Additive Manufacturing Modeling and Simulation: AM Materials, Processes, and Mechanics: Poster Session
Sponsored by: TMS Additive Manufacturing Committee
Program Organizers: Jing Zhang, Purdue University in Indianapolis; Brandon McWilliams, US Army Research Laboratory; Li Ma, Johns Hopkins University Applied Physics Laboratory; Yeon-Gil Jung, Korea Institute of Ceramic Engineering & Technology
Tuesday 4:45 PM
November 3, 2020
Room: Poster Hall
Location: MS&T Virtual
Session Chair: Jing Zhang, Indiana University – Purdue University Indianapolis
Creep Modeling of 3D Printed 718 Nickel Alloys: Harshal Dhamade1; Abhilash Gulhane1; Jian Zhang1; Bong-Gu Kim2; Yeon-Gil Jung2; Jing Zhang1; 1Indiana University - Purdue University Indianapolis; 2Changwon National University
In this work, a finite element based creep model for additively manufactured 718 nickel alloys is developed. Using a user defined creep subroutine with the Liu-Murakami and Kachanov-Rabotnov isotropic creep damage formulation, the model is capable to simulate the whole creep range, including the secondary and tertiary creep stages. The model was firstly validated using wrought 316 stainless steel material. Then the model is applied to 718 nickel based alloy fabricated using selective laser melting. The model predictions show a good agreement with the experimental creep data. The model developed in this work can be used to predict the creep behavior for 3D printed metals under uniaxial loading conditions.
Fabrication of Ceramic Core for Single Crystal Casting of Gas Turbine Blade: Hye-Yeong Park1; Eun-Hee Kim1; SeungCheol Yang1; Hyun-Hee Choi1; Jing Zhang2; Yeon-Gil Jung1; 1Changwon National University; 2Indiana University – Purdue University Indianapolis
A ceramic core employed in a single-crystal casting process should endure for a long time at casting temperatures above 1500 ℃. In this work, an inorganic binder was applied to fabricate cores with sufficient strength and complete elution characteristics to withstand casting temperatures. The ceramic powder was coated with a silica precursor, and then dried at 80 ℃ for 1 h. The dried powder was mixed with wax and injection-molded. The injected core was heat-treated at 1200 and 1500 ℃ for 1 h. The additional heat treatment at 1550 ℃ for 3 h. The inorganic binder-coated core with a superior firing strength had no cracks or surface defects after the heat treatment, compared with the core without the inorganic binder. In addition, the turbine blade was well-cast as a single crystal and the internal core was completely eluted.
Mechanical and Surface Properties of Inconel 718 Alloy Fabricated by Additive Manufacturing: Junseong Kim1; Dowon Song2; Yun kon Joo3; Guanlin Lyu3; SeungCheol Yang3; Jing Zhang1; Yeon-Gil3; 1Indiana University - Purdue University Indianapolis; 2Hanyang University; 3Changwon National University
In this study, the applicability of the superalloy fabricated by additive manufacturing was investigated in comparison to the conventionally forged superalloy. The microstructure and mechanical properties of the 3D printed Inconel 718 alloy before and after hot isostatic pressing were characterized and compared to the conventionally forged alloy. The as-printed alloy showed lower hardness and elastic modulus than the HIP-treated and forged alloy due to its large amounts of defects, showing many pores at the melt pool boundary on the fractured surface after tensile test. The HIP-treated alloy showed denser microstructure, implying lower fracture toughness. The yield strength was increased after HIP, while the tensile strength showed increase. However, the elongation was evidently deteriorated after HIP. The plastic deformation of the HIP-treated alloy after yielding was low, resulting in a rapid fracture. Also, the surface properties for the superalloy prepared by 3D printing were improved by applying the diffusion coating.
Experimental and Modeling Study of Gas Adsorption in Metal-organic Framework Coated on 3D Printed Plastics: Tejesh Dube1; Jian Zhang1; Bong-Gu Kim2; Yeon-Gil Jung2; Jing Zhang1; 1Indiana University – Purdue University Indianapolis; 2Changwon National University
Metal-organic frameworks (MOFs) are a class of compounds consisting of metal ions or clusters coordinated to organic ligands in porous structure forms. This work combines MOFs with 3D printing technologies, in which 3D printed plastics serve as a mechanical structural support for MOFs powder. The objective of the thesis is to understand the gas adsorption behavior of MIL-101 (Cr) MOF coated on 3D printed PETG, a glycol modified version of polyethylene terephthalate, through a combined experimental and modeling study. The results show that pure MIL-101 (Cr) MOFs were successfully synthesized. For the PETG substrate, disk-shape plastic samples with a controlled pore morphology were designed and fabricated using the fused deposition modeling (FDM) process. MOFs were coated on the PETG substrates using a layer-by-layer (LbL) assembly approach. The computational model illustrates that the MOFs show increased outputs in adsorption of nitrogen as pressure increases, similar to the trend observed in the adsorption experiment. The model also shows promising results for carbon dioxide uptake at low pressures, and hence the developed MOFs based components would serve as a viable candidate in gas adsorption applications.
