6th World Congress on Integrated Computational Materials Engineering (ICME 2022): Monday Plenary
Program Organizers: William Joost; Kester Clarke, Los Alamos National Laboratory; Danielle Cote, Worcester Polytechnic Institute; Javier Llorca, IMDEA Materials Institute & Technical University of Madrid; Heather Murdoch, U.S. Army Research Laboratory; Satyam Sahay, John Deere; Michael Sangid, Purdue University

Monday 8:00 AM
April 25, 2022
Room: Regency Ballroom AB
Location: Hyatt Regency Lake Tahoe

Session Chair: William Joost


8:00 AM  Plenary
An ICME Approach to Development of a Low-Cost Magnesium Sheet Component for Automotive Applications: Bita Ghaffari1; 1Ford Motor Company
    Improving vehicle fuel economy is an ever-present motivation for lightweighting in the automotive industry. Though great progress has been made by optimization and expanded utilization of aluminum alloys and high-strength steel alloys, further improvements are possible by increased use of magnesium alloys. Though these alloys have made headway as cast parts, the usage of sheet alloys has been greatly hampered by difficulties in producing components that satisfy the target mechanical and corrosion properties at acceptable cost. This talk will present the various ICME-based methodologies used in the U.S. Department of Energy project “USAMP Low-Cost Mg Sheet Component Development and Demonstration.” Several teams at universities and national labs have participated in alloy design and rolling optimization, investigated physical mechanisms affecting formability, and developed enhanced material models that have enabled formability simulations of large automotive panels from Mg alloy sheet. The work encompasses atomistic, microstructure, and continuum scales of model development. The results, as well as challenges and possible gaps, will be discussed.

8:40 AM  Plenary
ICME of Additively Manufactured Metals: New Computational Tools and the Central Role of Materials Data : Alexander Chadwick1; Christopher Hareland1; Peter Voorhees1; 1Northwestern University
    The materials design process requires links between processing conditions and the resulting microstructure. We illustrate two approaches to coupling the processing conditions of additive manufacturing (AM) to microstructure. A phase field model has been developed that follows the evolution of thousands of grains in three dimensions as a heat source propagates along a surface at the high rates seen during AM. Through this approach it is possible to determine the effects of the solidification conditions, the weld pool geometry, and multiple passes of the heat source on the resulting grain morphology. The multicomponent nature of engineering alloys presents opportunities, along with the flexibility of AM processing, to choose an alloy composition and processing path that achieves the desired microstructure. A model for rapid solidification of multicomponent alloys that accounts for the nonideal nature of liquid diffusion and phase equilibrium will be presented.

9:20 AM  Plenary
DAMASK - Experiences from 10 Years ICME Software Development for Physics-based ICME: Martin Diehl1; Pratheek Shanthraj2; Philip Eisenlohr3; Franz Roters4; Dierk Raabe4; 1KU Leuven, Max-Planck-Institut für Eisenforschung GmbH; 2University of Manchester; 3Michigan State University; 4Max-Planck-Institut für Eisenforschung GmbH
    Crystal plasticity modeling methods have evolved into one of the cornerstones of computational materials science and engineering. They combine the tensorial nature of the individual crystallographic shear modes such as carried by dislocations, martensitic transformations, shear bands or mechanical twins with the orientation dependence and polyphase structure of crystalline matter. With the Düsseldorf Advanced Material Simulation Kit (DAMASK) we aim to provide a modular and extensible framework for crystal plasticity simulations at various length scales. At the core of DAMASK is a flexible and hierarchically structured model of material point behavior for the solution of elastoplastic boundary value problems along with damage and thermal physics within a finite-strain continuum framework. This talks sketches implementation details of DAMASK, such as the staggered integration scheme for the material state, the coupling of different physical effects, and the integration into different solvers for boundary and initial value problems. Besides discussing the technical details of the current version, lessons learned from developing a modular simulation framework embedded into an ecosystem for pre- and post-processing are presented. To this end, the history of DAMASK – starting from a user subroutine for commercial FEM solvers to its transition into a stand-alone multiphysics framework is briefly outlined. Finally, several illustrative examples are given to demonstrate how DAMASK is used to understand the mechanical behavior of polycrystalline materials.

10:00 AM Break