Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error

Brown, Judith Alice; Bishop, Joseph E.

doi:10.1088/1361-651X/aaf107

Title: Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error

Abstract

Here, the repetitive rapid solidification that occurs in metal additive manufacturing (AM) processes creates microstructures distinctly different from wrought materials. Local variability in AM microstructures (either by design or unintentional) raises questions as to how AM structures should be modeled at the part-scale to minimize modeling error. The key goal of this work is to demonstrate a posteriori error estimation applied to an AM part. It is assumed that the actual microstructure is unknown and an approximate, spatially uniform material model is used. Error bounds are calculated for many reference models based on AM microstructures with elongated grain morphology and localized or global fiber textures during a post-processing step. The current findings promote confidence that a posteriori model form error estimation could be used effectively in mechanical performance simulations of AM parts to quickly obtain quantitative error metrics between an approximate model result and many microstructure-based reference models. The a posteriori error estimation introduces significant time savings compared to computing the full reference model solutions. Tight bounds on model form error are obtained when texture variations in the reference models occur on large length scales. For materials with property variation at small length scales, multi-scale error estimation techniques are neededmore »« less

Authors:

^[1];

^[1]

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

Publication Date:: Mon Jan 07 00:00:00 EST 2019

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

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

OSTI Identifier:: 1492376

Report Number(s):: SAND-2018-13372J
Journal ID: ISSN 0965-0393; 670518

Grant/Contract Number:: AC04-94AL85000

Resource Type:: Accepted Manuscript

Journal Name:: Modelling and Simulation in Materials Science and Engineering

Additional Journal Information:: Journal Volume: 27; Journal Issue: 2; Journal ID: ISSN 0965-0393

Publisher:: IOP Publishing

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; additive manufacturing; texture; mechanical properties; model form error; microstructure variability; a posteriori error estimation

Citation Formats


                    Brown, Judith Alice, and Bishop, Joseph E. Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error.  United States: N. p., 2019. 
Web.  doi:10.1088/1361-651X/aaf107.

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                    Brown, Judith Alice, & Bishop, Joseph E. Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error.  United States.  https://doi.org/10.1088/1361-651X/aaf107

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                    Brown, Judith Alice, and Bishop, Joseph E. Mon .  
"Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error".  United States.  https://doi.org/10.1088/1361-651X/aaf107.  https://www.osti.gov/servlets/purl/1492376.

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@article{osti_1492376,

  title        = {Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error},

  author       = {Brown, Judith Alice and Bishop, Joseph E.},

  abstractNote = {Here, the repetitive rapid solidification that occurs in metal additive manufacturing (AM) processes creates microstructures distinctly different from wrought materials. Local variability in AM microstructures (either by design or unintentional) raises questions as to how AM structures should be modeled at the part-scale to minimize modeling error. The key goal of this work is to demonstrate a posteriori error estimation applied to an AM part. It is assumed that the actual microstructure is unknown and an approximate, spatially uniform material model is used. Error bounds are calculated for many reference models based on AM microstructures with elongated grain morphology and localized or global fiber textures during a post-processing step. The current findings promote confidence that a posteriori model form error estimation could be used effectively in mechanical performance simulations of AM parts to quickly obtain quantitative error metrics between an approximate model result and many microstructure-based reference models. The a posteriori error estimation introduces significant time savings compared to computing the full reference model solutions. Tight bounds on model form error are obtained when texture variations in the reference models occur on large length scales. For materials with property variation at small length scales, multi-scale error estimation techniques are needed to properly account for the many interfaces present between areas with different properties.},

  doi          = {10.1088/1361-651X/aaf107},

  journal      = {Modelling and Simulation in Materials Science and Engineering},

  number       = 2,

  volume       = 27,

  place        = {United States},

  year         = {Mon Jan 07 00:00:00 EST 2019},

  month        = {Mon Jan 07 00:00:00 EST 2019}

}

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Title: Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error

Abstract

Citation Formats

Modeling of additive manufacturing processes for metals: Challenges and opportunities journal, August 2017

Metal Additive Manufacturing: A Review journal, April 2014

The Roadmap for Additive Manufacturing and Its Impact journal, March 2014

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Effects of process time interval and heat treatment on the mechanical and microstructural properties of direct laser deposited 316L stainless steel journal, September 2015

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Effects of substrate crystallographic orientations on crystal growth and microstructure formation in laser powder deposition of nickel-based superalloy journal, April 2015

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

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

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

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

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

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

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

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Site specific control of crystallographic grain orientation through electron beam additive manufacturing journal, November 2014

Uncertainty quantification in prediction of material properties during additive manufacturing journal, July 2017

Towards rapid qualification of powder-bed laser additively manufactured parts journal, May 2016

Hierarchical modeling of heterogeneous bodies journal, December 1996

Analysis and adaptive modeling of highly heterogeneous elastic structures journal, September 1997

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Quantifying the Impact of Material-Model Error on Macroscale Quantities-of-Interest Using Multiscale a Posteriori Error-Estimation Techniques journal, January 2016

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Direct numerical simulations in solid mechanics for understanding the macroscale effects of microscale material variability journal, April 2015

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

Multi-scale goal-oriented adaptive modeling of random heterogeneous materials journal, August 2006

Principles of Solidification journal, October 2011

Modeling of additive manufacturing processes for metals: Challenges and opportunities
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Metal Additive Manufacturing: A Review
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The Roadmap for Additive Manufacturing and Its Impact
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journal, March 2013

Effects of process time interval and heat treatment on the mechanical and microstructural properties of direct laser deposited 316L stainless steel
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Evolution of solidification texture during additive manufacturing
journal, November 2015

Effects of substrate crystallographic orientations on crystal growth and microstructure formation in laser powder deposition of nickel-based superalloy
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Highly Anisotropic Steel Processed by Selective Laser Melting
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Texture control during laser deposition of nickel-based superalloy
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Mechanical behavior of selective laser melted 316L stainless steel
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Energy input effect on morphology and microstructure of selective laser melting single track from metallic powder
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Lattice Structures Manufactured by SLM: On the Effect of Geometrical Dimensions on Microstructure Evolution During Processing
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Simulation and experimental comparison of the thermo-mechanical history and 3D microstructure evolution of 304L stainless steel tubes manufactured using LENS
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journal, April 2014

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