Macroscale Property Prediction for Additively Manufactured IN625 from Microstructure through Advanced Homogenization

Design of additively manufactured metallic parts requires computational models that can predict the mechanical response of parts considering the microstructural, manufacturing, and operating conditions. This article documents our response to Air Force Research Laboratory (AFRL) Additive Manufacturing Modeling Challenge 3, which asks the participants to predict the mechanical response of tensile coupons of IN625 as function of microstructure and manufacturing conditions. A representative volume element (RVE) approach was coupled with a crystal plasticity material model solved within the Fast Fourier Transformation (FFT) framework for mechanics to address the challenge. During the competition, material model calibration proved to be a challenge, prompting the introduction in this manuscript of an advanced material model identification method using proper generalized decomposition (PGD). Finally, a mechanistic reduced order method called Self-consistent Clustering Analysis (SCA) is shown as a possible alternative to the FFT method for solving these problems. Apart from presenting the response analysis, some physical interpretation and assumptions associated with the modeling are discussed.