Design Tool for Topological Optimization of Air-Platform Structural Components made by Additive Manufacturing

AlphaSTAR Corporation (ASC) will (i) deliver models that characterize the additive manufacturing (AM) machine process parameters and fabrication material associated with selective laser melting (SLM) of Ti-6Al-4V and (ii) develop an integrated structural and material design framework capable of simulating the AM of air-platform components, while predicting thermal history and manufactured properties and thereby providing a methodology to optimize the topology of the structure to produce lighter, stronger and less expensive parts and lead to certification. ASC will utilize GENOA to predict bulk thermal response, deflection, delamination, residual stress, damage initiation, crack propagation, and post-fabrication mechanical performance of SLM-fabricated parts. Real test data will be collected to accelerate material qualification and numerical model validation. ASC will exploit thermal monitoring and process control to determine relationship between SLM process parameters and thermal history in order to reduce the occurrence of porosity and residual stress formation of topological optimized structure. The approach will follow a building block strategy. Success at the material coupon level will provide guidance for the preparation and testing of a simple model, which will provide direction and guidance for components, which will ultimately lead to the development, fabrication, testing and certification of a air-platform components for Naval platforms.