Thermomechanical Analysis of PBF-LB/M AlSi7Mg0.6 with Respect to Rate-Dependent Material Behaviour and Damage Effects

Abstract

This paper describes the self-heating effects resulting from mechanical deformation in the additively manufactured aluminium alloy AlSi7Mg0.6. The material’s self-heating effect results from irreversible changes in the material’s microstructure that are directly coupled with the inelastic deformations. These processes are highly dissipative, which is reflected in the heat generation of the material. To describe such effects, a numerical framework that combines an elasto-viscoplastic Chaboche model with the Gurson Tvergaard Needleman damage approach is analysed and thermomechanically extended. This paper characterises the sample preparation, the experimental set-up, the development of the thermomechanical approach, and the material model. A user material subroutine applies the complete material model for the finite element software Abaqus 2022. To validate the material model and the parameters, a complex tensile test is performed. In order to check the finite element model, the energy transformation ratio is included in the evaluation. The numerical analyses of the mechanical stress evolution and the self-heating behaviour demonstrate good agreement with the experimental test. In addition, the calculation shows the expected behaviour of the void volume fraction that rises from the initial value of 0.0373% to a higher value under a complex mechanical load.