CT-Based FEM: Assessment of the Influence of Porosity on the Mechanical Behavior and Failure of AM Components

Abstract This work aims to present a digital-twin for prediction of the mechanical behavior and failure of additive manufacturing components, considering the characteristics of heterogeneities, mainly porosities, which appear during the manufacturing process. Therefore, the proposed methodology is based on the development of a CT-based FEM model, as well as the study of different porosity features by CT analysis and FEM modelling. Their influence on predictions is also evaluated. To this end, tensile test specimens were manufactured by means of L-PBF, according to ASTM E8/E8M. Afterwards, the analysis and digitalization of each specimen were carried out using CT, followed by FEM modelling of each one. Finally, the results obtained by the analysis were correlated with experimental tensile tests. Taking advantage of the virtual model proposed, virtual cases and hypothesis were also analyzed. Hence, the promising future of the proposed methodology is highlighted.