Skip Nav Destination
ASTM Selected Technical Papers
Structural Integrity of Additive Manufactured Materials and Parts
By
Nima Shamsaei,
Nima Shamsaei
Symposium Chair and STP Editor
1
Auburn University
, Auburn, AL,
US
Search for other works by this author on:
Mohsen Seifi
Mohsen Seifi
Symposium Chair and STP Editor
2
ASTM International
, Washington, DC,
US
Search for other works by this author on:
ISBN:
978-0-8031-7708-6
No. of Pages:
378
Publisher:
ASTM International
Publication date:
2020
eBook Chapter
A Multiscale Material Modeling Approach to Predict the Mechanical Properties of Powder Bed Fusion (PBF) Metal
By
Yang Li
,
Yang Li
1
Research and Innovation Center
, Ford Motor Co., 2101 Village Rd., Dearborn, MI 48121,
US
Search for other works by this author on:
Hongyi Xu
,
Hongyi Xu
2
Dept. of Mechanical Engineering, University of Connecticut
, 191 Auditorium Rd., Storrs, CT 06269,
US
Search for other works by this author on:
Wei-Jen Lai
,
Wei-Jen Lai
1
Research and Innovation Center
, Ford Motor Co., 2101 Village Rd., Dearborn, MI 48121,
US
Search for other works by this author on:
Ziang Li
,
Ziang Li
1
Research and Innovation Center
, Ford Motor Co., 2101 Village Rd., Dearborn, MI 48121,
US
Search for other works by this author on:
Xuming Su
Xuming Su
1
Research and Innovation Center
, Ford Motor Co., 2101 Village Rd., Dearborn, MI 48121,
US
Search for other works by this author on:
Page Count:
11
-
Published:2020
Citation
Li, Y, Xu, H, Lai, W, Li, Z, & Su, X. "A Multiscale Material Modeling Approach to Predict the Mechanical Properties of Powder Bed Fusion (PBF) Metal." Structural Integrity of Additive Manufactured Materials and Parts. Ed. Shamsaei, N, & Seifi, M. 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959 : ASTM International, 2020.
Download citation file:
Metal parts manufactured via the powder bed fusion (PBF) process have drawn tremendous interest in the automotive industry. While numerous studies have shown the unique microstructure of the metal from the PBF process, significant variation of material properties with process parameters has been widely observed, indicating that huge amounts of experiments are required during material characterization. Thus, multiscale material modeling approaches are in great demand so that the properties of the metals via the PBF process can be predicted with confidence, to save costs and time during the design stage. In the present study, a multiscale modeling approach is proposed in which the microscale and mesoscale models are considered in finite element analysis. At the microscale, the model captures the microstructure characteristics within the melt pools to predict the representative properties resulting from epitaxial grain morphology and orientation. The properties are then homogenized and input into a mesoscale model in which the “fish-scale-like” melt pools and boundaries between them are modeled. Stochastic reconstruction of the micro- and mesoscale models are performed based on statistical microstructure information obtained from optical micrographs and scanning electron microscopy (SEM) images. Predicted mechanical properties are compared with experimental data to demonstrate the capability of the approach. The study keeps focus on AlSi10Mg built by selective laser melting (SLM), while universal applicability to other material systems is expected.
References
1.
Frazier
W. E.
, “Metal Additive Manufacturing: A Review
,” Journal of Materials Engineering and Performance
23
, no. 6
(2014
): 1917–1928.2.
Ngo
T. D.
, Kashani
A.
, Imbalzano
G.
, Nguyen
K.
, and Hui
D.
, “Additive Manufacturing (3D Printing): A Review of Materials, Methods, Applications and Challenges
,” Composites Part B: Engineering
143
(2018
): 172–196.3.
Gibson
I.
, Rosen
D. W.
, and Stucker
B.
, Additive Manufacturing Technologies
, Vol. 17
(New York
: Springer
, 2014
).4.
Lewandowski
J. J.
and Seifi
M.
, “Metal Additive Manufacturing: A Review of Mechanical Properties
,” Annual Review of Materials Research
46
(2016
): 151–186.5.
Zhou
L.
, Mehta
A.
, Schulz
E.
, McWilliams
B.
, Cho
K.
, and Sohn
Y.
, “Microstructure, Precipitates and Hardness of Selectively Laser Melted AlSi10Mg Alloy before and after Heat Treatment
,” Materials Characterization
143
(2018
): 5–17.6.
Allison
J.
, Li
M.
, Wolverton
C.
, and Su
X.
, “Virtual Aluminum Castings: An Industrial Application of ICME
,” JOM
58
, no. 11
(2006
): 28–35.7.
Allison
J.
, “Integrated Computational Materials Engineering: A Perspective on Progress and Future Steps
,” JOM
63
, no. 4
(2011
): 15–18.8.
