Microscale Structure to Property Prediction for Additively Manufactured IN625 through Advanced Material Model Parameter Identification

Challenge 4 of the Air Force Research Laboratory additive manufacturing modeling challenge series asks the participants to predict the grain-average elastic strain tensors of a few specific challenge grains during tensile loading, based on experimental data and extensive characterization of an IN625 test specimen. In this article, we present our strategy and computational methods for tackling this problem. During the competition stage, a characterized microstructural image from the experiment was directly used to predict the mechanical responses of certain challenge grains with a genetic algorithm-based material model identification method. Later, in the post-competition stage, a proper generalized decomposition (PGD)-based reduced order method is introduced for improved material model calibration. This data-driven reduced order method is efficient and can be used to identify complex material model parameters in the broad field of mechanics and materials science. The results in terms of absolute error have been reported for the original prediction and re-calibrated material model. The predictions show that the overall method is capable of handling large-scale computational problems for local response identification. The re-calibrated results and speed-up show promise for using PGD for material model calibration.