Review on Computational Modeling of Process–Microstructure–Property Relationships in Metal Additive Manufacturing

Metal additive manufacturing (AM) is an emerging technology with great potential for the fabrication of components with highly complex shapes at low cost. Its broad implementation, especially in safety-critical structural and high temperature applications, relies on the ability to produce AM parts with suitable and consistent mechanical properties. Current research indicates that computational modeling of the complex physical phenomena involved in AM can lead to shorter production times and less expensive material/component manufacturing, while simultaneously improving the residual stress distribution, distortion, microstructure, and porosity. These structural characteristics influence the mechanical properties of AM components, and the relationships between them must be identified to meet design specifications. This review organizes current research efforts described in literature and provides a systematic summary of available modeling techniques related to the simulation/prediction of process–microstructure–property relationships for AM-fabricated materials.