Wolff
S. J.
, Lin
S.
, Faierson
E. J.
, Liu
W. K.
, Wagner
G. J.
, and Cao
J.
. “A Framework to Link Localized Cooling and Properties of Directed Energy Deposition (DED)-Processed Ti-6Al-4V
,” Acta Materialia
132
(2017
): 106–117.9.
Yan
W.
, Smith
J.
, Ge
W.
, Lin
F.
, and Liu
W. K.
. “Multiscale Modeling of Electron Beam and Substrate Interaction: A New Heat Source Model
,” Computational Mechanics
56
, no. 2
(2015
): 265–276.10.
Lian
Y.
, Lin
S.
, Yan
W.
, Liu
W. K.
, and Wagner
G. J.
, “A Parallelized Three-Dimensional Cellular Automaton Model for Grain Growth during Additive Manufacturing
,” Computational Mechanics
61
, no. 5
(2018
): 543–558.11.
Rai
A.
, Helmer
H.
, and Körner
C.
, “Simulation of Grain Structure Evolution during Powder Bed Based Additive Manufacturing
,” Additive Manufacturing
13
(2017
): 124–134.12.
Kim
D.
, Hwang
J.
, Kim
E.
, Heo
Y.
, Woo
W.
, and Choi
S.
, “Evaluation of the Stress-Strain Relationship of Constituent Phases in AlSi10Mg Alloy Produced by Selective Laser Melting Using Crystal Plasticity FEM
,” Journal of Alloys and Compounds
714
(2017
): 687–697.13.
Kapoor
K.
, Yoo
Y. S.
, Book
T. A.
, Kacher
J. P.
, and Sangid
M. D.
, “Incorporating Grain-Level Residual Stresses and Validating a Crystal Plasticity Model of a Two-Phase Ti-6Al-4V Alloy Produced via Additive Manufacturing
,” Journal of the Mechanics and Physics of Solids
121
(2018
): 447–462.14.
Prithivirajan
V.
and Sangid
M. D.
, “The Role of Defects and Critical Pore Size Analysis in the Fatigue Response of Additively Manufactured IN718 via Crystal Plasticity
,” Materials & Design
150
(2018
): 139–153.15.
Andani
M. T.
, Karamooz-Ravari
M. R.
, Mirzaeifar
R.
, and Ni
J.
, “Micromechanics Modeling of Metallic Alloys 3D Printed by Selective Laser Melting
,” Materials & Design
137
(2018
): 204–213.16.
Khairallah
S. A.
, Anderson
A. T.
, Rubenchik
A.
, and King
W. E.
, “Laser Powder-Bed Fusion Additive Manufacturing: Physics of Complex Melt Flow and Formation Mechanisms of Pores, Spatter, and Denudation Zones
,” Acta Materialia
108
(2016
): 36–45.17.
Denlinger
E. R.
, Gouge
M.
, Irwin
J.
, and Michaleris
P.
, “Thermomechanical Model Development and In Situ Experimental Validation of the Laser Powder-Bed Fusion Process
,” Additive Manufacturing
16
(2017
): 73–80.18.
Chen
Q.
, Liang
X.
, Hayduke
D.
, Liu
J.
, Cheng
L.
, Oskin
J.
, Whitmore
R.
, and To
A. C.
, “An Inherent Strain Based Multiscale Modeling Framework for Simulating Part-Scale Residual Deformation for Direct Metal Laser Sintering
,” Additive Manufacturing
28
(2019
): 406–418.19.
Smith
J.
, Xiong
W.
, Yan
W.
, Lin
S.
, Cheng
P.
, Kafka
O. L.
, Wagner
G. J.
, Cao
J.
, and Liu
W. K.
, “Linking Process, Structure, Property, and Performance for Metal-Based Additive Manufacturing: Computational Approaches with Experimental Support
,” Computational Mechanics
57
, no. 4
(2016
): 583–610.20.
King
W. E.
, Anderson
A. T.
, Ferencz
R. M.
, Hodge
N. E.
, Kamath
C.
, and Khairallah
S. A.
, “Overview of Modelling and Simulation of Metal Powder Bed Fusion Process at Lawrence Livermore National Laboratory
,” Materials Science and Technology
31
, no. 8
(2015
): 957–968.21.
Martukanitz
R.
, Michaleris
P.
, Palmer
T.
, DebRoy
T.
, Liu
Z.
, Otis
R.
, Heo
T. W.
, and Chen
L.
, “Toward an Integrated Computational System for Describing the Additive Manufacturing Process for Metallic Materials
,” Additive Manufacturing
1
(2014
): 52–63.22.
Takata
N.
, Kodaira
H.
, Sekizawa
K.
, Suzuki
A.
, and Kobashi
M.
