Opportunities Of Physics-Based Multi-Scale Modeling Tools In Assessing Intra-Grain Heterogeneities, Polycrystal Properties And Residual Stresses Of AM Metals

Microstructure is the origin of the properties and performance for additively manufactured metals. Rapid solidification enable the formation of various grain/phase structures as well as solute segregation and initial dislocation structures that all contribute to the properties of the alloy. We present the following methods in this work. An effective way to approach process-structure-properties linkage in rapid solidification is to utilize a phase field solidification model coupled with a thermomechanical crystal plasticity. This allows us to assess both intra-grain/polycrystal level dislocation/stress heterogeneities introduced during solidification and residual stresses. Single-track laser melting is a method to analyze materials printability. In this scope, crystal plasticity is a tool to investigate heterogeneities and cracking tendency of solidified microstructures during cooling. Finally, at the part level it is possible to utilize homogenized/embedded crystal plasticity models to provide the thermomechanical response of the material. We review the pre-mentioned multiscale model outputs, interactive dialogue, and opportunities.