Rapid prediction of overload fatigue life based on phase-field modeling of microstructures under different scanning strategies

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING Additive manufacturing Pub Date : 2025-04-05 DOI:10.1016/j.addma.2025.104771

Haifeng Zhai , Wei Jiang , Yang Wang , Yanzhao Yang , Haiting Lv

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Abstract

Understanding the mechanisms of microstructure evolution is essential for accurately predicting and improving the final mechanical properties of materials. To enable efficient simulation of multi-layer, multi-track additive manufacturing (AM) processes with various scanning strategies, a three-dimensional phase-field (PF) model was developed to capture grain evolution in AM. The model effectively reproduces grain nucleation, epitaxial growth, and coarsening. Three representative scanning strategies (stripe, loop, and chessboard) were experimentally validated. The simulation results showed strong consistency with experimental observations regarding melt pool dynamics, grain morphology, and defect evolution. The crystal plasticity finite element method (CPFEM) was utilized to predict overload fatigue life, and a novel strategy was introduced to rapidly and efficiently estimate fatigue life by reconstructing the microstructure corresponding to different scanning strategies. This study offers novel methodological insights into grain growth and evolution mechanisms in AM and extends the predictive framework for overload fatigue life estimation.

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不同扫描策略下基于相场建模的微结构过载疲劳寿命快速预测

了解微观组织演变的机理是准确预测和提高材料最终力学性能的关键。为了有效地模拟具有不同扫描策略的多层、多轨迹增材制造（AM）过程，开发了三维相场（PF）模型来捕获增材制造中的晶粒演变。该模型有效地再现了晶粒形核、外延生长和粗化过程。实验验证了三种具有代表性的扫描策略（条纹、循环和棋盘）。在熔池动力学、晶粒形貌和缺陷演化等方面，模拟结果与实验观察结果具有较强的一致性。利用晶体塑性有限元法（CPFEM）预测疲劳寿命，提出了一种通过重构不同扫描策略对应的显微组织来快速有效估计疲劳寿命的新方法。本研究为研究增材制造中晶粒生长演化机制提供了新的方法见解，并扩展了超载疲劳寿命估计的预测框架。

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来源期刊

Additive manufacturing Materials Science-General Materials Science

CiteScore

19.80

自引率

12.70%

发文量

648

审稿时长

35 days

期刊介绍： Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.