Elucidating microstructural influences on fatigue behavior for additively manufactured Hastelloy X using Bayesian-calibrated crystal plasticity model

Crystal plasticity (CP) modeling is a vital tool for predicting the mechanical behavior of materials, but its calibration involves numerous (>8) constitutive parameters, often requiring time-consuming trial-and-error methods. This paper proposes a robust calibration approach using Bayesian optimization (BO) to identify optimal CP model parameters under fatigue loading conditions. Utilizing cyclic data from additively manufactured Hastelloy X specimens at 500 degree-F, the BO framework, integrated with a Gaussian process surrogate model, significantly reduces the number of required simulations. A novel objective function is developed to match experimental stress-strain data across different strain amplitudes. Results demonstrate that effective CP model calibration is achieved within 75 iterations, with as few as 50 initial simulations. Sensitivity analysis reveals the influence of CP parameters at various loading points on the stress-strain curve. The results show that the stress-strain response is predominantly controlled by parameters related to yield, with increased influence from backstress parameters during compressive loading. In addition, the effect of introducing twins into the synthetic microstructure on fatigue behavior is studied, and a relationship between microstructural features and the fatigue indicator parameter is established. Results show that larger diameter grains, which exhibit a higher Schmid factor and an average misorientation of approximately 42 degrees +/- 1.67 degree, are identified as probable sites for failure. The proposed optimization framework can be applied to any material system or CP model, streamlining the calibration process and improving the predictive accuracy of such models.