Abstract: Additively manufactured (AM) metals exhibit highly complex microstructures, particularly in terms of grain morphology which typically features heterogeneous grain size distribution, irregular and anisotropic grain shapes, and the so-called columnar grains. The conventional morphological descriptors based on grain shape idealization are generally inadequate for representing complex and anisotropic grain morphology of AM microstructures. The primary aspect of microstructural grain morphology is the state of grain boundary spacing or grain size whose effect on the mechanical response is known to be crucial. In this paper, we formally introduce the notion of axial grain size from which we derive mean axial grain size, effective grain size, and grain size anisotropy as robust morphological descriptors capable of effectively representing highly complex grain morphologies. We instantiated a discrete sample of polycrystalline aggregate as a representative volume element (RVE) featuring random crystallographic orientation and misorientation distributions. However, the instantiated RVE incorporates the typical morphological features of AM microstructures including distinctive grain size heterogeneity and anisotropic grain size owing to its pronounced columnar grain morphology. We ensured that any anisotropy observed in the macroscopic mechanical response of the instantiated sample primarily originates from its underlying anisotropic grain size. The RVE was then employed for mesoscale full-field crystal plasticity simulations corresponding to uniaxial tensile deformation along various axes via a spectral solver and a physics-based crystal plasticity constitutive model which was developed, calibrated, and validated in earlier studies. Through the numerical analyses, we isolated the contribution of anisotropic grain size to the anisotropy in the mechanical response of polycrystalline aggregates, particularly those with the characteristic complex grain morphology of AM metals. This contribution can be described by an inverse square relation.

Key words: Axial grain size, Grain size anisotropy, Strain hardening anisotropy, Grain morphology, Morphological texture, Columnar grains, Additive manufacturing