About this Abstract |
| Meeting |
TMS Specialty Congress 2026
|
| Symposium
|
World Congress on Reproducibility, Qualification, and Standards Development of Additive Manufacturing and Beyond (RQSD 2026)
|
| Presentation Title |
Reducing Uncertainty in Lifing Predictions for Additively Manufactured Components Using the One-Part-And-Life (OPAL) Framework |
| Author(s) |
Carl Fauver, Erin DeCarlo, Sakshi Braroo, James Sobotka |
| On-Site Speaker (Planned) |
Carl Fauver |
| Abstract Scope |
The part-to-part variability observed in additively manufactured (AM) parts has made qualification and certification (Q&C) of AM processes difficult, especially for fatigue applications where failures are driven by process-induced anomalies. Consequently, realizing the promise of distributed AM remains a massive challenge. Informed by advanced in-situ sensing and physics-based modeling, we propose a new One Part and Life (OPAL) framework where we leverage a defect and microstructure twin to inform component life predictions within a modified version of the probabilistic damage tolerance software DARWIN®. This presentation discusses enhancements to DARWIN’s microstructure-based lifing capabilities to improve lifing accuracy. Prior efforts in this domain adjusted fatigue crack growth (FCG) rates for Inconel 718 based on average grain size but are not immediately extensible to AM alloys built by laser powder-based fusion methods. We demonstrate recent efforts to develop a novel crystal plasticity-based mapping between FCG rates and local microstructural features. |
| Proceedings Inclusion? |
Undecided |