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Deformation mechanisms and defect tolerance in the microstructure of 3D-printed alloys

Published online by Cambridge University Press:  06 April 2020

Matthew Moneghan ,
Christopher Williams  and
Reza Mirzaeifar
Matthew Moneghan
Affiliation:
Department of Mechanical Engineering, Virginia Tech, Blacksburg, Virginia 24061, USA
Christopher Williams
Affiliation:
Department of Mechanical Engineering, Virginia Tech, Blacksburg, Virginia 24061, USA
Reza Mirzaeifar*
Affiliation:
Department of Mechanical Engineering, Virginia Tech, Blacksburg, Virginia 24061, USA
*
a)Address all correspondence to this author. e-mail: rmirzaei@vt.edu
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Abstract

A novel approach is utilized to investigate the deformation mechanisms at the microstructural level in 3D-printed alloys. The complex formation methods leave a unique and complicated microstructure in the as-built 3D-printed alloys. The microstructure is three leveled, composed of meltpools, grains, and cells. Deformation mechanisms in this microstructure are still highly unexplored due to the complexities of analysis at this scale. To understand these, we establish an image processing framework that converts scanning electron microscope (SEM) images directly into models that are scaled up and 3D printed with representative stiff and soft materials for the proposed material types within the body. These bodies are loaded in uniaxial tension with digital image correlation to study the strain gradient and stress delocalization as a result of the microstructure. The same models were tested through Finite Element Analysis (FEA) with materials similar to reality. Our testing shows the hierarchical material distribution leads to an increased damage tolerance.

Keywords

3D printing metalsadditive manufacturingmicrostructuredefect tolerance

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Article
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Journal of Materials Research , Volume 35 , Issue 15: Focus Issue: Additive Manufacturing of Metals: Complex Microstructures and Architecture Design , 14 August 2020 , pp. 1984 - 1997
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Copyright © Materials Research Society 2020

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