TunaBaykasoğlu, CengizAkyıldız, ÖncüC.To, Albert2024-01-242024-01-242023Tunay, M., Baykasoğlu, C., Akyildiz, O., & C. To, A. (2023). A fully coupled thermal–microstructural–mechanical finite element process model for directed energy deposition additive manufacturing of Ti–6Al–4V. Science and Technology of Welding and Joining, 28(2), 118-127.1362-1718https://doi.org/10.1080/13621718.2022.2127211https://hdl.handle.net/11491/8729A fully coupled thermal–microstructural–mechanical finite element modelling framework is developed to investigate the distortion and residual stresses during directed energy deposition (DED) of multi-phase Ti–6Al–4V alloy. The Johnson–Cook constitutive model is used to predict the yield strength of each phase as a function of strain, strain rate and temperature where the flow stress is calculated by a linear mixing rule based on the volumetric phase fractions. A thin-walled rectangular sample is chosen as the reference geometry and the results are compared with experimentally measured in situ thermal history and distortion data, where a reasonable agreement is achieved. The proposed modelling framework with physics-based material constitutive model provides useful information for a better understanding of process–microstructure–property relations in additive manufacturing by DED.eninfo:eu-repo/semantics/closedAccessDirected energy depositionThermal–microstructural–mechanical simulationFiniteelement methodSolid-statephase transformationResidual stressDistortionArticle28211812710.1080/13621718.2022.2127211Q3WOS:000860576200001Q1