ICME 2023: ICME Design Tools: II
Program Organizers: Charles Ward, AFRL/RXM; Heather Murdoch, U.S. Army Research Laboratory
Tuesday 1:20 PM
May 23, 2023
Room: Caribbean IV
Location: Caribe Royale
Session Chair: Katherine Sebeck, US Army Ground Vehicle Systems Center
1:20 PM
The Role of Computational Materials Design in the Circular Economy of Materials: Paul Mason1; Anders Engstrom1; 1Thermo-Calc Software
Growing awareness of environmental issues is influencing the entire materials and product development life-cycle. This begins with the extraction of raw materials and innovating how they are processed. Next, designing alloys that result in lower energy costs, either in terms of their processing, or through higher operating performance. Then, beginning with the end in mind, enabling materials to re-enter the economy at the end of life through improved recyclability. ICME can be applied to all stages of the materials life-cycle to develop strategies around these topics and in this presentation, several examples will be given where CALPHAD tools have been used to: Developing new higher efficiency alloys Develop more efficient manufacturing processes that result in less energy consumption or a higher yield Enable increased use of recycled materialsDevelop and optimize alternative processes for scrap melters who are dealing with ever-increasing levels of undesirable elements and impurities
1:40 PM
Accelerating Development and Characterization of Nuclear Materials Processing: An Integrated Methodology: Erin Barker1; Eric Smith1; David Brown1; Neil Henson1; Keerti Kappagantula1; Donald Todd1; 1Pacific Northwest National Laboratory
Current efforts to modernize materials processing are hindered by a lack of fundamental, science-based understanding of the materials system (combination of feedstock material, production process, and finished part). A deeper understanding of the relationships between production process, material microstructure, and performance properties is the key to accelerating development timelines, achieving cost savings, and opening opportunities for game-changing materials systems for national security and nuclear energy. To address this challenge, an integrated methodology is being developed that brings together predictive modeling, inline monitoring, and data analytics. This methodology will enable high-fidelity in-silico experiments, efficient design of experiments, and process control which, taken together, will significantly accelerate development and qualification of materials systems. A key mechanism for integration within this effort is rigorous collection, curation, and sharing of data. This presentation will outline the methodology, highlight key advances in characterization, modeling, and ML, and demonstrate the key component of data management.
2:00 PM
Evolution of Model-based Material Definitions: David Furrer1; Dennis Dimiduck2; Charles Ward3; 1Pratt & Whitney; 2BlueQuartz LLC; 3IMMI Journal
There has been considerable effort to develop an integrated computational materials engineering (ICME) framework. A relatively new concept of model-based material definitions has also emerged that can support a truly integrated, multi-disciplinary engineering capability. Prior literature has provided some initial background and guidance relative to establishing and utilizing a model-based materials definitions construct as part of seamless engineering workflow. This work further addresses and provides explanations of how materials and process model-based definitions are evolving and are being incorporated into workflows for interdisciplinary component design engineering optimization. Formalization of model-based material definition standards have the ability to change the way products are engineered and how software tools have the potential to change to meet this opportunity. Model-based material and process definitions have the ability to support rapid material and product certification and qualification, especially for those that are sensitive to manufacturing processing and exhibit inherent structure and mechanical property gradients.
2:20 PM
Model-based Material and Process Definitions for Additive Component Design and Qualification: Somnath Ghosh1; Anthony Rollett2; David Furrer3; 1Johns Hopkins University; 2Carnegie Mellon University; 3Pratt & Whitney
Physics-based materials and process modeling has developed to a point where it is supporting the design and qualification of new components produced by additive manufacturing (AM). Focused models that describe various elements of the AM process, the evolution of microstructure and defects, and location-specific mechanical properties are key elements. Computational tools, when used as integrated modeling workflows, provide for a model-based definition framework for additive materials and processes. ICME property prediction starts with the thermal history, possibly at the scale of the individual melt pool or each layer if the local behavior is homogeneous. Examples will include spatial variation of geometry leading to variations in the local thermal history, microstructure, and properties in Ti-6Al-4V. Statistical description of microstructure provides statistically equivalent representative volume elements for predicting local mechanical properties. The alignment of model-guided testing and associated predicted properties can provide for a path to efficient and smart certification and qualification.
2:40 PM Break