Modeling of Electron Beam Physical Vapor Deposition Process for Fabricating Thermal Barrier Coatings: Anvesh Dhulipalla1; Yafeng Li2; Jian Zhang1; Hye-Yeong Park3; Yeon-Gil Jung3; Jing Zhang1; 1Indiana University - Purdue University Indianapolis; 2Tianjin Polytechnic University; 3Changwon National University
This study presents a validated high-fidelity model of Electron Beam Physical Vapor Deposition (EB-PVD) process that can predict the coating thickness on samples on a rotating stage. Two simulation techniques were developed to compute coating thickness. The first one is a ray tracing (RT) method, assuming a line-of-sight coating process and taking the shadowing effects into consideration. The second one is based on heat transfer method. The thickness is predicted based on the calculated temperature profile. Case studies of coating thickness prediction on different part geometries, including a gas turbine blade, will be demonstrated.
Modeling of Impact Property of 3D Printed 718 Nickel Alloys: Sugrim Sagar1; Jian Zhang1; Junseong Kim2; Yeon-Gil Jung2; Jing Zhang1; 1Indiana University - Purdue University Indianapolis; 2Changwon National University
In this study, Charpy impact property of 3D printed 718 nickel alloys is investigated using the finite element modeling method. The Johnson-Cook constitutive material model with damage properties is implemented in an explicit finite element formulation. The temperature-dependent impact energy is calculated, and the results are qualitatively in agreement with experimental data.
Strength Improvement of The Ceramic Core by Applying Dual Polymers In 3D Printing Process: Hyunhee Choi1; Bong-Gu Kim1; Hye-Yeong Park1; Junseong Kim1; SeungCheol Yang1; Yeon-Gil Jung1; Jing Zhang2; 1Changwon National Univerisity/ Department of Materials Science and Engineering; 2Indiana University-Purdue University Indianapolis
In this study, new organic-inorganic binder conversion process, which can be applied in 3D printing, was introduced for preparing the ceramic core with improved mechanical strength using two polymers with different chemical properties, and inorganic binder. Green body was fabricated with a 3D printer and ceramic slurry prepared by mixing the starting powder and two polymers (non-aqueous and aqueous). The green body was immersed in water to remove the aqueous polymer, leaving space for penetrating an inorganic binder in the green body. After removing the aqueous polymer, the sample was immersed in the inorganic binder solution composed of TEOS and NaOMe, and then dried at 80℃. The prepared sample was heat-treated at 1000℃ for converting the inorganic binder to glass. The application of the dual polymer increased the penetrating amount of the inorganic binder in the green body, and finally the strength of the ceramic core increased after the heat-treatment.
Probabilistic Process Design of Laser Powder Bed Fusion Using Coupled Monte Carlo and Inverse First Order Reliability Method: Lingbin Meng1; Xuehui Yang1; Xiaoping Du1; Brandon McWilliams2; Jing Zhang1; 1Indiana University - Purdue University Indianapolis; 2CCDC Army Research Laboratory
The quality inconsistency due to the existence of uncertainty hinders the widespread applications of laser powder bed fusion (L-PBF) process in some industries. In this work, a novel method is proposed the probabilistic process design problem. The method couples the inverse first order reliability method (I-FORM) with the Monte Carlo simulation (MCS) to improve the efficiency. With the uncertainty level of all the input variables and the target reliability, the method predicts the combinations of the processing parameters that can satisfy the reliability requirement. A case study is presented using the normalized enthalpy criterion as the design requirement.
Virtual Reality Module for Additive Manufacturing Education: Jing Zhang1; Glorio Singui1; Shambhuraj Wadghule1; Xuehui Yang1; Jian Zhang1; Chauncey Frend1; 1Indiana University - Purdue University Indianapolis
We present the recent progress of developing virtual reality (VR) modules for the additive manufacturing curriculum offered at Indiana University – Purdue University Indianapolis. Using plastic 3D printing technology or Fused Deposition Modeling (FDM) as an example, we developed a CAD model of the 3D printer, and added interactive features to produce a VR module. The overall goal of the project is to create an innovative pedagogical approach using multi-module VR for instruction specifically targeted at higher level undergraduate or graduate programs. 3D printing or additive manufacturing has become emerging technology. However, there is no clearly defined educational model for preparing entry-level professionals in AM industry. This work will establish a framework for engineering faculty and student to adopt them for the new career opportunity. In the on-going research, students are being asked to use the VR module in comparison with the hands-on lab.