{"title":"Phase-field ductile fracture simulations of thermal cracking in additive manufacturing","authors":"Hui Ruan , Xiang-Long Peng , Yangyiwei Yang , Dietmar Gross , Bai-Xiang Xu","doi":"10.1016/j.jmps.2024.105756","DOIUrl":null,"url":null,"abstract":"<div><p>We present a multiphysics phase-field fracture model for thermo-elasto-plastic solids in the context of finite deformation and apply it to simulate the hot cracking phenomenon during metal additive manufacturing. The model is derived in a thermodynamically consistent manner, with the intercoupling mechanisms among elastoplasticity, phase-field crack and heat transfer comprehensively considered. It involves particularly coupled parameters among these materials physics, e.g. plasticity-dependent degradation function and fracture toughness, damage-dependent yield surface and thermal properties, and temperature-dependent elastoplastic properties and fracture strength. The finite element implementation of the coupled phase-field model is benchmarked with simulation results of a tensile test of an I-shape specimen, encompassing elastoplasticity, hardening, necking, crack initiation and propagation, in contrast to the related experimental results. The validated model is further employed to simulate the multiphysics hot cracking phenomenon in additive manufacturing in the context of both the effective powder-bed model and the powder-resolved model thanks to prior non-isothermal phase-field powder-bed-fusion simulations. Simulation results reveal certain key features of the hot crack and its dependency on process parameters like beam power and scan speed, which are helpful for the fundamental understanding of crack formation mechanisms and process optimization.</p></div>","PeriodicalId":17331,"journal":{"name":"Journal of The Mechanics and Physics of Solids","volume":null,"pages":null},"PeriodicalIF":5.0000,"publicationDate":"2024-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0022509624002229/pdfft?md5=bcb0799573283e048c5265d5fa2f631e&pid=1-s2.0-S0022509624002229-main.pdf","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of The Mechanics and Physics of Solids","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0022509624002229","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
Abstract
We present a multiphysics phase-field fracture model for thermo-elasto-plastic solids in the context of finite deformation and apply it to simulate the hot cracking phenomenon during metal additive manufacturing. The model is derived in a thermodynamically consistent manner, with the intercoupling mechanisms among elastoplasticity, phase-field crack and heat transfer comprehensively considered. It involves particularly coupled parameters among these materials physics, e.g. plasticity-dependent degradation function and fracture toughness, damage-dependent yield surface and thermal properties, and temperature-dependent elastoplastic properties and fracture strength. The finite element implementation of the coupled phase-field model is benchmarked with simulation results of a tensile test of an I-shape specimen, encompassing elastoplasticity, hardening, necking, crack initiation and propagation, in contrast to the related experimental results. The validated model is further employed to simulate the multiphysics hot cracking phenomenon in additive manufacturing in the context of both the effective powder-bed model and the powder-resolved model thanks to prior non-isothermal phase-field powder-bed-fusion simulations. Simulation results reveal certain key features of the hot crack and its dependency on process parameters like beam power and scan speed, which are helpful for the fundamental understanding of crack formation mechanisms and process optimization.
期刊介绍:
The aim of Journal of The Mechanics and Physics of Solids is to publish research of the highest quality and of lasting significance on the mechanics of solids. The scope is broad, from fundamental concepts in mechanics to the analysis of novel phenomena and applications. Solids are interpreted broadly to include both hard and soft materials as well as natural and synthetic structures. The approach can be theoretical, experimental or computational.This research activity sits within engineering science and the allied areas of applied mathematics, materials science, bio-mechanics, applied physics, and geophysics.
The Journal was founded in 1952 by Rodney Hill, who was its Editor-in-Chief until 1968. The topics of interest to the Journal evolve with developments in the subject but its basic ethos remains the same: to publish research of the highest quality relating to the mechanics of solids. Thus, emphasis is placed on the development of fundamental concepts of mechanics and novel applications of these concepts based on theoretical, experimental or computational approaches, drawing upon the various branches of engineering science and the allied areas within applied mathematics, materials science, structural engineering, applied physics, and geophysics.
The main purpose of the Journal is to foster scientific understanding of the processes of deformation and mechanical failure of all solid materials, both technological and natural, and the connections between these processes and their underlying physical mechanisms. In this sense, the content of the Journal should reflect the current state of the discipline in analysis, experimental observation, and numerical simulation. In the interest of achieving this goal, authors are encouraged to consider the significance of their contributions for the field of mechanics and the implications of their results, in addition to describing the details of their work.