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

We propose to develop an AM Process Parameter Optimizer (PPO) analytical package for AM process for a desired product performance stemming from mechanical and/or functional requirement. Our proposed PPO tool will include an inner multi-scale, multi-physics thermo-mechanical engine, and an outer sensitivity and optimization layer to provide first order input design space for the AM machine settings instead of going through a series of iterations and checks. Furthermore, PPO takes the users desired mechanical and functional requirement for a selected Selective Laser Melting (SLM) process, and provides suggested input process variables and its spread for a particular machine.The key algorithmic developments in PPO are the sensitivity and optimization modules. These will be developed from a simulation based engineering design approach but accounting for inherent variability and uncertainty. TDAs thermomechanical model will also be enhanced in this effort to deal with simulation based design approach as proposed here. Design of Experiments will be carried out to study multiple input factors and their effect on desired output properties. TDAs research partner in this effort is Mississippi State University who will conduct the experiments based on DoE.