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Carrasco-Garrido, CristinaAuthor

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March 11, 2025
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Article

A Frugal Approach Toward Modeling of Defects in Metal 3D Printing Through Statistical Methods in Finite Element Analysis

Publicated to: COMPUTATION. 13 (2): 35- - 2025-02-01 13(2), DOI: 10.3390/computation13020035

Authors:

Raya, AM; Braun, M; Carrasco-Garrido, C; González-Albuixech, VF
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Affiliations

Univ Nebrija UAN, Univ Nebrija, Res Grp GREEN, Madrid 28015, Spain - Author
Univ Politecn Madrid UPM, Tech Univ Madrid, Dept Fluid Mech & Aerosp Prop, Madrid 28040, Spain - Author
Univ Politecn Madrid UPM, Tech Univ Madrid, Dept Org Engn Business Adm & Stat, Madrid 28040, Spain - Author
Univ Politecn Madrid UPM, Tech Univ Madrid, Dept Phys Appl Aeronaut & Naval Engn, Madrid 28040, Spain - Author
Univ Rey Juan Carlos URJC, Rey Juan Carlos Univ, Dept Business Adm, Madrid 28032, Spain - Author
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Abstract

Metal additive manufacturing has emerged as a revolutionary technology for the fabrication of high-complexity components. However, this technique presents unique challenges related to the structural integrity and final strength of the parts produced due to inherent defects, such as porosity, cracks, and geometric deviations. These defects significantly impact the fatigue life of the material by acting as stress concentrators that accelerate failure under cyclic loading. On the one hand, this type of model is very complicated in its approach, since, even with encouraging results, the complexity of the calculation with these variables makes it difficult to obtain a simple result that allows for a generalized interpretation. On the other hand, using more familiar methods, it is possible to qualitatively guess the behavior that helps obtain results with better applicability, even at limited levels of precision. This paper presents a simplified finite element method combined with a statistical approach to model the presence of porosity in metal components produced by additive manufacturing. The proposed model considers a two-dimensional square plate subjected to tensile stress, with randomly introduced defects characterized by size, shape, and orientation. The percentage of porosity that affects each aspect determines the adjustment of the mechanical properties of finite elements. A series of simulations were performed to generate multiple models with random defect distributions to estimate maximum stress values. This approach demonstrates that complex models are not always necessary for a preliminary practical estimate of the effects of new manufacturing techniques. Furthermore, it demonstrates the potential for the extension of frugal computational techniques, which aim to minimize computational and experimental costs in the engineering field. The article discusses future research directions, particularly those related to potential business applications, including commercial uses. This follows a discussion of the existing limitations of this study.
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Keywords

Additive manufacturingDefectsElectroFatigueFatigue lifeFinite element methodsFrugal computational techniqueFrugal computational techniquesHeterogeneityManufactured ti-6al-4vMicrostructurePorosity

Quality index

Bibliometric impact. Analysis of the contribution and dissemination channel

The work has been published in the journal COMPUTATION due to its progression and the good impact it has achieved in recent years, according to the agency WoS (JCR), it has become a reference in its field. In the year of publication of the work, 2025, it was in position 52/136, thus managing to position itself as a Q2 (Segundo Cuartil), in the category Mathematics, Interdisciplinary Applications. Notably, the journal is positioned en el Cuartil Q2 para la agencia Scopus (SJR) en la categoría Computer Science (Miscellaneous).

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Impact and social visibility

From the perspective of influence or social adoption, and based on metrics associated with mentions and interactions provided by agencies specializing in calculating the so-called "Alternative or Social Metrics," we can highlight as of 2026-04-05:

  • The use, from an academic perspective evidenced by the Altmetric agency indicator referring to aggregations made by the personal bibliographic manager Mendeley, gives us a total of: 12.
  • The use of this contribution in bookmarks, code forks, additions to favorite lists for recurrent reading, as well as general views, indicates that someone is using the publication as a basis for their current work. This may be a notable indicator of future more formal and academic citations. This claim is supported by the result of the "Capture" indicator, which yields a total of: 11 (PlumX).

With a more dissemination-oriented intent and targeting more general audiences, we can observe other more global scores such as:

  • The Total Score from Altmetric: 1.
  • The number of mentions on the social network X (formerly Twitter): 1 (Altmetric).

It is essential to present evidence supporting full alignment with institutional principles and guidelines on Open Science and the Conservation and Dissemination of Intellectual Heritage. A clear example of this is:

  • The work has been submitted to a journal whose editorial policy allows open Open Access publication.
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Awards linked to the item

The authors are grateful for the support of the Regional Government of Madrid and the Ministry of Science, Innovation, and Universities of the Kingdom of Spain, as well as the funding provided by the European Union (EU) to M.B. from NextGenerationEU (PRTR-C17.I1).
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