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Abstract This article focuses specifically on material modeling applied to structure-property predictions. It provides general guidelines and considerations in terms of modeling the salient material features that ultimately impact the mechanical performance of parts produced by additive manufacturing (AM). Two of the primary ingredients needed to predict structure-property relationships via material modeling include a geometrical representation of the microstructural features of interest (e.g., grain structure and void defects) and a suitable constitutive model describing the material behavior, both of which can be scale and resource dependent. The article also presents modeling challenges to predict various aspects of (process-) structure-property relationships in AM. 

Abstract Fatigue short‐cracks in Mg alloys display complex growth behavior due to high plastic anisotropy and crack path dependence on local microstructural features. In this study, the three‐dimensional crystallography of short‐crack paths in Mg alloy WE43 was characterized by mapping near‐field high‐energy X‐ray diffraction microscopy (HEDM) reconstructed grain maps to high‐resolution X‐ray CT reconstructions of the fracture surfaces in the crack initiation and short‐crack growth regions of six ultrasonic fatigue specimens. Crack–grain–boundary intersections were analyzed at 81 locations across the six crack paths. The basal intragranular, non‐basal intragranular, or intergranular character of short‐crack growth following each boundary intersection was correlated to crystallographic and geometric parameters of the trailing and leading grains, three‐dimensional grain boundary plane, and advancing crack front. The results indicate that crack paths are dependent on the combined crystallographic and geometric character of the local microstructure, and crack path prediction can be improved by use of dimensionality reduction on subsets of high‐linear‐correlation microstructural parameters.