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. 2023 Nov 21;13(1):20372.
doi: 10.1038/s41598-023-47651-2.

Crystal plasticity simulations with representative volume element of as-build laser powder bed fusion materials

Dmitry S Bulgarevich  1 , Sukeharu Nomoto  2 , Makoto Watanabe  2 , Masahiko Demura  2
Affiliations

Crystal plasticity simulations with representative volume element of as-build laser powder bed fusion materials

Dmitry S Bulgarevich et al. Sci Rep. .

Abstract

Additive manufacturing of as-build metal materials with laser powder bed fusion typically leads to the formations of various chemical phases and their corresponding microstructure types. Such microstructures have very complex shape and size anisotropic distributions due to the history of the laser heat gradients and scanning patterns. With higher complexity compared to the post-heat-treated materials, the synthetic volume reconstruction of as-build materials for accurate modelling of their mechanical properties is a serious challenge. Here, we present an example of complete workflow pipeline for such nontrivial task. It takes into account the statistical distributions of microstructures: object sizes for each phase, several shape parameters for each microstructure type, and their morphological and crystallographic orientations. In principle, each step in the pipeline, including the parameters in the crystal plasticity model, can be fine-tuned to achieve suitable correspondence between experimental and synthetic microstructures as well as between experimental stress-strain curves and simulated results. To our best knowledge, this work represents an example of the most challenging synthetic volume reconstruction for as-build additive manufacturing materials to date.

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Conflict of interest statement

The authors declare no competing interests.

Figures

Figure 1
Figure 1
Schematic of the LPBF process.
Figure 2
Figure 2
Data flow pipeline for tensile test simulation of metal materials.
Figure 3
Figure 3
Microstructures in as-build IN738LC: (a) EBSD images in IPF colors and crystallographic ODF plots, (b) X-ray CT and SEM images.
Figure 4
Figure 4
The outline of EBSD data statistical analysis for XY-plane image from Fig. 3. (a) The central panel plot demonstrates the thresholding of the grain size data in terms of ECD on Columnar Core and other microstructures. (b) The top panel is used for estimation of Columnar Core fV based on running sum of grain area fractions. (c) The right panel plot illustrates the lognormal fit of thresholded ECD distribution for evaluation of μ and σ parameters in PDFL-N. (d) The insert in central panel plot is used to estimate the b/a parameter ratio for thresholded ECD distribution. See text for more details.
Figure 5
Figure 5
The reconstructed synthetic volume: (a) RVE in three color schemes: microstructure-wise, grain-wise, and grain crystallography-wise (except cracks); (b) the cloned RVE along x, y, and z- axes: all microstructures, thresholded columnar ones, and cracks from right to left, respectively.
Figure 6
Figure 6
Lambert pole (color) and axes ODF figures for relevant microstructure in RVE.
Figure 7
Figure 7
Comparison of literature, experimental and simulated SSCs with various phenomenological model CP parameters. Panels (a–i) are for variation of indicated parameter by keeping all others fixed. Other parameters are the same as in Table 3.
Figure 8
Figure 8
Comparison of literature and our experimental SSCs with simulated ones with uniaxial tension along x–axis (a) and z–axis (c) for different RVEs (b). The indicated 0.2% proof stresses are from simulated SSCs. See text for more details.
Figure 9
Figure 9
Accumulated stress and strain distribution maps for IN738LC RVE with parameters for CP from Table 3 at ~ 0.03 nominal strain.
Figure 10
Figure 10
Accumulated stress and strain distribution maps for hypothetically heat treated RVE of IN738LC with cuboidal grains at ~ 0.03 nominal strain with parameters for CP from Table 3.
Figure 11
Figure 11
Color maps with largest Schmid factors for RVEs from Figs. 7, 8 and 9 with indicated slip systems.
See this image and copyright information in PMC

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