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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium Simulations/Experiments Integration for Next Generation Hypersonic Materials
Presentation Title Accelerating a Digital Twin of Direct Energy Deposition Additive Manufacturing
Author(s) Saad Khairallah
On-Site Speaker (Planned) Saad Khairallah
Abstract Scope A multi-scale high fidelity model is developed to simulate the process of additively manufacturing small coupon parts in direct energy deposition. The model accounts for powder transport from the coaxial nozzle to the work piece as well as the effect of the carrier gas. Full laser ray tracing model is used to preheat the flying powder particles and to create the melt pool. Furthermore, microstructural cellular automata finite element analysis is carried out to determine the grain size distribution and orientation upon solidification. The high cost of modeling is brought down by using deep learning neural network as well as data driven reduced order modeling. The model is preliminarily applied to study several Titanium based alloys and to compare resulting microstructure and mechanical performance. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE- AC52-07NA27344. Lawrence Livermore National Security, LLC. LLNLABS-837562.
Proceedings Inclusion? Planned:


Accelerating a Digital Twin of Direct Energy Deposition Additive Manufacturing
Composite Metal/Ceramic Coatings with Exceptional Thermal Shock Resistance
Computational Design of Ni-based SX Superalloys: A Critical Assessment of Machine-learned and Thermodynamic Models in View of Experimental Properties
Computational Discovery and Experimental Validation of Ultra-high Strength BCC Refractory Metal-based MPEAs for Extreme Environments
Degradation Resistance of Refractory Multi-principal Element Alloys for Extreme Environments
High-throughput CALPHAD Exploration of Multi-principal Element Alloy (MPEA) Space for Targeted Properties and Structure
How Do You Integrate Both Simulations and Experiments into a Materials Discovery Optimization Campaign? A Case Study in Multi-fidelity Optimization
Material Design by Additive Manufacturing of Multi-component Metal Alloys
Modeling Thermomechanical Buckling in Combined Extreme Environments
On the Deformation Processes of BCC Refractory Complex Concentrated Alloys
Phase Transforming Metal-ceramic Multilayers for Ultrahigh Temperatures
Simultaneous Bayesian Calibration of Strength, Kinetics, and Phase Boundaries

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