Crystal plasticity model of residual stress in additive manufacturing using the element elimination and reactivation method

Selective laser melting is receiving increasing interest as an additive manufacturing technique. Residual stresses induced by the large temperature gradients and inhomogeneous cooling process can favour the generation of cracks. In this work, a crystal plasticity finite element model is developed to simulate the formation of residual stresses and to understand the correlation between plastic deformation, grain orientation and residual stresses in the additive manufacturing process. The temperature profile and grain structure from thermal-fluid flow and grain growth simulations are implemented into the crystal plasticity model. An element elimination and reactivation method is proposed to model the melting and solidification and to reinitialize state variables, such as the plastic deformation, in the reactivated elements. The accuracy of this method is judged against previous method based on the stiffness degradation of liquid regions by comparing the plastic deformation as a function of time induced by thermal stresses. The method is used to investigate residual stresses parallel and perpendicular to the laser scan direction, and the correlation with the maximum Schmid factor of the grains along those directions. The magnitude of the residual stress can be predicted as a function of the depth, grain orientation and position with respect to the molten pool. The simulation results are directly comparable to X-ray diffraction experiments and stress–strain curves.

Investigation on Plastic Flow Behaviors of FCC Polycrystalline Aluminum under Pre-Cyclic Tension-Compression Loading: Experiments and Crystal Plasticity Modeling

The plastic flow behaviors of FCC polycrystalline aluminum after pre-cyclic tension-compression deformation are mainly investigated in tension–torsion stress space by the physically based crystal plasticity model introducing a back-stress. A global finite element model (GFEM) constructed of sufficient grains was established to simulate the same-size thin-walled tube specimen constrained and loaded as the experiments of yield surfaces. The computational results showed that the shape of subsequent yield surfaces and the plastic flow directions directly depended on the given offset strain levels and the applied re-loading paths under different pre-cyclic deformations. The angle deviation between the plastic flow direction and the theoretical orthogonal direction further indicated that there was a large difference between them in the inverse pre-straining direction, but the difference was negligible in the pre-straining direction. From the influence of the anisotropic evolution of the subsequent yield surfaces on plastic flow, we found that the plastic normality rule followed the smooth yield locus; conversely, the significant non-associated flow was attributed to the distorted yield locus. Furthermore, it was also demonstrated that the anisotropic evolution and the plastic flow trend of the subsequent yield surfaces obtained by experiments can be better reproduced by the crystal plasticity model.