Crystal plasticity approach for predicting mechanical responses in wire-arc directed energy deposition of NbZr1 refractory alloy

Saiful Islam; Sainand Jadhav; Taejoon Park; Farhang Pourboghrat; Xuesong Fan; Peter K. Liaw; Duck Bong Kim

doi:10.1016/j.addma.2024.104107

Crystal plasticity approach for predicting mechanical responses in wire-arc directed energy deposition of NbZr1 refractory alloy

Saiful Islam, Sainand Jadhav, Taejoon Park, Farhang Pourboghrat, Xuesong Fan, Peter K. Liaw, Duck Bong Kim

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

The refractory alloy, such as Niobium-1 wt% Zirconium (NbZr1) alloy, is a promising candidate for diverse applications in extreme environments. This study investigates an integrated experimental and computational methodology that can predict the mechanical properties of wire-arc directed energy deposited (DED) refractory NbZr1 alloy. The effect of large columnar grains with strong texture induced by the wire-DED process has been successfully incorporated into the representative volume element (RVE). Performing crystal plasticity (CP) simulation on RVE of NbZr1, deformation behavior and stress-strain relationship are predicted to explore the process-structure-property (PSP) relationship. The RVE has been created in synthetic microstructure generation software utilizing the grain statistics derived from electron backscatter diffraction (EBSD) analysis, capturing essential microstructural features. A phenomenological constitutive model and appropriate boundary conditions have been applied and solved, using the CP fast Fourier transform method. The CP model has been calibrated and validated utilizing the tensile test data along the build direction and deposition direction, respectively. The error in predicting yield strength and ultimate tensile strength is 0.91% and 0.67%, respectively, for the calibration simulation, whereas these values are 2.51% and 1.81% for the validation simulation. The results suggest strong agreement between the simulation and experimental observation. Even though global deformation behavior remains consistent across multiple RVEs with the same microstructural features, local stress-strain values vary, indicating structural anisotropy, which is also consistent with the digital image correlation (DIC) result. It is proven that this proposed CP method can effectively predict the mechanical responses of components with large grains and strong textures resulting from the wire-arc DED.

Original language	English
Article number	104107
Journal	Additive Manufacturing
Volume	84
DOIs	https://doi.org/10.1016/j.addma.2024.104107
State	Published - Mar 25 2024
Externally published	Yes

Funding

The authors of this paper acknowledge the Center for Manufacturing Research (CMR) and Tennessee Technological University's Department of Manufacturing and Engineering Technology for their support. This material is based upon work supported by the National Science Foundation under Grant No. 2141905. The authors of this paper acknowledge the Center for Manufacturing Research (CMR) and Tennessee Technological University\u2019s Department of Manufacturing and Engineering Technology for their support. This material is based upon work supported by the National Science Foundation under Grant No. 2141905.

Keywords

Crystal plasticity
Mechanical properties
Refractory alloy
Representative volume element (RVE)
Wire-arc directed energy deposition (DED)

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@article{463bd3587ade4beb84aeccb03e239aec,

title = "Crystal plasticity approach for predicting mechanical responses in wire-arc directed energy deposition of NbZr1 refractory alloy",

abstract = "The refractory alloy, such as Niobium-1 wt\% Zirconium (NbZr1) alloy, is a promising candidate for diverse applications in extreme environments. This study investigates an integrated experimental and computational methodology that can predict the mechanical properties of wire-arc directed energy deposited (DED) refractory NbZr1 alloy. The effect of large columnar grains with strong texture induced by the wire-DED process has been successfully incorporated into the representative volume element (RVE). Performing crystal plasticity (CP) simulation on RVE of NbZr1, deformation behavior and stress-strain relationship are predicted to explore the process-structure-property (PSP) relationship. The RVE has been created in synthetic microstructure generation software utilizing the grain statistics derived from electron backscatter diffraction (EBSD) analysis, capturing essential microstructural features. A phenomenological constitutive model and appropriate boundary conditions have been applied and solved, using the CP fast Fourier transform method. The CP model has been calibrated and validated utilizing the tensile test data along the build direction and deposition direction, respectively. The error in predicting yield strength and ultimate tensile strength is 0.91\% and 0.67\%, respectively, for the calibration simulation, whereas these values are 2.51\% and 1.81\% for the validation simulation. The results suggest strong agreement between the simulation and experimental observation. Even though global deformation behavior remains consistent across multiple RVEs with the same microstructural features, local stress-strain values vary, indicating structural anisotropy, which is also consistent with the digital image correlation (DIC) result. It is proven that this proposed CP method can effectively predict the mechanical responses of components with large grains and strong textures resulting from the wire-arc DED.",

