Additive Manufacturing: Materials Design and Alloy Development II: Fundamentals of Alloy Design
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Integrated Computational Materials Engineering Committee
Program Organizers: Behrang Poorganji, Morf3d; James Saal, Citrine Informatics; Orlando Rios, University of Tennessee; Hunter Martin, HRL Laboratories LLC; Atieh Moridi, Cornell University
Monday 8:00 AM
February 24, 2020
Room: 6F
Location: San Diego Convention Ctr
Session Chair: Behrang Poorganji, Morf3d
8:00 AM Introductory Comments Behrang Poorganji
8:05 AM Keynote
Additive Manufacturing and Architected Materials: New Process Developments and Materials: Christopher Spadaccini1; 1Lawrence Livermore National Laboratory
We are combining advanced design methods such as topology optimization, with advanced additive micro- and nanomanufacturing techniques to create new material systems with previously unachievable property combinations – mechanical metamaterials. The performance of these materials is fundamentally controlled by geometry at multiple length-scales rather than chemical composition alone. We have demonstrated designer properties of these mechanical metamaterials in polymers, metals, ceramics and combinations thereof. Properties include ultra-stiff lightweight materials, negative stiffness, and negative thermal expansion to name a few, as well as functional properties such electrical, optical, acoustic, and chemical responses. We have primarily utilized our custom developed additive manufacturing techniques to create these structures and materials. These include projection microstereolithography (PuSL), direct ink writing (DIW), electrophoretic deposition (EPD), volumetric AM (VAM) via tomographic reconstruction (VAM), parallel two-photon polymerization, and diode-based additive manufacturing (DiAM) of metals. We will also review design and synthesis of the feedstock materials themselves.
8:35 AM Keynote
Accelerated Development of Functional Materials via Additive Manufacturing: Ryan Ott1; Fanqiang Meng1; Emrah Simsek1; Ikenna Nlededim1; Matthew Kramer1; 1Ames Laboratory/Cmi
Functional materials (e.g., permanent magnets, magnetocalorics, elastocalorics, etc.) are increasingly important in numerous technologies including clean energy. Developing new functional materials, however, requires minimizing critical materials usage and maximizing compatibility with advanced processing methods. Additive Manufacturing (AM) offers the potential to both accelerate alloy development as well as integrate the materials into complex geometries and architectures. Here we discuss using directed energy deposition AM to synthesize different functional materials. This includes accelerated alloy development for rapidly identifying optimal compositions for bulk processing to the actual AM synthesis of components with tailored structure and properties. The opportunities and challenges associated with AM synthesis of functional materials are discussed.
9:05 AM
Development of Non-equilibrium Thermodynamic Tools for Additive Manufacturing: Kaisheng Wu1; Deepankar Pal2; Adam Hope1; Paul Mason1; 1Thermo-Calc Software Inc; 2ANSYS Inc.
The complicated and highly non-equilibrium conditions of additive manufacturing pose a grand challenge to existing computational thermodynamic and kinetic tools that have had great values for traditional solidification and heat treatment processes. Meanwhile, increasingly sophisticated numerical algorithms in microstructural and mechanical simulations for AM applications require a variety of materials data that are not only reasonably accurate, but also deliberately processed and organized. In the present work, a cooling rate dependent solute drag model for multi-component systems has been developed to account for the non-equilibrium solute partitioning during the rapid cooling AM process. It has also been embedded in Scheil model for micro-segregation behavior. Work has also been done to provide well-curated materials data, e.g., heat capacity, density, etc. for facilitating subsequent mechanical analyses. These functionalities have been integrated into ANSYS additive manufacturing software to perform processing simulations. Preliminary results of some alloys have been shown to demonstrate their capabilities.
