Finite Element 3D Mesh Generation From Experimental Microstructures

Simulation and predictions of material processes at multi-length scales require a detailed understanding of microstructures. While a meaningful study requires large data sets, the size of data sets has been limited due to the lack of automated image processing and mesh generation algorithms. We obtained as images a relatively large population of data from 19 samples of Aluminum foils by Electron Backscattered Diffraction (EBSD) technique. The experimentally obtained data were analyzed in detail and compared with existing theoretical distribution models. We describe a novel set of algorithms that extract boundary information from these images and provide a complete boundary description to the mesh generation step. The mesh generation step in turn produces a 3D mesh as input for the finite element code and maintains mesh quality as the simulation proceeds. We show that proper microstructural characterization of materials and prediction of evolution requires a careful implementation of several key steps including image processing and mesh generation algorithms.