

Crystallographic texture evolution in bulk deformation processing of FCC metals
journal, January 1992

Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V
journal, January 2017

Metal Additive Manufacturing: A Review of Mechanical Properties
journal, July 2016

Extreme-Value Statistics Reveal Rare Failure-Critical Defects in Additive Manufacturing : Extreme-Value Statistics Reveal Rare Failure- Critical Defects…
journal, April 2017

On the Anisotropic Mechanical Properties of Selective Laser-Melted Stainless Steel
journal, September 2017

A Monte Carlo model for 3D grain evolution during welding
journal, August 2017

Highly Anisotropic Steel Processed by Selective Laser Melting
journal, May 2013

Defects and 3D structural inhomogeneity in electron beam additively manufactured Inconel 718
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