Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model

This paper investigates the influence of initial porosity and its evolution on the mechanical behavior of metallic materials manufactured by additive manufacturing (AM), using the Gurson model to predict the initiation and propagation of damage in specimens produced via Laser Powder Bed Fusion (LPBF). The methodology combines experimental uniaxial tensile tests, numerical simulations based on the Gurson model, and the parametric identification method (PIP) to calibrate constitutive parameters (σy0, σ∞, δ, ξ). The specimens, made of AlSi10Mg with different printing directions (horizontal and vertical) and porosity levels, were evaluated to determine the relationship between density, anisotropy, and mechanical properties. The experimental results revealed that vertical printing accelerates fracture due to the concentration of stresses at the interfaces between layers, while the numerical simulations, compared with the von Mises model, showed greater accuracy of the Gurson model in predicting damage in porous materials. The analysis of porosity evolution highlighted the impact of void size and spacing on coalescence and ductility. The proposed methodology was validated, establishing a useful approach for evaluating the mechanical behavior of materials manufactured by AM. This work contributes to the advancement of the design of lightweight and resistant components, with applications in sectors such as aerospace and automotive, and suggests directions for future studies, including the investigation of other alloys and dynamic loading conditions.