Efficient computational framework for image-based micromechanical analysis of additively manufactured Ti-6Al-4V alloy

The increase in additively manufactured (AM) Ti-6Al-4V alloys in high-performance industrial applications has necessitated the development of robust computational models that can aid in their qualification and certification. Physics-based micromechanical models, relating the AM-processed material microstructure and defect state with the overall material response and life, can play an important role in reducing uncertainty in component behavior and increasing acceptance. Motivated by this need, the present paper develops a novel image-based crystal plasticity finite element model (CPFEM) for efficient micromechanical simulation of the additively manufactured Ti-6Al-4V alloy, whose Widmanstätten microstructure is characterized by 12 HCP α lath variants in the parent β grain. A unique feature of this work is the creation of an efficient crystal plasticity framework for the parent β grain polycrystalline ensembles with parametric representation of the α lath statistics of size, shape, orientation, and crystallography. This statistical representation is expected to significantly enhance its efficiency over models that represent each α lath explicitly in the microstructure. Defects in the form of voids are represented at two scales. The smaller voids in the microstructure are manifested as porosity or void volume fraction distribution in the crystal plasticity model. Larger voids are represented explicitly in the statistically equivalent microstructural volume element (SEMVE) model. The models are built from experimentally acquired electron back scatter diffraction (EBSD) and micro-focus X-ray computed tomography (XCT) images and calibrated and validated with mechanical testing data. This paper extends the developments in Pinz et al. (2022) through the development of a special self-consistent boundary condition in the context of a concurrent model to overcome limitations of periodicity boundary conditions. The concurrent model embeds the SEMVE in a homogenized exterior domain represented by a rate-dependent isotropic plasticity model. Parametric studies are conducted to comprehend the effect of void size, shape and orientation on the overall material response.