Process-induced defects and failure mechanisms in metal additive manufacturing: A mesoscale coupled damage and plasticity modeling and X-ray computed tomography approach

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2024-11-26 DOI:10.1016/j.engfailanal.2024.109123

Jairan Nafar Dastgerdi , Milad Lotf Yasouri , Heikki Remes

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引用次数: 0

Abstract

This study aims to clarify the effect of process-induced defects on the damage behavior of metal additive manufactured (AM) components at the mesoscale using a numerical approach based on the coupled continuum damage mechanics (CDM) and plasticity model to provide a guideline for assessing the strength of metal AM components by considering defects’ features and their interaction. For this purpose, the finite element (FE) simulations, instantiated from the real microstructures captured by the initial X-ray computed tomography (XCT) imaging from the intact sample at several locations around the specimen, are deployed to reveal the activity of multiple failure mechanisms. FE simulations precisely identify the sites and the mechanism of ductile failure compared to experimentally observed sites of damage initiation and evolution based on XCT imaging in a temporal domain during tensile loading for the AM 316L stainless steel sample. It is found that the intervoid necking mechanism mainly controls the interaction of internal and surface defects and internal defects in close proximity. Then, the other intervoid sheeting and intervoid shearing mechanisms are active sequentially during the failure process. A systematic investigation is carried out to first reveal the defect-property relationships in damage progression and deformation patterns of these materials and then to define acceptance limits for internal and surface defects’ shape, size, distribution, and proximity to each other, identifying when the imperfections become defects. The results of this study can pave the road to overcoming the limitation of more widespread use of metal AM materials in different industries by providing a validated numerical approach to optimizing process parameters based on understanding the interaction between different process parameters, resultant internal and surface defects, and damage behavior of these materials under service loading.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.