Understanding the effect of microstructure on the failure behavior of additively manufactured Al2O3 ceramics: 3D micromechanical modeling

Abstract

Additively manufactured (AM) ceramics are gaining popularity due to improved flexibility in the design of customized structures. Microstructure-based finite element (FE) models were developed to study the strain-rate-dependent failure behavior of AM Al2O3 ceramics under uniaxial compression. Upon validation with experimental data, the model was leveraged to quantify the history of intergranular and transgranular failure mechanisms across microstructures. It was revealed that the intergranular mechanism plays a key role in the material strength across strain rates. Crystallographic orientations were found to remarkably decrease the material strength due to the earlier initiation and faster growth of the intergranular mechanism. The increase in porosity was found to amplify the transgranular mechanism resulting from a higher number of pores acting as crack nucleation sites, decreasing the material strength regardless of strain rate. The model reflected the existence of a threshold for grain boundary strength, beyond which further enhancements yield marginal improvements in material strength. Additionally, the effect of grain size on the initiation and evolution of failure mechanisms was studied and the corresponding limitations of the model were discussed. The current work correlates the microstructure of the material to its macroscale response through micromechanical models, informing the design of better-performing AM Al2O3 ceramics.

Keywords

• Additive manufacturing (AM)
• Alumina (Al2O3) ceramic
• Failure mechanisms
• Micromechanical modeling
• Representative volume element (RVE)