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Applied Sciences
Volume 15
Issue 18
10.3390/app151810004
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model

by
Vinícius dos Santos Gonçalves
1,
Omid Emadinia
2,
Francisco Matos
2,
Déborah De Oliveira
1,
José Alexander Araújo
1 and
Lucival Malcher
1,2,*
1
Department of Mechanical Engineering, Faculty of Technology, University of Brasília, Brasília 70910-900, DF, Brazil
2
INEGI, Institute of Science and Innovation in Mechanical Engineering, University of Porto, 4200-465 Porto, Portugal
*
Author to whom correspondence should be addressed.
Appl. Sci. 2025, 15(18), 10004; https://doi.org/10.3390/app151810004
Submission received: 24 July 2025 / Revised: 21 August 2025 / Accepted: 27 August 2025 / Published: 12 September 2025
(This article belongs to the Special Issue Advances in Solid Mechanics and Its Applications)
Versions Notes

Abstract

This paper investigates the influence of initial porosity and its evolution on the mechanical behavior of metallic materials manufactured by additive manufacturing (AM), using the Gurson model to predict the initiation and propagation of damage in specimens produced via Laser Powder Bed Fusion (LPBF). The methodology combines experimental uniaxial tensile tests, numerical simulations based on the Gurson model, and the parametric identification method (PIP) to calibrate constitutive parameters (σy0, σ∞, δ, ξ). The specimens, made of AlSi10Mg with different printing directions (horizontal and vertical) and porosity levels, were evaluated to determine the relationship between density, anisotropy, and mechanical properties. The experimental results revealed that vertical printing accelerates fracture due to the concentration of stresses at the interfaces between layers, while the numerical simulations, compared with the von Mises model, showed greater accuracy of the Gurson model in predicting damage in porous materials. The analysis of porosity evolution highlighted the impact of void size and spacing on coalescence and ductility. The proposed methodology was validated, establishing a useful approach for evaluating the mechanical behavior of materials manufactured by AM. This work contributes to the advancement of the design of lightweight and resistant components, with applications in sectors such as aerospace and automotive, and suggests directions for future studies, including the investigation of other alloys and dynamic loading conditions.
Keywords: additive manufacturing; Gurson model; porosity; mechanical behavior additive manufacturing; Gurson model; porosity; mechanical behavior

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MDPI and ACS Style

Gonçalves, V.d.S.; Emadinia, O.; Matos, F.; De Oliveira, D.; Araújo, J.A.; Malcher, L. Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model. Appl. Sci. 2025, 15, 10004. https://doi.org/10.3390/app151810004

AMA Style

Gonçalves VdS, Emadinia O, Matos F, De Oliveira D, Araújo JA, Malcher L. Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model. Applied Sciences. 2025; 15(18):10004. https://doi.org/10.3390/app151810004

Chicago/Turabian Style

Gonçalves, Vinícius dos Santos, Omid Emadinia, Francisco Matos, Déborah De Oliveira, José Alexander Araújo, and Lucival Malcher. 2025. "Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model" Applied Sciences 15, no. 18: 10004. https://doi.org/10.3390/app151810004

APA Style

Gonçalves, V. d. S., Emadinia, O., Matos, F., De Oliveira, D., Araújo, J. A., & Malcher, L. (2025). Influence of Additive Manufacturing Printing Parameters via LPBF on the Mechanical Strength of Metallic Materials: Numerical Analysis by Gurson-Based Model. Applied Sciences, 15(18), 10004. https://doi.org/10.3390/app151810004

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