ICME 2023: AM - Processing I
Program Organizers: Charles Ward, AFRL/RXM; Heather Murdoch, U.S. Army Research Laboratory
Monday 9:50 AM
May 22, 2023
Room: Caribbean VI & VII
Location: Caribe Royale
Session Chair: Raymundo Arroyave, Texas A&M University
9:50 AM Invited
Robotic Blacksmithing: Towards the Autonomous Control of Geometry and Microstructure Via Iterative, Open-die Forming: Michael Groeber1; Glenn Daehn1; Stephen Niezgoda1; Tobias Mahan1; Walt Hansen1; 1The Ohio State University
The use of advanced incremental forming has been validated by blacksmiths and parts can be made that are much larger than a given available press. Systems with large robots and modestly-sized presses can develop these large forgings and in a fraction of the current time as dies do not need to be designed or built. Beyond these practical advantages, the goal of this work is to produce components where location-specific material properties/performance metrics are met in addition to the geometry requirements. We will present an initial robotic system - both its cyber and physical components. We will also highlight initial results in achieving required component geometries with desired microstructural characteristics. We will also present the details of the control algorithms developed for the system to operate in a semi-autonomous manner.
10:20 AM
Alloy Evaluation and Flow Forming Process Modeling for Net Shape Aerospace Structures: Wesley Tayon1; M. Mulvaney2; Elizabeth Urig2; 1NASA Langley Research Center; 2University of Virginia
Over the past decade, NASA Langley Research Center (LaRC) has led several manufacturing demonstration projects exploiting flow forming technology. The work has resulted in the commercial-scale manufacture of 10-ft. diameter single-piece, integrally stiffened cylinders. Near-net-shape flow forming offers simplified manufacturing schedules and cost savings through reduced part count. Reduction or elimination of machining, welding, and/or riveting can also lead to significant performance gains.NASA LaRC recently established a flow forming research facility to investigate new alloys and stiffener geometries for fuselage and launch vehicle cryotank applications. Candidate aluminum alloys and heat treatment combinations have been characterized through advanced mechanical testing and microscopy to maximize workability during flow forming trials. Elasto-plastic deformation simulations of the forming process have been performed using the finite element software DEFORM and correlated with forming trial results. The overall objective is to optimize structural performance through a combination of innovative materials, processes, and designs.
10:40 AM
Building Explainable Models - Determining Process-structure-property Relationships for Friction Stir Processed Metals: Moses Obiri1; 1Pacific Northwest National Laboratory
Friction stir processing (FSP) is a technique for altering the microstructure of a material via concentrated plastic deformation and typically leads to improved mechanical, fatigue, and wear performance. The deformation is created by forcibly inserting a non-consumable tool into the workpiece and rotating it while pushing it laterally. To enhance performance attributes such as hardness, and yield strength, the relationship between process parameters and microstructural features are being researched. Numerous process variables are known to influence the microstructure and properties of the FSP material; however, the exact relationships between process variables, and microstructure and performance properties have yet to be completely studied. Using response surface approaches, we create explainable polynomial models for describing process-microstructure-property relationships in this effort that are corroborated as necessary by high fidelity physics models. In addition, parametric and non-parametric techniques are employed to quantify uncertainty, and subsequent experiments are designed using quasi-Monte Carlo Spacefilling techniques.
11:00 AM
Simulation of Dynamic Recrystallization in a 316L Stainless Steel Friction Stir Weld with Kinetic Monte Carlo Modeling: William Frazier1; Lei Li1; Ayoub Soulami1; Matthew Olszta1; Donald Todd1; Keerti Kappagantula1; Neil Henson1; Erin Barker1; Eric Smith1; 1Pacific Northwest National Laboratory
In order to improve upon existing predictive capabilities for the evolution of alloy microstructures subjected to friction stir processing (FSP), an approach was developed integrating a Kinetic Monte Carlo (KMC) Potts Model of recrystallization and grain growth with macroscale Smoothed Particle Hydrodynamics (SPH) simulations of a 316L stainless steel plate. To this end, the KMC Potts Model used the thermomechanical data provided by SPH calculations of the FSP process in order to predict the recrystallization behavior, final grain size, and grain size distribution within the processed region as a function of position. Potts Model simulations were thus able to predict microstructure as a function of 316L stainless steel thermomechanical history and FSP process parameters. Simulation results were validated through experimental comparison with scanning electron microscopy data obtained by 316L stainless steel samples subjected to corresponding process parameters. The fidelity of our results to these experiments are discussed.
11:20 AM
HIP Diffusion Bonding Process Modeling for Fabrication of U-10Mo LEU Fuel: Taylor Mason1; Patrick Mcneff1; Rajib Kalsar1; Yucheng Fu1; Kriston Brooks1; Naveen Karri1; Vineet Joshi1; 1Pacific Northwest National Laboratory
Uranium-10Mo alloy has been identified as a promising low enriched uranium (LEU) fuel candidate to replace high enriched uranium oxide dispersion fuel (HEU) for use in United States high performance research reactors. Aluminum alloy 6061 (AA6061) cladding encapsulates the U-10Mo fuel foil and is diffusion bonded using hot isostatic pressing (HIP). Limited research has been performed to understand the effect of key HIP parameters on the minimum cladding thickness and strength of the cladding bond. This research has combined finite element modeling with experimental studies on a range of HIP can assembly configurations to evaluate their resulting fuel cladding properties. The experimental work informed the thermal and stress finite element models to predict and elucidate the effect of differing HIP can assembly configurations and process parameters on resulting U-10Mo LEU fuel product. This work identified the main factors for inhibiting heat transfer and producing min clad within the fuel product.