Image-based multiscale modeling with spatially varying microstructures from experiments: Demonstration with additively manufactured metal in fatigue and fracture

Orion L. Kafka, Kevontrez K. Jones, Cheng Yu, Puikei Cheng, Wing Kam Liu*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

21 Scopus citations

Abstract

This manuscript presents a novel modeling framework to predict mechanical performance in material with spatially varying microstructure. The framework combines an efficient process model for AM, a database of experimental 3D images of defects in AM metal, and a microstructure-based multiscale modeling method that leverages recent advances in reduced order modeling. Thus the examples presented will explore heterogeneous and processing dependent dispersion of voids in additively manufactured (AM) metals. The method presented here allows for parametric studies with repeated instantiations of different possible configurations of microstructures (images of defects) throughout the simulated part. Two demonstrations of the method are provided using a database of synchrotron x-ray computed tomography images of porosity collected at the Advanced Photon Source for Inconel 718 built with Laser Engineered Net Shaping®: one case is high cycle fatigue crack incubation and the other is fracture initiation. In both, we show that the model can capture the effects on performance of variability within and between builds. Although not all variability is captured or quantified, the method shows promise for application in AM metals because of its unique ability to mechanistically connect part-scale performance with individual microstructures and the distribution of these microstructures throughout the part.

Original languageEnglish (US)
Article number104350
JournalJournal of the Mechanics and Physics of Solids
Volume150
DOIs
StatePublished - May 2021

Funding

The experimental X-ray imaging was conducted via a user-access proposal with the help of Xianghui Xiao of Beamline 2BM at the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory, United States under Contract No. DE-AC02-06CH11357 . The preliminary experimental work also made use of the MatCI Facility which receives support from the MRSEC Program ( NSF DMR-1720139 ) of the Materials Research Center at Northwestern University. OLK and WKL were funded by the National Science Foundation ’s Mechanics of Materials and Structures (MOMS) program under the Grant No. MOMS/CMMI-1762035 . OLK also acknowledges the support of the NSF Graduate Research Fellowship, United States under Grant No. DGE-1324585a . WKL also thanks the Center for Hierarchical Materials Design (CHiMaD), United States under Grant Nos. 70NANB13Hl94 , 70NANB14H012 , and CHiMaD Phase 2, United States under 70NANB19H005 .

Keywords

  • Directed energy deposition
  • Fatigue
  • Fracture
  • Multiscale and reduced order modeling
  • Process-structure-properties-performance
  • Uncertainty quantification

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Mechanical Engineering

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