About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
In-Situ Monitoring and Control of Solidification & Deformation Processes in Metal Additive Manufacturing
|
| Presentation Title |
'Simulation Twins' - Sensing and Control of Unseen Quantities Through Real-Time Assimilation of Imaging to FEA |
| Author(s) |
James C. Haley, Ashley Gannon, Bruno Turcksin, Callan Herberger, Steven DeWitt |
| On-Site Speaker (Planned) |
James C. Haley |
| Abstract Scope |
During Directed Energy Deposition, microstructural variability arises from the complex thermal cycling and solid-state phase transformations induced by the heat source scan strategy. Material systems with rate and composition dependent transformations such as austenite/martensite or dynamic tempering produce geometry-dependent heterogeneity that challenge qualification efforts. To combat difficulties in quantifying these thermal cycles for the whole component, we present results from a “Simulation Twin” – a spatially registered in-situ DIC and thermal system with a real-time finite element model capable of assimilating real-world data. Here we show how this approach is used to calibrate assumptions dynamically and produce a holistic, uncertainty-aware estimate of the thermal history of every element of the component. We discuss applications ranging from microstructural optimization through machine parameter manipulation, to FE guided model reference feedback control. Our results demonstrate how sensing is empowered through coupling with real-time physics models to provide grounded estimates of unmeasurable, critical quantities. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Machine Learning |