Micromechanical modeling approach to single track deformation, phase transformation and residual stress evolution during selective laser melting using crystal plasticity

Lindroos, M.; Pinomaa, Tatu; Antikainen, Atte; Lagerbom, Juha; Reijonen, Joni; Lindroos, Tomi; Andersson, Tom; Laukkanen, Anssi

doi:10.1016/j.addma.2020.101819

Cited by 14 publications

(9 citation statements)

References 31 publications

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“…In the context of MAM, one such example of micromechanical CPFEM modelling is towards understanding grain level residual stress evolution in Ti6Al4V alloy fabricated using LPBF [458]. In another instance, micromechanical CPFEM is used to elucidate solid-state stresses, strain, and phase transformation during the single-track LPBF process of tool steel [459]. Likewise, a micromechanical dislocation density-based CPFEM approach appraised the effects of process induced defects such as porosity, un-melted powder, and carbides on fracture [460].…”

Section: Crystal Plasticity Finite-element Modelmentioning

confidence: 99%

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Sharma

Joshi

Pantawane

et al. 2023

International Materials Reviews

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This review article provides a critical assessment of the progress made in computational modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict physical phenomena, concepts of microstructural evolution, residual stresses, role of multiple thermal cycles, and formation of multi-dimensional defects along with the achieved degree of experimental validation. The uniqueness of this article stems from the inclusion of comprehensive information on computational progress in the field of fusion-based, sintering-based, and mechanical deformation-based AM. A computational model's role in determining the process framework for the desired outcome of the set properties of the AM components is recognised while presenting the process-microstructure maps, thereby appraising computational ability towards the qualification of products. The inclusion of a detailed discussion on the bi-directional coupling of machine learning and physics-based computational models provides a futuristic roadmap for the digital twin of metal-based AM.

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Section: Crystal Plasticity Finite-element Modelmentioning

confidence: 99%

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Sharma

Joshi

Pantawane

et al. 2023

International Materials Reviews

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“…These interactions hinder plastic deformation and work harden the material. Some studies employ more complex, physically based models to include dislocation kinetics (e.g., [157,168,174,175]).…”

Section: Constitutive Models Of the Plastic Behaviour Of Grainsmentioning

confidence: 99%

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

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In the rapidly evolving field of additive manufacturing (AM), the predictability of part properties is still challenging due to the inherent multiphysics complexity of the technology. This results in time-consuming and costly experimental guess-and-check approaches for manufacturing each individual design. Through synthesising advancements in the field, this review argues that numerical modelling is instrumental in mitigating these challenges by working in tandem with experimental studies. Unique hierarchical microstructures induced by extreme AM process conditions– including melt pool patterns, grains, cellular–dendritic substructures, and precipitates—affect the final part properties. Therefore, the development of microstructure-informed mechanical models becomes vital. Our review of numerical studies explores various modelling approaches that consider the microstructural features explicitly and offers insights into multiscale stress–strain analysis across diverse materials fabricated by powder bed fusion AM. The literature indicates a growing consensus on the key role of multiscale integrated process–structure–property–performance (PSPP) modelling in capturing the complexity of AM-produced materials. Current models, though increasingly sophisticated, still tend to relate only two elements of the PSPP chain while often focusing on a single scale. This emphasises the need for integrated PSPP approaches validated by a solid experimental base. The PSPP paradigm for AM, while promising as a concept, is still in its infantry, confronting multifaceted challenges that require in-depth, multidisciplinary expertise. These challenges range from accounting for multiphysics phenomena (e.g., advanced laser–material interaction) and their interplay (thermo-mechanical and microstructural evolution for simulating Type II residual stresses), accurately defined assumptions (e.g., flat molten surface during AM or purely epitaxial solidification), and correctly estimated boundary conditions for each element of the PSPP chain up to the need to balance the model’s complexity and detalisation in terms of both multiphysics and discretisation with efficient multitrack and multilayer simulations. Efforts in bridging these gaps would not only improve predictability but also expedite the development and certification of new AM materials.

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“…For example, a loss of Mn would reduce austenite stability and N solubility, leading to possible N degassing, pore formation, or precipitation of undesirable phases such as carbonitrides. Consequently, the change in chemical composition during the fabrication process, the segregation and spatial distribution of the respective alloying elements in the heterogeneous microstructure and the posttreatment are as important as the processability of PBF‐LB/M itself, and thus both are addressed in this While a large number of publications and studies deal with the AM of Cr–Ni austenites, there are only a very small number of studies on the additive processing of Fe–Cr–Mn–C–N‐based HIA [ 3–7 ]…”

Section: Introductionmentioning

confidence: 99%

Processing of High Interstitial Austenitic Steel with Powder Bed Fusion‐Laser Beam/Metal: Evolution of Chemical Inhomogeneity and Microstructural Features during Postprocessing

Kimm,

Hanke,

Weber

et al. 2024

Adv Eng Mater

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Powder Bed Fusion‐Laser Beam/Metal (PBF LB/M) additive manufacturing provides a high potential to overcome the poor machinability of nickel‐free high interstitial alloy austenitic (HIA) steels. Therefore, this study focuses on the PBF LB/M processibility of HIA X40MnCrMoN21‐18‐2 and the effect of post‐processing on microstructure and chemical homogeneity. Samples were fabricated on a laboratory and industrial PBF‐LB/M machine and subsequently post‐processed by conventional solution annealing or hot isostatic pressing (HIP). The influence of the processing steps on the microstructure and on the chemical composition was evaluated by scanning electron microscopy, X‐ray diffraction, transmission electron microscopy, atom probe tomography and electron backscatter diffraction. The commercially available HIA powder exerts good processability, both by optimized and pre‐defined PBF LB/M parameters. Loss of Mn and N was detected after PBF‐LB/M processing. Chemical homogenization but no further change in composition occurred during post‐processing. The as‐built microstructure showed segregation of elements (N, Mo, Cr, Mn) in intercellular spaces. A thermodynamic calculation confirmed that N approaches a para‐equilibrium state in the PBF‐LB/M as‐built condition, while C does not. Porosity could be reduced by thermomechanical post‐treatment with HIP. At the same time, HIP partially recrystallized the microstructure, while (Mn+Cr)2SiO4 type oxides delayed recovery and recrystallization of the microstructure.This article is protected by copyright. All rights reserved.

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Micromechanical modeling approach to single track deformation, phase transformation and residual stress evolution during selective laser melting using crystal plasticity

Cited by 14 publications

References 31 publications

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Processing of High Interstitial Austenitic Steel with Powder Bed Fusion‐Laser Beam/Metal: Evolution of Chemical Inhomogeneity and Microstructural Features during Postprocessing

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