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<p>Metal additive manufacturing, particularly metal fused filament fabrication (FFF), presents notable advantages, including cost-effectiveness and design flexibility, which make it an attractive choice for various applications. However, the presence of porosity in metal FFF parts introduces inconsistency to mechanical properties and poses significant complications &#xa0;to structural reliability, potentially impacting the performance of components. This study investigates the behavior of 17-4PH stainless steel produced through FFF, focusing on how porosity affects material behavior. Experimental analyses were performed to quantify the porosity&#xa0;of FFF, forming the basis of a modeling approach that directly incorporates porosity by element removal within the finite element model. Algorithms for element removal were established using pore size distributions derived from microscopic analysis and image processing data. Tensile test simulations on the porous models demonstrated that this method provides reasonable accuracy in predicting stress–strain behavior across both elastic and plastic regions, capturing key material responses. Furthermore, comparing the results of the proposed model with existing predictive models underscores its effectiveness in accurately modeling the behavior of porous FFF 17-4PH stainless steel.</p>

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Modeling the effect of microstructural porosity on the material behavior of fused filament fabricated 17-4PH stainless steel

  • 期刊论文

  • 发表日期：

    2025年3月31日

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  • Bita Porrang,
  • Surbhi Srivastava,
  • Ali Hosseini

摘要

Metal additive manufacturing, particularly metal fused filament fabrication (FFF), presents notable advantages, including cost-effectiveness and design flexibility, which make it an attractive choice for various applications. However, the presence of porosity in metal FFF parts introduces inconsistency to mechanical properties and poses significant complications  to structural reliability, potentially impacting the performance of components. This study investigates the behavior of 17-4PH stainless steel produced through FFF, focusing on how porosity affects material behavior. Experimental analyses were performed to quantify the porosity of FFF, forming the basis of a modeling approach that directly incorporates porosity by element removal within the finite element model. Algorithms for element removal were established using pore size distributions derived from microscopic analysis and image processing data. Tensile test simulations on the porous models demonstrated that this method provides reasonable accuracy in predicting stress–strain behavior across both elastic and plastic regions, capturing key material responses. Furthermore, comparing the results of the proposed model with existing predictive models underscores its effectiveness in accurately modeling the behavior of porous FFF 17-4PH stainless steel.