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 »
- Authors:
-
- 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:
- 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.
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
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.
@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}
}
Web of Science
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