, “Change in Microstructure of Selectively Laser Melted AlSi10Mg Alloy with Heat Treatments
” Materials Science and Engineering: A
704
(2017
): 218–228.23.
Hadadzadeh
A.
, Amirkhiz
B. S.
, Odeshi
A.
, Li
J.
, and Mohammadi
M.
, “Role of Hierarchical Microstructure of Additively Manufactured AlSi10Mg on Dynamic Loading Behavior
,” Additive Manufacturing
28
(2019
): 1–13.24.
Hadadzadeh
A.
, Amirkhiz
B. S.
, and Mohammadi
M.
, “Contribution of Mg2Si Precipitates to the Strength of Direct Metal Laser Sintered AlSi10Mg
,” Materials Science and Engineering: A
739
(2019
): 295–300.25.
Liu
X.
, Zhao
C.
, Zhou
X.
, Shen
Z.
, and Liu
W.
, “Microstructure of Selective Laser Melted AlSi10Mg Alloy
,” Materials & Design
168
(2019
): 107677.26.
Xiong
Z. H.
, Liu
S. L.
, Li
S. F.
, Shi
Y.
, Yang
Y. F.
, and Misra
R. D. K.
, “Role Of Melt Pool Boundary Condition in Determining the Mechanical Properties of Selective Laser Melting AlSi10Mg Alloy
,” Materials Science and Engineering: A
740
(2019
): 148–156.27.
Dai
D.
, Gu
D.
, Zhang
H.
, Xiong
J.
, Ma
C.
, Hong
C.
, and Poprawe
R.
, “Influence of Scan Strategy and Molten Pool Configuration on Microstructures and Tensile Properties of Selective Laser Melting Additive Manufactured Aluminum Based Parts
,” Optics & Laser Technology
99
(2018
): 91–100.28.
Thijs
L.
, Kempen
K.
, Kruth
J.
, and Van Humbeeck
J.
, “Fine-Structured Aluminium Products with Controllable Texture by Selective Laser Melting of Pre-Alloyed AlSi10Mg Powder
,” Acta Materialia
61
, no. 5
(2013
): 1809–1819.29.
Ghasri-Khouzani
M.
, Peng
M. H.
, Attardo
R.
, Ostiguy
P.
, Neidig
J.
, Billo
R.
, Hoelzle
D.
, and Shankar
M. R.
, “Comparing Microstructure and Hardness of Direct Metal Laser Sintered AlSi10Mg Alloy between Different Planes
,” Journal of Manufacturing Processes
37
(2019
): 274–280.30.
Standard Test Methods for Tension Testing of Metallic Materials
, ASTM E8/E8M-16a (West Conshohocken, PA
: ASTM International
, approved August 1, 2016
), 31.
Huang
Y.
, A User-Material Subroutine Incorporating Single Crystal Plasticity in the ABAQUS Finite Element Program, Mech. Report 178 (Cambridge, MA: Harvard University, Division of Engineering and Applied Sciences
, 1991
).32.
Kysar
J. W.
, Addendum to “A User-Material Subroutine Incorporating Single Crystal Plasticity in the ABAQUS Finite Element Program, Mech. Report 178” (Cambridge, MA: Harvard University, Division of Engineering and Applied Sciences
, 1997
).33.
Peirce
D.
, Asaro
R. J.
, and Needleman
A.
, “Material Rate Dependence and Localized Deformation in Crystalline Solids
,” Acta Metallurgica
31
, no. 12
(1983
): 1951–1976.
This content is only available via PDF.
You do not currently have access to this chapter.
Email alerts
Related Chapters
Novel and Efficient Mathematical and Computational Methods for the Analysis and Architecting of Ultralight Cellular Materials and their Macrostructural Responses
Advances in Computers and Information in Engineering Research, Volume 2
Industrially-Relevant Multiscale Modeling of Hydrogen Assisted Degradation
International Hydrogen Conference (IHC 2012): Hydrogen-Materials Interactions
Multiscale Modeling of Cavitation using a Level Set Method with Cavity Detection
Proceedings of the 10th International Symposium on Cavitation (CAV2018)
Elucidating the Impact of Processing Parameters of Additive Manufactured Materials Using Microscale Tensile Samples
Structural Integrity of Additive Manufactured Parts
Related Articles
Laser Powder Bed Fusion Additive Manufacturing of Maraging Steel: A Review
J. Manuf. Sci. Eng (November,2023)
XFEM Analysis of Strain Rate Dependent Mechanical Properties of Additively Manufactured 17-4 Precipitation Hardening Stainless Steel
J. Eng. Mater. Technol (July,2023)
A Review of the Applications of Machine Learning for Prediction and Analysis of Mechanical Properties and Microstructures in Additive Manufacturing
J. Comput. Inf. Sci. Eng (December,2024)
