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Meeting MS&T26: Materials Science & Technology
Symposium Additive Manufacturing Modeling, Simulation, and Machine Learning: Microstructure, Mechanics, and Process
Presentation Title An Agentic AI-Assisted Workflow for Simulation-Informed WAAM of Nuclear Sensor Brackets
Author(s) Ashley Gannon, Katarzyna Borowiec, Stephen DeWitt
On-Site Speaker (Planned) Ashley Gannon
Abstract Scope Deploying wire arc additively manufactured (WAAM) components in nuclear environments requires confidence in both the manufacturing process and the resulting material performance. Even with expert operator intuition, printing components often requires an iterative development process that can generate substantial material waste, accrue machine time and labor costs, and increase schedule risk. This work presents and demonstrates an agentic AI-assisted workflow for WAAM through the fabrication of stainless steel neutron sensor brackets. The workflow currently includes agents for component design, toolpath planning, meshing, thermal simulation, and process optimization, with ongoing work to incorporate agents for process documentation. Witness specimens from these fabricated brackets exceeded ASME Section II, Part D requirements for SA-240 Type 316L stainless steel and the brackets have been installed on the exterior of a nuclear reactor. These results demonstrate how agentic AI workflows can support traceable, simulation-informed WAAM process development.

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Computational Toolkit for Microstructure-Property Mapping of Multiphase Complex Structured Materials
A Low Cost Geometrically Driven Laser Powder Bed Fusion Microstructure Model
A Material-Agnostic Framework for Rapid Generation of Updatable Process Maps for Powder-Blown Laser Directed Energy Deposition (L-DED)
A Multiscale Finite Element Analysis of the Dynamic Fragmentation of Additively Manufactured Porous Metal Rings
A Neural Network Approach for the Automated Classification of Material Textures
A Predictive Tool for Optimizing Processing Parameters Used in LPBF for 316L Stainless Steel
Accelerating High-Fidelity 3D Melt Pool Simulation with Latent Diffusion
AI-Enabled Modeling and Machine Learning for Process–Microstructure–Property Control in Additive Manufacturing
An Agentic AI-Assisted Workflow for Simulation-Informed WAAM of Nuclear Sensor Brackets
Beyond Single-Track Maps: Multi-Dimensional Process Mapping for LPBF Thermal Behavior and Microstructural Control
CNN Encoder–Decoder Segmentation of Fatigue-Relevant Surface Porosity in LPBF Ti-6Al-4V
Combined Effects of Pore Diameter, Orientation, and Stress State on Fracture of LB-PBF SS316L
Comparative Assessment of Crack Susceptibility Criteria Using CALPHAD Solidification Modeling and Graded Thermal Experiments
Comparison of Inert Gas Flow, Spatter Transport and Powder Pickup in Commercial and Open Format Laser Powder Bed Fusion Platforms
Constructing Surrogate Models with Constraints for Additive Manufacturing
Crack Growth and Failure Under High Cycle Fatigue of Pore-Containing 316L Stainless Steel Fabricated with Laser Powder Bed Fusion
Decoupling Energy Density Effects in Laser Powder Bed Fusion of Aluminum Alloy
Deterministic Microstructure Programming for Consistent and Functionally Graded Properties in Laser Powder Bed Fusion of Inconel 718
Efficient Melt-Pool Modeling Informed by Computational Fluid Dynamics for Part Scale Porosity and Microstructure Prediction
Experimental Investigation Into the Effects of Laser Parameters and Cooling Rates on Solidification Microstructures in Metal Additive Manufacturing
Fast Prediction of Thermal History in Powder Bed Fusion Through Autoregressive Transformer-Based Diffusion
Identifying Mechanical Drivers of Fatigue Damage in Additively Manufactured Inconel 718 Using In-Situ Synchrotron Characterization
Improving Lifing Predictions for Additively Manufactured Components Using the One-Part-And-Life (OPAL) Framework
In-Situ Targeted Reheating for Residual Stress Mitigation in Laser Directed Energy Deposition
Investigation of Near-Pore Microstructure in Laser Powder Bed Fusion Alloy 718
Large-Area EBSD Analysis of Laser Hot-Wire DED Additive Manufacturing
Large Scale Open-Source Experimental Data for Advancing Modeling and Analytics in Cold Spray Processing
Machine Learning-Based Defect Characterization from Fracture Surfaces in LPBF Ti-6Al-4V
Machine Learning-Based Processing Parameter Optimization of Additive Manufacturing of Soft Magnetic Steel
Microstructure-Aware Generative AI Model for Long-Term Spatiotemporally Consistent Prediction of Corrosion and Crack Evolution
Prediction of Defects, Microstructure, and Properties in Laser Powder Bed Fusion Using Physics-Aware Deep Learning
Process Parameter Optimization in Laser Powder Bed Fusion Additive Manufacturing
Property Optimization Through Full-Part Thermal History Control in Laser Powder Bed Fusion Additive Manufacturing
Quantitative Validation Methodologies for Physics-Based Microstructure Prediction Models in Metal Additive Manufacturing
Sensitivity of Grain-Averaged Elastic Strain and Orientation Predictions on the Mesh Density and Boundary Conditions in Crystal Plasticity Finite Element Simulations
Statistics-Based Modeling of Spatter-Related Defects Using High-Throughput CT and Operando Mechanistic Insights
Three-Dimensional Characterization and Modeling of Laser Powder Bed Fusion of 316L
Toward Transferable Dimensionless Process Maps for Active Learning-Based Optimization in Wire-Arc Additive Manufacturing
Validating Thermo-Calc Predictions of Oxygen Effects on LPBF Printability and Melt Pool Geometry in 316L Stainless Steel
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