Predicting Failure of Ti-6Al-4V Specimens Fabricated by Electron Beam Powder Bed Fusion Technique Using Johnson-Cook Model

Predicting Failure of Ti-6Al-4V Specimens Fabricated by Electron Beam Powder Bed Fusion Technique Using Johnson-Cook Model | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Predicting Failure of Ti-6Al-4V Specimens Fabricated by Electron Beam Powder Bed Fusion Technique Using Johnson-Cook Model Bahman Paygozar This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9540886/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This work focuses on accurately predicting the fracture response of rectangular Ti-6Al-4V dog-bone specimens manufactured via electron beam powder bed fusion (EB-PBF). Uniaxial tensile experiments were carried out alongside corresponding numerical simulations. The results from standard tensile tests were first utilized to determine the material’s elastic–plastic properties. Subsequently, the experimentally obtained load-displacement curves were employed to calibrate the parameters used in failure simulations using the Johnson-Cook (J-C) material and damage models, by systematically matching numerical predictions with experimental observations. This calibration procedure ensured an accurate representation of both damage initiation and its subsequent evolution. Key metrics, including stiffness and yield load derived from the tensile tests, were compared with numerical results. The deviation between simulations and experiments remained within an acceptable margin, not exceeding 5% for the dog-bone specimens. Overall, these results underscore the effectiveness of the J-C model as a robust and reliable approach for predicting failure in EB-PBF fabricated Ti-6Al-4V components subjected to tensile loading. Electron beam powder bed fusion dog-bone specimen Johnson-Cook damage model calibration Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9540886","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":630276315,"identity":"6ed48ef2-cc27-4972-8889-81c83e81bb4d","order_by":0,"name":"Bahman Paygozar","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA4klEQVRIiWNgGAWjYBACAziLvQFMMTYQr4XnAFg1kGAmVotEApFazKWbn0l+qaiTN5/5+PhjHgYb2Q0H+I99wKfFcs4xM2mZM2yGc26nJTbzMKQZbzjAzDwDr8NuJJhJS7bxMM6QzjEEajmcCNKC3y830r8BtUjYz5A8/xGo5T8xWnLMJD+2GSTOkOBhBGo5QFiL5ZwzxdYMZxKSZ/CkGc6cY5BsPPMwszFeLebS7Rtv/qios53BfvjBhzcVdrJ9xxsf49XCIMHAIs2DcCcQE4gWkBbmjz8IKRoFo2AUjIKRDQAD3kdqxPbQsgAAAABJRU5ErkJggg==","orcid":"","institution":"TOBB University of Economics and Technology","correspondingAuthor":true,"prefix":"","firstName":"Bahman","middleName":"","lastName":"Paygozar","suffix":""}],"badges":[],"createdAt":"2026-04-27 11:23:22","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9540886/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9540886/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":107973006,"identity":"fa71ca0b-2714-40ce-82a8-22a48a16f618","added_by":"auto","created_at":"2026-04-28 07:10:17","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":651799,"visible":true,"origin":"","legend":"","description":"","filename":"1.AnonymisedManuEBPBFJCModel.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9540886/v1_covered_69a78eac-f8d2-4713-9737-a3d069379fe6.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Predicting Failure of Ti-6Al-4V Specimens Fabricated by Electron Beam Powder Bed Fusion Technique Using Johnson-Cook Model","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Electron beam powder bed fusion, dog-bone specimen, Johnson-Cook damage model, calibration","lastPublishedDoi":"10.21203/rs.3.rs-9540886/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9540886/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"This work focuses on accurately predicting the fracture response of rectangular Ti-6Al-4V dog-bone specimens manufactured via electron beam powder bed fusion (EB-PBF). Uniaxial tensile experiments were carried out alongside corresponding numerical simulations. The results from standard tensile tests were first utilized to determine the material’s elastic–plastic properties. Subsequently, the experimentally obtained load-displacement curves were employed to calibrate the parameters used in failure simulations using the Johnson-Cook (J-C) material and damage models, by systematically matching numerical predictions with experimental observations. This calibration procedure ensured an accurate representation of both damage initiation and its subsequent evolution. Key metrics, including stiffness and yield load derived from the tensile tests, were compared with numerical results. The deviation between simulations and experiments remained within an acceptable margin, not exceeding 5% for the dog-bone specimens. 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