Title: Microstructure-Sensitive ICME Workflows for Fatigue Critical Applications
Authors: Krzysztof S. Stopka, Gary Whelan, and David L. McDowell
Abstract: Fatigue cracks form and grow in fatigue critical structural alloys that are relevant to Naval aviation applications from nucleant grains, phases, or constituent particles in the high cycle fatigue (HCF) regime. To enable progress in configuring Integrated Computational Materials Engineering (ICME) towards addressing improved fleet performance, we present a multilevel scripted ICME workflow that employs microstructure-sensitive simulations. An inductive design exploration framework considers various sources of uncertainty to inform robust decisions regarding materials development necessary to achieve desired performance of fatigue critical components, given accessible process paths and resulting microstructures. Uncertainty propagation through model chains (whether models are surrogates, empirical, or based on simulation) is considered. Digital statistical volume element representations of microstructure are employed, with structure-property relations based on microstructure-sensitive computational fatigue modeling using the crystal plasticity finite element method, addressing sensitivity to microstructure resulting from process path including both intrinsic (grain/phase size, shape and orientation distributions) and extrinsic (residual stresses, surface roughness, nonmetallic inclusions or pores) features. The digital workflow considers extreme value (minimum property) fatigue response as the primary performance requirement. The framework is exercised to explore available microstructures for α-β Ti-6Al-4V. The work has potential to impact development of new and improved fatigue critical material systems relevant to naval applications.
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