Understanding the high-temperature behavior of alloys designed for additive manufacturing

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The proposed project aims to determine the quasi-static and dynamic mechanical behavior of new commercial iron-based alloys, M789 and Corrax stainless steels, designed for additive manufacturing (AM) using a Gleeble 563 thermomechanical simulator and a customized high-temperature Split-Hopkinson Pressure Bar (SHPB) machine. The additively manufactured steel samples, known to possess an excellent combination of tensile strength and corrosion resistance, will be supplied by voestalpine Additive Manufacturing Center (vAMC). After extensive high-temperature experiments, a custom-built data analysis application (Simu-Mat 1.0) will be employed to determine the recommended empirical, semi-empirical, and machine learning constitutive models. Once the suitable models have been defined (focusing on empirical and semi-empirical), these will be incorporated in finite element analysis using ANSYS or ABAQUS to accurately simulate M789 and Corrax stainless steels' mechanical response at various temperatures and strain rates. Microstructural analysis will also be conducted to establish the processing-microstructure-property-performance relationships in these new commercial alloys. The combined experimental and simulation work from this project will help prevent material issues associated with in-service AM components, identify additional industry applications, and make the component certification process more achievable. This work's output will assist the research and development activities of vAMC in alloy development for continuous sustainability. Three students will be trained in AM technology, quasi-static and dynamic mechanical testing, microstructural analysis, and numerical modeling to address the shortage of highly skilled talent in the metal additive manufacturing community.