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
    • ProperTune

    Cite this

    @article{828e24bf2f2a42a5bb47cd6cba1a4d21,
    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.",
    keywords = "additive manufacturing, slective laser melting, phase field modeling, heat-transfer modeling, micromechanical modeling, crystal plasticity, integrated computational materials engineering, ProperTune",
    author = "Tatu Pinomaa and Ivan Yashchuk and Matti Lindroos and Tom Andersson and Nikolas Provatas and Anssi Laukkanen",
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    year = "2019",
    month = "10",
    day = "24",
    doi = "10.3390/met9111138",
    language = "English",
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    journal = "Metals",
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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

    TY - JOUR

    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

    N1 - Project 117056

    PY - 2019/10/24

    Y1 - 2019/10/24

    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.

    AB - 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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    KW - slective laser melting

    KW - phase field modeling

    KW - heat-transfer modeling

    KW - micromechanical modeling

    KW - crystal plasticity

    KW - integrated computational materials engineering

    KW - ProperTune

    UR - http://www.scopus.com/inward/record.url?scp=85074230391&partnerID=8YFLogxK

    U2 - 10.3390/met9111138

    DO - 10.3390/met9111138

    M3 - Article

    VL - 9

    JO - Metals

    JF - Metals

    SN - 2075-4701

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    M1 - 1138

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