Abstract
A novel dislocation density based crystal plasticity finite element model (DDCP-FEM) framework has been extended to predict subgrain formation during ultrasonic additive manufacturing of Al 3003 H-18 tempered foils. The present study identifies various microstructural transitions such as recrystallization and dislocation density evolutions that occur during the processing of these foils as a function of input processing parameters such as normal force, ultrasonic oscillation amplitude, and initial microstructure. Furthermore, changes in average grain sizes in the Al 3003 H-18 foils have been calculated before and after processing from both microstructures and the simulation study. The simulation predictions were in good agreement with experimental results. This provides evidence that DDCP-FEM can be used as a tool for optimizing input processing parameters so that minimal grain fragmentation occurs during processing leading to better mechanical properties for 3 dimensional components made using ultrasonic additive manufacturing.
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