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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Verification, Calibration, and Validation Approaches in Modeling the Mechanical Performance of Metallic Materials
Presentation Title Crystal Plasticity Calibration and Surrogate Modeling for Thermo-Mechanical Behavior of Additively Manufactured Ti-6Al-4V Alloy
Author(s) Mohamed Elleithy, Pinar Acar
On-Site Speaker (Planned) Mohamed Elleithy
Abstract Scope This work presents a Crystal Plasticity (CP) framework for modeling the thermo-mechanical behavior of additively manufactured Ti-6Al-4V using DAMASK. Calibration is performed using uniaxial tensile experimental data to optimize constitutive parameters: critical resolved shear stress, saturation stress, hardening modulus, and rate sensitivity, via minimization of stress-strain mismatch. DAMASK’s spectral solver captures anisotropic plasticity and microstructural evolution via full-field simulations. To extend predictive capabilities across the thermal and kinematic space of additive manufacturing (AM), temperature- and strain-rate-dependent CP simulations are conducted using DAMASK’s coupled thermo-mechanical formulation. The resulting dataset informs a Machine Learning (ML) surrogate model, emulating CP predictions with reduced cost. This surrogate enables rapid exploration of processing–structure–property linkages under extreme thermal gradients and strain rates, characteristic of AM techniques such as Additive Friction Stir Deposition and Direct Energy Deposition. The integrated CP–ML framework aims to support ICME workflows by enabling microstructure-sensitive design of titanium alloys under realistic manufacturing conditions.
Proceedings Inclusion? Planned:
Keywords ICME, Mechanical Properties, Titanium

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