Additive Manufacturing: ICME Gap Analysis: Session I
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Integrated Computational Materials Engineering Committee
Program Organizers: Dongwon Shin, Oak Ridge National Laboratory; Richard Otis, Jet Propulsion Laboratory; Xin Sun, Oak Ridge National Laboratory; Greta Lindwall, KTH Royal Institute of Technology; Mei Li, Ford Motor Company; David Furrer, Pratt & Whitney
Tuesday 8:30 AM
February 25, 2020
Room: 7B
Location: San Diego Convention Ctr
Session Chair: Dongwon Shin, Oak Ridge National Laboratory; Richard Otis, Jet Propulsion Laboratory
8:30 AM Introductory Comments
8:35 AM Invited
The Future of Additive Manufacturing, a Vision for NASA’s Jet Propulsion Laboratory: Andrew Shapiro1; R. Peter Dillon1; Bryan McEnerney1; 1Jet Propulsion Laboratory
Additive manufacturing at NASA’s JPL is part of a larger, rapidly moving evolution of advanced manufacturing, materials, modeling and design. There are many areas in NASA where additive manufacturing can provide substantial benefits. These include integration of multiple spacecraft functions, fabrication of complex shapes, and integration of multiple parts for a single function. Ultimately, advanced manufacturing will enable a complete change in the way we design spacecraft including the integration of multiple functions, real-time multiphysics functional analysis for design trades, topology optimization, 3-D lattices, and built-in test methodologies. These will be facilitated by models at all scales, informed by in-situ data collection. There remain a number of challenges in achieving this vision. Several potential solutions to the challenges could be implemented in the near future.
9:10 AM Invited
Challenges in Modeling Microstructure Evolution During Additive Manufacturing Based on Phase-field Method: Yanzhou Ji1; Zhuo Wang2; Lei Chen2; Long-Qing Chen1; 1Pennsylvania State University; 2Mississippi State University
The phase-field method has recently been applied to modeling additive manufacturing (AM) of metallic alloys. For example, it has been employed by a number of groups to model powder consolidation, gas pore evolution, dendrite morphology evolution, grain growth and solid-state transformations during AM. However, in order to develop the phase-field method as efficient and reliable ICME tool for AM, we have to overcome several challenges. These include (1) the huge amount of computational resource required for full-scale three-dimensional simulations under realistic AM processing conditions, (2) the lack of reliable materials data as input parameters and their uncertainty, (3) the difficulty to conduct parallel experiments to validate the predicted microstructure evolution, (4) the complexity involved in the coupling among different microstructure features at different spatial and time scales, and (5) the identification of uncertainty sources and their propagation during the microstructure simulations.
9:45 AM Invited
Utilization of Non-metallic Inclusion and Optimization of Alloy Compositions for AM Process: Jung-Wook Cho1; In-Ho Jung2; 1Postech; 2Seoul National University
Non-metallic inclusions (NMI) have been utilized as nucleation sites in solidification of steel and precipitates to improve the strength of steel. However, NMI have not been actively studied in the additive manufracturing (AM) process for alloys. As liquid alloy temperature can be easily raised above 2000 K, the behavior of NMI can be highly differently from the convention process. Accurate thermodynamic and kinetic understanding of chemical reactions between liquid alloys and gas species such as oxygen, nitrogen and sulfur at high temperatures is essential for active controls of the inclusions and their utilization in AM process. In this presentation, beneficial effects of NMI for the mechanical properties of stainless steel products by AM process will be demonstrated. The key concept for the optimization of AM alloy composition to utilize NMI will be introduced, and the current limitation of our knowledge to realize this concept will be overviewed.
10:20 AM Break
10:45 AM Invited
ICME and Additive Manufacturing Research in NSF’s Advanced Manufacturing Program: Khershed Cooper1; Ralph Wachter1; 1National Science Foundation
The NSF supports research in Additive Manufacturing through its Advanced Manufacturing (AM) Program. The AM program seeks innovative proposals in materials engineering and manufacturing processes to produce novel materials and structures, in aggregate, forming useful components and products. Besides laser-based metal and polymer fusion and filament-based deposition processes, bioprinting, printable electronics, and nanoscale 3D printing are among the novel additive manufacturing methods investigated. There is a need for additively manufactured components to have longer useful lives, which requires addressing resilience to minor defects and faults and even tampering. This need opens new opportunities for research in ICME applications in additive manufacturing, which should move the technology to a level where quality high-value parts and components are made reliably and certifiably, especially, since many of them will be made in low volumes. This talk will describe NSF’s Advanced Manufacturing program, its research in additive manufacturing and the needed application of ICME.
11:20 AM Invited
Challenges in Integration and Validation of a Coupled FEM and Phase Field Approach for Modeling Additive Manufacturing: Daniel Lewis1; Antoinette Maniatti1; 1Rensselaer Polytechnic Institute
This talk reports on the challenges in vertical integration of a coupled Finite Element and Phase Field approach for modeling the microstructure development in the selective laser melting process. Two areas will be highlighted in this talk. First, we will describe the software tools needed to assist with tasks such as simulation of multi-layer builds, define scan path strategies, and permit data sharing between FEM and phase field methods. Secondly, we will describe the types of experimental hardware needed to validate build microstructures and permit calibrated modeling of the AM process.