| About this Abstract |
| Meeting |
2024 TMS Annual Meeting & Exhibition
|
| Symposium
|
Cold Spray Additive Manufacturing: Part Quality and Performance
|
| Presentation Title |
Residual-stress-based Crystal Plasticity Model for Simulation of Cold Spray Al6061 |
| Author(s) |
Aulora Gail Rusk, YubRaj Paudel, Shiraz Mujahid, Marc Pepi, Peter Czech, Haitham El Kadiri, Hongjoo Rhee |
| On-Site Speaker (Planned) |
Aulora Gail Rusk |
| Abstract Scope |
While cold-spray additive manufacturing (CSAM) offers superior build rates with low heat input, the method also induces heterogeneous compressive residual stresses, with spatial variations in microstructure and mechanical properties leading to poor inter-particle (intersplat) bonding and diminished component performance. Thermal post-processing has been studied as a viable method to recover material performance through enhancement of intersplat bonding and redistribution of highly localized residual stresses. To better capture behavior of as-built and post-processed CSAM microstructures, the present work introduces residual stress and spatial variation parameters into a modified microscale-mesoscale viscoplastic self-consistent (VPSC) framework. The physically informed model utilizes data obtained from experimental diffraction measurements and published literature to predict deformation responses along with stress and strain incompatibilities within regions of interest in CSAM Aluminum 6061 microstructures. Further crystal plasticity simulations were used to perform a parametric study exploring the sensitivity of predicted plastic flow to model parameters.
(DISTRIBUTION A- Approved for public release; distribution is unlimited.) |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Aluminum |