Geometrical and crystal plasticity modelling: Towards the establishment of a process-structure-property relationship for additively manufactured 316L struts

This paper presents a methodology to establish a process structure property (PSP) relationship for the additive manufacturing (AM) of thin AISI 316L struts, as might be used in coronary stent applications. The methodology is based on a new geometrically based process-structure method for AM process variables, and crystal plasticity finite element (CPFE) modelling that includes the representation of melt pool microstructure morphology and texture. The effects of AM process variables are characterised with respect to ductility, yield strength and UTS across a range of process variables, including hatch spacing, layer thickness and build orientation (two orientations are considered: horizontal and vertical). The CPFE-predicted effect of build orientation is shown to be consistent with experimental test results. The present methodology has allowed identification of optimal hatch spacing and layer thickness for a given laser spot size, power and scanning speed. CPFE modelling of AM melt pool texture is shown to be key to successful prediction of the effects of process variables on mechanical behaviour.