keywords = "Crystal plasticity, Mechanical properties, Refractory alloy, Representative volume element (RVE), Wire-arc directed energy deposition (DED)",

author = "Saiful Islam and Sainand Jadhav and Taejoon Park and Farhang Pourboghrat and Xuesong Fan and Liaw, \{Peter K.\} and Kim, \{Duck Bong\}",

note = "Publisher Copyright: {\textcopyright} 2024 Elsevier B.V.",

year = "2024",

month = mar,

day = "25",

doi = "10.1016/j.addma.2024.104107",

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journal = "Additive Manufacturing",

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AU - Islam, Saiful

AU - Jadhav, Sainand

AU - Park, Taejoon

AU - Pourboghrat, Farhang

AU - Fan, Xuesong

AU - Liaw, Peter K.

AU - Kim, Duck Bong

PY - 2024/3/25

Y1 - 2024/3/25

N2 - The refractory alloy, such as Niobium-1 wt% Zirconium (NbZr1) alloy, is a promising candidate for diverse applications in extreme environments. This study investigates an integrated experimental and computational methodology that can predict the mechanical properties of wire-arc directed energy deposited (DED) refractory NbZr1 alloy. The effect of large columnar grains with strong texture induced by the wire-DED process has been successfully incorporated into the representative volume element (RVE). Performing crystal plasticity (CP) simulation on RVE of NbZr1, deformation behavior and stress-strain relationship are predicted to explore the process-structure-property (PSP) relationship. The RVE has been created in synthetic microstructure generation software utilizing the grain statistics derived from electron backscatter diffraction (EBSD) analysis, capturing essential microstructural features. A phenomenological constitutive model and appropriate boundary conditions have been applied and solved, using the CP fast Fourier transform method. The CP model has been calibrated and validated utilizing the tensile test data along the build direction and deposition direction, respectively. The error in predicting yield strength and ultimate tensile strength is 0.91% and 0.67%, respectively, for the calibration simulation, whereas these values are 2.51% and 1.81% for the validation simulation. The results suggest strong agreement between the simulation and experimental observation. Even though global deformation behavior remains consistent across multiple RVEs with the same microstructural features, local stress-strain values vary, indicating structural anisotropy, which is also consistent with the digital image correlation (DIC) result. It is proven that this proposed CP method can effectively predict the mechanical responses of components with large grains and strong textures resulting from the wire-arc DED.

AB - The refractory alloy, such as Niobium-1 wt% Zirconium (NbZr1) alloy, is a promising candidate for diverse applications in extreme environments. This study investigates an integrated experimental and computational methodology that can predict the mechanical properties of wire-arc directed energy deposited (DED) refractory NbZr1 alloy. The effect of large columnar grains with strong texture induced by the wire-DED process has been successfully incorporated into the representative volume element (RVE). Performing crystal plasticity (CP) simulation on RVE of NbZr1, deformation behavior and stress-strain relationship are predicted to explore the process-structure-property (PSP) relationship. The RVE has been created in synthetic microstructure generation software utilizing the grain statistics derived from electron backscatter diffraction (EBSD) analysis, capturing essential microstructural features. A phenomenological constitutive model and appropriate boundary conditions have been applied and solved, using the CP fast Fourier transform method. The CP model has been calibrated and validated utilizing the tensile test data along the build direction and deposition direction, respectively. The error in predicting yield strength and ultimate tensile strength is 0.91% and 0.67%, respectively, for the calibration simulation, whereas these values are 2.51% and 1.81% for the validation simulation. The results suggest strong agreement between the simulation and experimental observation. Even though global deformation behavior remains consistent across multiple RVEs with the same microstructural features, local stress-strain values vary, indicating structural anisotropy, which is also consistent with the digital image correlation (DIC) result. It is proven that this proposed CP method can effectively predict the mechanical responses of components with large grains and strong textures resulting from the wire-arc DED.

KW - Crystal plasticity

KW - Mechanical properties

KW - Refractory alloy

KW - Representative volume element (RVE)

KW - Wire-arc directed energy deposition (DED)

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JO - Additive Manufacturing

JF - Additive Manufacturing

M1 - 104107

ER -

Crystal plasticity approach for predicting mechanical responses in wire-arc directed energy deposition of NbZr1 refractory alloy

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