Analysis of additively manufactured anisotropic microstructures through crystal plasticity frameworks

Analysis of additively manufactured anisotropic microstructures through crystal plasticity frameworks

BULUT Orhun, GÜNAY Enes, FENERCIOĞLU Tevfik Ozan, YALÇINKAYA Tuncay

download PDF

Abstract. In additive manufacturing processes, the resulting products might have highly anisotropic granular morphologies due to the complex thermal history. The most commonly observed morphology is columnar structure. The resulting morphology of grains is accompanied by the orientation alignment leading to plastic anisotropy. It has been shown in a recent study through local crystal plasticity calculations that the morphology evolution does not influence the mechanical behavior without considering the texture evolution [1]. However, the local frameworks do not consider the effect of the grain size which could be complicated due to high aspect ratio of the grains. This study aims to investigate the influence of the developed anisotropic grain structure on the macroscopic response through both local and non-local crystal plasticity frameworks to address the capacity of these models in capturing the realistic response. An additional subroutine is implemented (see [2]) into the crystal plasticity frameworks to obtain the slip resistance values at each material point based on grain geometries and misorientations. This allows the size dependent yielding of the crystals.

Keywords
Crystal Plasticity, Size Effect, Additive Manufacturing

Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: BULUT Orhun, GÜNAY Enes, FENERCIOĞLU Tevfik Ozan, YALÇINKAYA Tuncay, Analysis of additively manufactured anisotropic microstructures through crystal plasticity frameworks, Materials Research Proceedings, Vol. 28, pp 179-188, 2023

