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A Residual Stress-Based Model for Viscoplastic Self-Consistent Simulation of Cold-Sprayed Al6061

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Abstract

Cold spray additively manufactured (CSAM) aluminum 6061 components are characterized by heterogeneous compressive residual stresses induced during manufacturing. This heterogeneity is further compounded by spatial variations in microstructures and mechanical properties, leading to poor inter-particle (intersplat) bonding and significant marring of overall component performance. Thermal post-processing is a keenly researched method for recovering mechanical toughness by enhancing intersplat bonding and altering highly concentrated residual stress distributions. The current work incorporates a modified microscale–mesoscale material model into a viscoplastic self-consistent simulation framework to capture material response in the as-sprayed and post-processed states. The updated model incorporates physically informed parameters emphasizing residual stresses measured experimentally through X-ray diffraction. The model calibrated using experimental tests and published literature was able to predict the stress–strain response of CSAM parts at post-heat-treated conditions. Results of the parametric study showed the significance of intersplat boundary effects on the overall yield and strain hardening of the CSAM parts. Without any information on the processing conditions of CSAM parts, the modified plasticity model predicted the deformation response using information gathered from microstructure characterization.

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Acknowledgments

The authors gratefully acknowledge support from The Office of the Secretary of Defense (OSD), DEVCOM—Army Research Laboratory and LIFT through the “K005-01 PROJECT# 21025” grant, entitled, “Research Utilizing the Chemistry–Process–Structure–Property–Performance (CPSPP) Paradigm”.

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Authors and Affiliations

  1. Center for Advanced Vehicular Systems, Mississippi State University, Starkville, USA

    YubRaj Paudel, Aulora Williams, Shiraz Mujahid, Hongjoo Rhee & Haitham El Kadiri

  2. Department of Mechanical Engineering, Mississippi State University, Starkville, USA

    Aulora Williams, Hongjoo Rhee & Haitham El Kadiri

  3. DEVCOM-Army Research Laboratory, Adelphi, USA

    Marc Pepi

  4. American Lightweight Materials Manufacturing Innovation Institute (ALMMII), Detroit, USA

    Peter Czech

  5. Rabat-Shore Rocade Rabat-Salé, Université Internationale de Rabat, Rabat, Morocco

    Haitham El Kadiri

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  1. YubRaj Paudel
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Correspondence to Aulora Williams.

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This invited article is part of a special topical issue of the Journal of Materials Engineering and Performance on Residual Stress Analysis: Measurement, Effects, and Control. The issue was organized by Rajan Bhambroo, Tenneco, Inc.; Lesley Frame, University of Connecticut; Andrew Payzant, Oak Ridge National Laboratory; and James Pineault, Proto Manufacturing on behalf of the ASM Residual Stress Technical Committee.

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Paudel, Y., Williams, A., Mujahid, S. et al. A Residual Stress-Based Model for Viscoplastic Self-Consistent Simulation of Cold-Sprayed Al6061. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09572-7

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  • DOI: https://doi.org/10.1007/s11665-024-09572-7

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