Extensible Modeling to Create Knowledgebase for AM Processing of Alloy GrCop-84

The research objective of the proposed work is to demonstrate feasibility of utilizing extensible modeling to create an AM knowledgebase for copper alloy, GrCop-84, and utilize it to design an AM process for GrCop-84. The work plan has three tasks: (1) Utilize process modeling to demonstrate feasibility of predicting AM process parameters for alloy GrCop-84 for the powder bed and blown powder processes and generate parameter verification data. (2) Perform extensible modeling to generate an AM knowledgebase for GrCop-84 for the powder bed and blown powder processes. Demonstrate compatibility of extensible modeling for another alloy of interest to NASA by generating a knowledgebase for that alloy using existing data at AO. (3) Demonstrate feasibility of applying extensible modeling of the AM process and rapid solidification modeling of AM microstructure to mitigate build defects, dimensional errors, and microstructure inhomogeneity for either the powder bed or blown powder process for alloy GrCop-84. The deliverables are: (1) AM processing parameters; (2) AM knowledgebase to account for modest changes in parameters; (3) A microstructure model for rapid solidification; (4) Demonstration of feasibility to mitigate build defects, dimensional errors, and microstructure inhomogeneity.