DOI: https://doi.org/10.21741/9781644902479-20

The article was published as article 20 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] S.S. Acar, O. Bulut, T. Yalçinkaya, Crystal plasticity modeling of additively manufactured metallic microstructures, Procedia Struct. Integrity 35 (2022) 219-227. https://doi.org/10.1016/j.prostr.2021.12.068
[2] D. Agius, A. Kareer, A. Al Mamun, C. Truman, D.M. Collins, M. Mostafavi, D. Knowles, A crystal plasticity model that accounts for grain size effects and slip system interactions on the deformation of austenitic stainless steels, Int. J. Plast. 152 (2022) 103249. https://doi.org/10.1016/j.ijplas.2022.103249
[3] F. Singer, D. Deisenroth, D. Hymas, M. Ohadi, Additively manufactured copper components and composite structures for thermal management applications, in: 2017 16th IEEE Intersociety Conference on Thermal and Thermomechanical Phenomena in Electronic Systems (ITherm), IEEE, 2017: pp. 174-183. https://doi.org/10.1109/ITHERM.2017.7992469
[4] M. Lowther, S. Louth, A. Davey, A. Hussain, P. Ginestra, L. Carter, N. Eisenstein, L. Grover, S. Cox, Clinical, industrial, and research perspectives on powder bed fusion additively manufactured metal implants, Addit. Manuf. 28 (2019) 565-584. https://doi.org/10.1016/j.addma.2019.05.033
[5] B. Blakey-Milner, P. Gradl, G. Snedden, M. Brooks, J. Pitot, E. Lopez, M. Leary, F. Berto, A. du Plessis, Metal additive manufacturing in aerospace: A review, Mater. Des. 209 (2021) 110008. https://doi.org/10.1016/j.matdes.2021.110008
[6] A. Uriondo, M. Esperon-Miguez, S. Perinpanayagam, The present and future of additive manufacturing in the aerospace sector: A review of important aspects, Proc. Inst. Mech. Eng., Part G: J. Aerosp. Eng. 229 (2015) 2132-2147. https://doi.org/10.1177/095441001456879
[7] J.C. Najmon, S. Raeisi, A. Tovar, Review of additive manufacturing technologies and applications in the aerospace industry, Additive Manufacturing for the Aerospace Industry. (2019) 7-31. https://doi.org/10.1016/B978-0-12-814062-8.00002-9
[8] T.F. van Nuland, J. van Dommelen, M.G. Geers, Microstructural modeling of anisotropic plasticity in large scale additively manufactured 316L stainless steel, Mech. Mater. 153 (2021) 103664. https://doi.org/10.1016/j.mechmat.2020.103664
[9] Z. Wang, K. Guan, M. Gao, X. Li, X. Chen, X. Zeng, The microstructure and mechanical properties of deposited-IN718 by selective laser melting, J. Alloys Compd. 513 (2012) 518-523. https://doi.org/10.1016/j.jallcom.2011.10.107
[10] E.W. Hovig, A.S. Azar, F. Grytten, K. Sørby, E. Andreassen, Determination of anisotropic mechanical properties for materials processed by laser powder bed fusion, Adv. Mater. Sci. Eng. 2018 (2018). https://doi.org/10.1155/2018/7650303
[11] E. Yasa, J. Deckers, J.-P. Kruth, The investigation of the influence of laser re-melting on density, surface quality and microstructure of selective laser melting parts, Rapid Prototyping J. 17 (2011) 312-327. https://doi.org/10.1108/13552541111156450
[12] C. Qiu, N.J. Adkins, M.M. Attallah, Microstructure and tensile properties of selectively laser-melted and of HIPed laser-melted Ti–6Al–4V, Mater. Sci. Eng. A 578 (2013) 230-239. https://doi.org/10.1016/j.msea.2013.04.099
[13] B. Song, X. Zhao, S. Li, C. Han, Q. Wei, S. Wen, J. Liu, Y. Shi, Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review, Front. Mech. Eng. 10 (2015) 111-125. https://doi.org/10.1007/s11465-015-0341-2
[14] A. Charmi, R. Falkenberg, L. Ávila, G. Mohr, K. Sommer, A. Ulbricht, M. Sprengel, R.S. Neumann, B. Skrotzki, A. Evans, Mechanical anisotropy of additively manufactured stainless steel 316L: An experimental and numerical study, Mater. Sci. Eng. A 799 (2021) 140154. https://doi.org/10.1016/j.msea.2020.140154
[15] A.A. Antonysamy, J. Meyer, P. Prangnell, Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti6Al4V by selective electron beam melting, Mater. Charact. 84 (2013) 153-168. https://doi.org/10.1016/j.matchar.2013.07.012
[16] K. Hara, K. Itoh, M. Kamiya, H. Fujiwara, K. Okamoto, T. Hashimoto, Alignment of crystallites in obliquely deposited cobalt films, Jpn. J. Appl. Phys. 33 (1994) 3448. https://doi.org/10.1143/JJAP.33.3448
[17] K. Moussaoui, W. Rubio, M. Mousseigne, T. Sultan, F. Rezai, Effects of Selective Laser Melting additive manufacturing parameters of Inconel 718 on porosity, microstructure and mechanical properties, Mater. Sci. Eng. A 735 (2018) 182-190. https://doi.org/10.1016/j.msea.2018.08.037
[18] B. Zhang, S. Liu, Y.C. Shin, In-Process monitoring of porosity during laser additive manufacturing process, Addit. Manuf. 28 (2019) 497-505. https://doi.org/10.1016/j.addma.2019.05.030
[19] T. Yalçinkaya, Strain gradient crystal plasticity: Thermodynamics and implementation, in: G. Z. Voyiadjis (Eds.), Handbook of Nonlocal Continuum Mechanics for Materials and Structures, Springer, London/Berlin, 2017, pp.1001-1033.
[20] T. Yalçinkaya, İ. Özdemir, İ. Tarik Tandoğan, Misorientation and grain boundary orientation dependent grain boundary response in polycrystalline plasticity, Computational Mechanics. 67 (2021) 937-954. https://doi.org/10.1007/s00466-021-01972-z
[21] Y. Huang, A user-material subroutine incorporating single crystal plasticity in the ABAQUS finite element program, Mech. Report 178 (1991).
[22] O. Bulut, S. S. Acar, T. Yalçinkaya, The influence of thickness/grain size ratio in microforming through crystal plasticity, Procedia Struct. Integrity 35 (2022) 228-236. https://doi.org/10.1016/j.prostr.2021.12.069
[23] T. Yalçinkaya, B. Tatli, I.E. Ünsal, I.U. Aydiner, Crack Initiation and Propagation in Dual-phase Steels Through Crystal Plasticity and Cohesive Zone Frameworks, Proce. Struct. Integrity 42 (2022) 1651-1659.
[24] C. S. Han, H. Gao, Y. Huang, W. D. Nix, Mechanism-based strain gradient crystal plasticity—I, Theory, J. Mech. Phys. Solids 53 (2005) 1188-1203. https://doi.org/10.1016/j.jmps.2004.08.008
[25] E. Nakamachi, C. Xie, H. Morimoto, K. Morita, N. Yokoyama, Formability assessment of FCC aluminum alloy sheet by using elastic crystalline viscoplastic finite element analysis, Int. J. Plast. 18 (2002) 617-632. https://doi.org/10.1016/S0749-6419(01)00052-3
[26] R. Quey, P. Dawson, F. Barbe, Large-scale 3D random polycrystals for the finite element method: Generation, meshing and remeshing, Comput. Methods Appl. Mech. Eng. 200 (2011) 1729-1745. https://doi.org/10.1016/j.cma.2011.01.002
[27] T. Yalçinkaya, S.O. Çakmak, C. Tekoğlu, A crystal plasticity based finite element framework for RVE calculations of two-phase materials: Void nucleation in dual-phase steels, Finite Elem. Anal. Des. 187 (2021) 103510. https://doi.org/10.1016/j.finel.2020.103510