A Multi-Scale Modeling, Simulation and Design Framework for Improving Performance and Life of Additively Manufactured Components
Abstract
Additive manufacturing (AM) processes for metallic materials, viz. powder-bed fusion, powder-feed andwire-feed systems, is bringing dramatic changes to the manufacturing industry. The unprecedented agilityachieved through layer-by-layer material addition is enabling near net-shape production of complexcomponents that are conceived by advanced design methods like topology optimization. Despite promiseand progress, their qualification and acceptance have been thwarted by the lack of consistency in materialbehavior and life-limiting properties e.g. ductility and fatigue, of parts produced by nominally identical AMprocesses. These inconsistencies are often attributed to subtle, yet characteristic variations in themicrostructural morphology like grain size, crystallographic texture and defect (e.g. porosity) structure,possibly a consequence of small perturbations in AM process parameters. This research is aimed ataddressing this shortcoming. By implementing a multi-pronged approach, integrating innovative methodsof integrated computational materials engineering (ICME), physics-based multi-scale modeling, multiobjectivedesign, materials characterization and testing, it will develop a robust pathway for locationspecific material design in structures fabricated by AM processes. This will provide guidance on processparameters and routes for improving product performance and life. Collaborative partnerships will bepursued with JHU/Applied Physics Laboratory, NAVAIR and Sandia National Laboratories (at no cost tothe project) for guidance and for data-sets needed to calibrate and validate the computational models andcodes. Extensive capabilities on AM fabrication, material characterization and testing exist at thecollaborator sites.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 31, 2020
- Source ID
- N000142014004
Entities
People
- Somanth Ghosh
Organizations
- Johns Hopkins University
- Office of Naval Research
- United States Navy