Process-Structure-Properties-Performance Modeling for Selective Laser Melting

Tatu Pinomaa (Corresponding Author), Ivan Yashchuk, Matti Lindroos, Tom Andersson, Nikolas Provatas, Anssi Laukkanen

Research output: Contribution to journalArticleScientificpeer-review

Abstract

Selective laser melting (SLM) is a promising manufacturing technique where the part design, from performance and properties process control and alloying, can be accelerated with integrated computational materials engineering (ICME). This paper demonstrates a process-structure-properties-performance modeling framework for SLM. For powder-bed scale melt pool modeling, we present a diffuse-interface multiphase computational fluid dynamics model which couples Navier–Stokes, Cahn–Hilliard, and heat-transfer equations. A computationally efficient large-scale heat-transfer model is used to describe the temperature evolution in larger volumes. Phase field modeling is used to demonstrate how epitaxial growth of Ti-6-4 can be interrupted with inoculants to obtain an equiaxed polycrystalline structure. These structures are enriched with a synthetic lath martensite substructure, and their micromechanical response are investigated with a crystal plasticity model. The fatigue performance of these structures are analyzed, with spherical porelike defects and high-aspect-ratio cracklike defects incorporated, and a cycle-amplitude fatigue graph is produced to quantify the fatigue behavior of the structures. The simulated fatigue life presents trends consistent with the literature in terms of high cycle and low cycle fatigue, and the role of defects in dominating the respective performance of the produced SLM structures. The proposed ICME workflow emphasizes the possibilities arising from the vast design space exploitable with respect to manufacturing systems, powders, respective alloy chemistries, and microstructures. By digitalizing the whole workflow and enabling a thorough and detailed virtual evaluation of the causal relationships, the promise of product-targeted materials and solutions for metal additive manufacturing becomes closer to practical engineering application.
Original languageEnglish
Article number1138
JournalMetals
Volume9
Issue number11
DOIs
Publication statusPublished - 24 Oct 2019
MoE publication typeA1 Journal article-refereed

Fingerprint

Melting
Fatigue of materials
Lasers
Powders
Defects
3D printers
Heat transfer
Alloying
Epitaxial growth
Martensite
Process control
Plasticity
Aspect ratio
Dynamic models
Computational fluid dynamics
Metals
Crystals
Microstructure
Temperature

Keywords

  • additive manufacturing
  • slective laser melting
  • phase field modeling
  • heat-transfer modeling
  • micromechanical modeling
  • crystal plasticity
  • integrated computational materials engineering

Cite this

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title = "Process-Structure-Properties-Performance Modeling for Selective Laser Melting",
abstract = "Selective laser melting (SLM) is a promising manufacturing technique where the part design, from performance and properties process control and alloying, can be accelerated with integrated computational materials engineering (ICME). This paper demonstrates a process-structure-properties-performance modeling framework for SLM. For powder-bed scale melt pool modeling, we present a diffuse-interface multiphase computational fluid dynamics model which couples Navier–Stokes, Cahn–Hilliard, and heat-transfer equations. A computationally efficient large-scale heat-transfer model is used to describe the temperature evolution in larger volumes. Phase field modeling is used to demonstrate how epitaxial growth of Ti-6-4 can be interrupted with inoculants to obtain an equiaxed polycrystalline structure. These structures are enriched with a synthetic lath martensite substructure, and their micromechanical response are investigated with a crystal plasticity model. The fatigue performance of these structures are analyzed, with spherical porelike defects and high-aspect-ratio cracklike defects incorporated, and a cycle-amplitude fatigue graph is produced to quantify the fatigue behavior of the structures. The simulated fatigue life presents trends consistent with the literature in terms of high cycle and low cycle fatigue, and the role of defects in dominating the respective performance of the produced SLM structures. The proposed ICME workflow emphasizes the possibilities arising from the vast design space exploitable with respect to manufacturing systems, powders, respective alloy chemistries, and microstructures. By digitalizing the whole workflow and enabling a thorough and detailed virtual evaluation of the causal relationships, the promise of product-targeted materials and solutions for metal additive manufacturing becomes closer to practical engineering application.",
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author = "Tatu Pinomaa and Ivan Yashchuk and Matti Lindroos and Tom Andersson and Nikolas Provatas and Anssi Laukkanen",
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Process-Structure-Properties-Performance Modeling for Selective Laser Melting. / Pinomaa, Tatu (Corresponding Author); Yashchuk, Ivan; Lindroos, Matti; Andersson, Tom; Provatas, Nikolas; Laukkanen, Anssi.

In: Metals, Vol. 9, No. 11, 1138, 24.10.2019.

Research output: Contribution to journalArticleScientificpeer-review

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T1 - Process-Structure-Properties-Performance Modeling for Selective Laser Melting

AU - Pinomaa, Tatu

AU - Yashchuk, Ivan

AU - Lindroos, Matti

AU - Andersson, Tom

AU - Provatas, Nikolas

AU - Laukkanen, Anssi

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N2 - Selective laser melting (SLM) is a promising manufacturing technique where the part design, from performance and properties process control and alloying, can be accelerated with integrated computational materials engineering (ICME). This paper demonstrates a process-structure-properties-performance modeling framework for SLM. For powder-bed scale melt pool modeling, we present a diffuse-interface multiphase computational fluid dynamics model which couples Navier–Stokes, Cahn–Hilliard, and heat-transfer equations. A computationally efficient large-scale heat-transfer model is used to describe the temperature evolution in larger volumes. Phase field modeling is used to demonstrate how epitaxial growth of Ti-6-4 can be interrupted with inoculants to obtain an equiaxed polycrystalline structure. These structures are enriched with a synthetic lath martensite substructure, and their micromechanical response are investigated with a crystal plasticity model. The fatigue performance of these structures are analyzed, with spherical porelike defects and high-aspect-ratio cracklike defects incorporated, and a cycle-amplitude fatigue graph is produced to quantify the fatigue behavior of the structures. The simulated fatigue life presents trends consistent with the literature in terms of high cycle and low cycle fatigue, and the role of defects in dominating the respective performance of the produced SLM structures. The proposed ICME workflow emphasizes the possibilities arising from the vast design space exploitable with respect to manufacturing systems, powders, respective alloy chemistries, and microstructures. By digitalizing the whole workflow and enabling a thorough and detailed virtual evaluation of the causal relationships, the promise of product-targeted materials and solutions for metal additive manufacturing becomes closer to practical engineering application.

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