Crystal plasticity approach for predicting mechanical responses in wire-arc directed energy deposition of NbZr1 refractory alloy

Abstract

The refractory alloy, such as Niobium-1 wt% Zirconium (NbZr1) alloy, is a promising candidate for diverse applications in extreme environments. This study investigates an integrated experimental and computational methodology that can predict the mechanical properties of wire-arc directed energy deposited (DED) refractory NbZr1 alloy. The effect of large columnar grains with strong texture induced by the wire-DED process has been successfully incorporated into the representative volume element (RVE). Performing crystal plasticity (CP) simulation on RVE of NbZr1, deformation behavior and stress-strain relationship are predicted to explore the process-structure-property (PSP) relationship. The RVE has been created in synthetic microstructure generation software utilizing the grain statistics derived from electron backscatter diffraction (EBSD) analysis, capturing essential microstructural features. A phenomenological constitutive model and appropriate boundary conditions have been applied and solved, using the CP fast Fourier transform method. The CP model has been calibrated and validated utilizing the tensile test data along the build direction and deposition direction, respectively. The error in predicting yield strength and ultimate tensile strength is 0.91% and 0.67%, respectively, for the calibration simulation, whereas these values are 2.51% and 1.81% for the validation simulation. The results suggest strong agreement between the simulation and experimental observation. Even though global deformation behavior remains consistent across multiple RVEs with the same microstructural features, local stress-strain values vary, indicating structural anisotropy, which is also consistent with the digital image correlation (DIC) result. It is proven that this proposed CP method can effectively predict the mechanical responses of components with large grains and strong textures resulting from the wire-arc DED.