Analytical Modeling of Materials Properties in Metal Additive Manufacturing

The emerging technology of additive manufacturing (AM) offers a sustainable and eco-friendly approach to manufacturing, which contrasts with traditional methods and supports global decarbonization efforts. However, AM still faces numerous challenges due to its complex processes across different materials and applications. The main focus of this investigation is to examine how microstructural changes impact material properties such as elastic modulus and Poisson's ratio, affecting performance factors like residual stress and fractures. This involves studying the material's microstructure, including its surface textures, grain size, and any defects. In this study, simulations of texture and grain size for multi-phase materials are performed based on accurate modeling of the processing conditions. The research also characterizes how microstructural changes in metal additive manufacturing affect material properties. Various models have been developed to predict manufacturing processes using physics-based frameworks, and experimental results have been used to validate these models. It has been observed that the computer-simulated effective elastic modulus, using the same experimental processing parameters, remains stable at around 109-117 GPa and is not significantly influenced by specific settings. Moreover, the simulated derivatives under the same settings are stable at around 850-900 MPa, which aligns closely with the experimental data. This research aims to bridge the gap between the micro- and macrostructures of AM and to transform the sector by providing a new perspective on science.