In-Situ Monitoring-Enabled Multiscale Modeling and Processing Optimization for Environmental and Mechanical Performance of Advanced Manufactured Materials

Overview: 

Recent studies have shown that the environment-assisted failure of L-PBF samples is different from their conventionally fabricated counterparts. However, no comprehensive framework has existed so far to correlate the manufacturing processes to environmental and mechanical performance of L-PBF products. Quality assurance significantly depends on a trial-and-error procedure, which is extremely expensive, time-consuming, and error-prone. In addition, the failure model obtained by testing laboratory L-PBF specimens cannot be extended to part-scale products, since the change of size and geometry leads to the variation of the thermal history, and consequently the formation of the microstructure, defects, and residual stress. Therefore, the applicability and effectiveness of the specimen-based model are limited. The goal of this project is to establish an in-situ processing data-based framework that can effectively link manufacturing process to environmental-related performance for part-scale L-PBF and allow processing optimization for improved failure performance. 

Key Outcome:

The proposed framework can be articulated by the three thrusts: 1) Establish a physics-constrained data-driven multiscale model to link process parameters to the location-dependent microstructures and residual stress; both in-situ processing data and ex-situ experiment data will be integrated with the multiscale model for more accurate prediction; 2) Build the structure-to-properties model from microstructure and residual stress to environment-assisted fatigue failure for part-scale L-PBF production; 3) Verification and validation of the proposed framework for practical components.

Publications:

1.     K. Sangoi, M. Nadimi, J. Song, Y. Fu*, “Heat Treatment Effect on the Corrosion Resistance of 316L Stainless Steel Produced by Laser Powder Bed Fusion”, Metals, 15 (2025) 41

2.     M. Nadimi, J. Song, L. Cheng, Y. Fu*, “Corrosion Evaluation and Microstructural Characteristics of Copper-Nickel Alloy Fabricated by Laser Powder Bed Fusion”, Journal of Alloys and Metallurgical Systems, 9 (2025) 100155

3.     C. Mathew, J. Song, E. Adu-Gyamfi, Y. Fu*, “Phase field numerical model for simulating the diffusion controlled stress corrosion cracking phenomena in anisotropic material”, Computational Materials Science 247 (2025) 113528

4.     J. Song, X. Jimenez, A. To, Y. Fu*, “Microstructures and Corrosion Properties of Wire Arc Additive Manufactured Copper-Nickel Alloys”, Materials 17 (2024) 876.

5.     J. Song, K. Sangoi, M. Nadimi, Y. Fu*. “Remarkably Enhanced Corrosion Performance of 316 L Stainless Steel via Laser Powder Bed Fusion Thin-Layer Deposition”. Materials Today Communication 38 (2023) 107690.

6.     J. Song, C. Matthew, K. Sangoi, Y. Fu*. “A Phase Field Model to Simulate Crack Initiation from Pitting Site in Isotropic and Anisotropic Elastoplastic Material”, Modelling and Simulation in Materials Science and Engineering, 31 (2023) 055002.

7.     B. Gnanasekaran, J. Song*, V. Vasudevan, Y. Fu*, “Corrosion Fatigue Characteristics of 316L Stainless Steel Fabricated by Laser Powder Bed Fusion”, Metals 11 (2021), 1046.