Additive manufacturing (AM) processes have the ability to build complex geometries from a wide variety of materials. A popular approach for metal-based AM processes involves the deposition of material particles on a substrate followed by fusion of those particles together using a high intensity heat source, e.g. a laser or an electron beam [1], in order to fabricate a solid part. These methods are of high priority in engineering research, especially in applications for the energy, health, and defense sectors. The primary reasons behind the rapid growth in interest for AM include: (1) the ability to create complex geometries which are otherwise cost-prohibitive or difficult to manufacture, (2) increased freedom of material composition design through the adjustment of the ratios of the composing powders, (3) a reduction in wasted materials, and (4) the fast, low-volume, production of prototype and functional parts without the additional tooling and die requirements of conventional manufacturing methods. However, the highly localized and intense nature of these processes elicits many experimental and computational challenges. These challenges motivate a strong need for computational investigation, as does the need to more accurately characterize the response of parts built using AM. The present work will discuss these challenges and methods for creating multiscale material models that account for the complex phenomena observed in the AM production environment. The linkage between process, structure, and property [2] of AM components, e.g., anisotropic plastic behavior [3],[4] combined anisotropic microstructural descriptors afforded through enhanced data compression techniques, will also be discussed.

Recording of the presentation

Location: Technical University of Catalonia (UPC), Vertex Building.
Date: 1 - 3 September 2015, Barcelona, Spain.

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[1] Yan, W., Smith, J., Ge, W., Lin, F., Liu, W.K., “Multiscale modeling of electron beam and substrate interaction: a new heat source model,” Computational Mechanics, 1-12 (2015).

[2] O’Keeffe, C., Tang, S., Kopacz, A.M., Smith, J., Rowenhorst, D., Spanos, G., Liu, W.K., Olson, G.B., “Multiscale Ductile Fracture Integrating Tomographic Characterization and 3D Simulation,” Acta Materialia, 82, 503-510 (2015).

[3] Smith, J., Liu, W.K., Cao, J., “A General Anisotropic Yield Criterion for Pressure-Dependent Materials,” International Journal of Plasticity, accepted manuscript.

[4] Smith, J., Moore, J. A., Cao, J., Liu, W.K., “A General Anisotropic Yield Criterion for DamageProne Materials with Sensitivity to Shear Loading,” Journal of Mechanics and Physics of Solids, in preparation.

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Published on 07/06/16

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