9:25 AM
Alloy Development For Additive Manufacturing For High Volume Automotive Applications: Anil Sachdev1; Tyson Brown1; 1General Motors Global Research & Development
While metal additive manufacturing is presenting itself as a disruptive technology, displacing the well-optimized manufacturing processes of the automotive sector will require several innovations to address the key showstoppers. One of these is materials, which need to be designed for additive manufacturing to exploit the fast heating and cooling rates afforded by the process. However, phase diagrams and associated thermodynamic databases routinely used for traditional processes do not generally extend to, for example, laser printing, where the volume of material being melted and solidified is several orders of magnitude lower than castings.This talk will address alloy development opportunities with specific focus on low-cost powder (and chemistries) for high tonnage of material used, the need for high integrity components, among others. The need for advanced simulation tools which incorporate the nuances of the process and standards which can harmonize multiple material and equipment suppliers will be emphasized.
9:45 AM Break
10:00 AM Keynote
An Overview of Metal Alloy Development Needs and Activities at NASA JPL: Douglas Hofmann1; 1NASA JPL/Caltech
NASA has an interest in sending robotic spacecraft to a number of hostile planetary surfaces, including Mars, Venus, Earth’s moon, Europa, Enceladus, Titan, comets and asteroids. Each mission requires materials specifically suited for robotic operations in those conditions. Towards this end, NASA JPL has been developing various additive manufacturing technologies and new alloys to enable future robotic space exploration. This talk will give an overview of some of those activities and potential future directions.
10:30 AM Invited
Thinking Beyond the Prototypical ICME Approach: Alloy Design for Additive Manufacturing: Peter Collins1; Richard LeSar1; 1Iowa State University
For companies seeking to adopt additive manufacturing, there is the simultaneous desire to rapidly qualify new AM processes for existing alloys as well as the recognition that, perhaps, new alloys with an improved balance of properties might be possible. In both, it is necessary to rapidly relate the most important aspects of the process to a material state that is predictable and well-behaved. A prototypical ICME approach might be suitable to understand process-property relationships, but is insufficient for new alloy design. Such insufficiency is due to: (i) a lack of understanding on which details of the process are most important (it depends?) and (ii) the wide composition space that exists for future alloys. We give examples of tools that have been used in AM-ICME frameworks, while discussing important technical gaps, simultaneously arguing for new tools and data that are required to conduct alloy design effectively and efficiently.
10:55 AM Invited
A Parameter Optimization Framework for Defect-free Metal Additive Manufacturing Using Laser Powder Bed Fusion: Ibrahim Karaman1; Raiyan Seede1; Bing Zhang1; David Shoukr1; Alaa Elwany1; Raymundo Arroyave1; 1Texas A&M University
Laser powder bed fusion (LPBF) has attracted significant attention due to its ability to produce near net shaped parts. However, there are numerous process parameters that must be adapted for different materials in this process. Improper selection of these parameters can result in highly porous parts and poor mechanical properties. Until recently, process parameter selection has been conducted via brute force experimentation, which is costly and time consuming. In an effort to optimize this selection process, a new protocol for determining printability maps is introduced. The protocol integrates an analytical thermal model with experimental validation, then uses geometric criteria for determining process parameters such that fully dense parts with minimal or no porosity can be produced. Using this framework, fully dense samples were achieved over a range of process parameters for several advanced materials, including recently developed ultra-high strength martensitic steel, a NiNb alloy, and a high entropy alloy.
11:20 AM
Uncertainty Quantification in Additive Manufacturing from CALPHAD to ICME Models: Jiadong Gong1; Changning Niu1; Abhinav Saboo1; Jason Sebastian1; Greg Olson1; 1QuesTek Innovations LLC
Designing new materials by additive manufacturing (AM) using an ICME approach begins with the use of chemical thermodynamics in the form of phase diagrams used to identify material concepts for further exploration, and ends with the use of chemical thermodynamics in the form of numerical process—structure models that enable optimization and sensitivity analysis of a material’s properties with respect to process conditions. Because the ICME design approach in AM is so dependent on chemical thermodynamics, a design is only as good as the thermodynamic data and models upon which the design is based. QuesTek has built out an uncertainty quantification and management framework applied to CALPHAD thermodynamic databases and ICME models with turnkey-ready user interfaces. In this framework, CALPHAD calculations will be performed in the cloud with a web interface. The uncertainty information will be further applied in QuesTek’s ICME models for AM design and optimization.