ICME 2023: ICME Des Tools: I
Program Organizers: Charles Ward, AFRL/RXM; Heather Murdoch, U.S. Army Research Laboratory
Monday 1:10 PM
May 22, 2023
Room: Caribbean IV
Location: Caribe Royale
Session Chair: Katherine Sebeck, US Army Ground Vehicle Systems Center
1:10 PM Invited
Designing Aerospace Components with Model-based Definitions to Enable Location-specific Tailoring of Properties: Michael Sangid1; Saikiran Gopalakrishnan1; Ritwik Bandyopadhyay1; 1Purdue University
The geometric design of components traditionally consider the material as a monolithic structure, therefore not accounting for microstructural gradients that occur during the manufacturing process. The resulting material design allowables are conservative and associated with large uncertainty bounds. To improve precision in the life estimates, a location-specific lifing framework is developed, which tracks manufacturing processes and retrieves microstructural information at distinct locations for use within a crystal plasticity fatigue life prediction model. These approaches are used within a model-based feature information network to link the geometric features with material’s simulation and analyses to streamline the product lifecycle management. A use case for microstructural-sensitive fatigue predictions of a dual microstructure heat treated turbine disk component is demonstrated near the bore (fine grains) and rim (coarse grains) regions. The proposed location-specific lifing framework presents new opportunities for simultaneously designing the component and tailoring the microstructures to meet the targeted performance.
1:40 PM
ICME Design Approach Based on Multi-scale FEM, Phase-field and Ab-initio Simulations: Paul Persson1; Luis Reig Buades1; Sandeep Kumar2; 1Dassault Systemes, BIOVIA Ltd.; 2Dassault Systemes Simulia Corp
We present a workflow that combines atomistic, phase-field and FEM simulations to study the effects of alloy composition and of manufacturing process on the working performance of a component. In this approach, a component-scale FEM model of the manufacturing process captures the effect of process parameters and produces the inputs for a phase-field simulation of microstructural evolution. From the phase field method, an RVE of the microstructure is generated and introduced into an FEM micro-mechanical simulation to assess the mechanical potential of the microstructure produced. The workflow also produces homogenized properties for a macro-scale structural performance analysis of the component. We use first-principle calculations to assess the effects of alloy composition on performance by calculating the properties needed in the macro and meso-scale manufacturing simulations. We illustrate the workflow by simulating additive manufacturing of β stable Titanium alloys.
2:00 PM
Process Chaining to Enable a Material-informed Digital Twin Prototype for Marine Structures: Charles Fisher1; Thomas Gnaepel-Herold2; Suok-Min Na1; Kelly Nygren3; Armand Beaudoin3; 1Naval Surface Warfare Center - Carderock; 2National Institute of Standards and Technology; 3Cornell High Energy Synchrotron Source
Residual stress from fabrication can severely degrade structural performance over a ship’s lifecycle. However, the evolution of the residual stress distribution throughout the shipbuilding process is not well understood. ICME techniques enable linking disparate software codes across multiple length scales, thereby facilitating simulation of the entire material lifecycle. This project pairs computational simulation with physical measurement for verification and validation (V&V) of the linked finite-element analysis (FEA) tools. The linked FEA tools, in a technique referred to as process chaining, enable simulation of a representative marine structure. Concurrently, the residual stress in an analogous physical structure was measured through each step of the fabrication process: incoming plate, cutting, and welded assembly. The effort followed specific areas within the component to understand the effects of fabrication on residual stress magnitude and distribution. This fabrication-cycle material information is essential to understand marine structures as the industry moves towards a digital twin standard.
2:20 PM
Simulated Microstructural Evolution and Tool Chain Development for Process Optimization of Cast & Wrought Nickel-base Superalloy Billet Material: Nicholas Krutz1; Pavanachand Chigurupati1; Corey O'Connell1; 1PCC Metals
The microstructure evolution of Nickel-base Superalloy ingot material through final melt and initial ingot breakdown is simulated using a multi-step simulation workflow. The local solidification rates predicted during the final melt are treated as inputs to predict the local grain features within the ingot. The sensitivity of the as-cast flow stress to local segregation predictions is evaluated. The data obtained from the melt simulation is mapped onto the element centroids of a continuum Finite Element simulation to evaluate the microstructure evolution during initial stages of ingot breakdown. The breakdown forging sequence is coupled to a mean field recrystallization model capable of capturing dynamic and post-dynamic recrystallization which updates the flow stress of the material point within the given simulation time step. The effect of grain orientation as implemented is evaluated. The simulation results are compared to laboratory data. The relative sensitivities of the inputs are identified to a first-order approximation.
2:40 PM
Model-based Material and Process Definition Application to Aerospace Component Design and Lifing
: Vasisht Venkatesh1; Stephen Barker1; Ryan Noraas1; Michael McClure1; Jean-Philippe Thomas1; Sergei Burlatsky1; David Furrer1; 1Pratt & Whitney
Traditional approaches to define materials and associated manufacturing processes have been successful for many decades. These approaches rely on large quantities of experimental data to assess material properties, sensitivity to manufacturing processing paths, and potential sources for variation. As materials, processes and component designs are more exacting relative to definition of capabilities a new approach as part of integrated computational materials engineering has been established and successfully demonstrated with a range of materials and processes. The ability to predict component location-specific properties as a function of manufacturing path and operational utilization enables enhanced capability to predict component damage accumulation and life. The framework for model-based material and process definitions will be reviewed along with examples of how it can augment and greatly improve the traditional approaches based simply on empirical testing to establish critical material design curves.
3:00 PM Break