Rapid, Low Cost, High-quality Component Qualification Using Multi-scale, Multi-physics Analytical Toolset for the Optimization of Metal Additive Manuf

The research objective of this proposal is to demonstrate feasibility of utilizing a multi-scale multi-physics analytical toolset to optimize the key process parameters of the direct metal laser sintering process (DMLS) for alloy Ti-6Al-4V and provide support for rapid qualification. The optimization is based on the concept of design requirements and quality metrics for defect distribution, residual stress, dimensional tolerances, stress relief, solidification microstructure, solid state transformations and hot isostatic pressing. Each quality metric is defined in terms of measurable goals or tolerance bounds and the optimization procedure is organized to fulfill each quality metric using analytical modeling. The analytical toolset includes the simulation of melt pool physics, residual stresses, distortion and the modeling microstructure evolution. The variability of the DMLS process is captured using a combination of discrete particle model and melt pool physics simulation. Deposition trials will be performed in order to verify that the optimized parameters comply with each quality metric.