Quantifying Uncertainty in the Mechanical Performance of Additively Manufactured Parts Due to Material and Process Variation

The Phase I objective is a proof of concept capability integrating process information, material properties and damage tolerance simulations into the Additive Manufacturing (AM) design certification process. VEXTEC has a toolbox of software and methods that consists of various software modules in multiple formats that are used to assess the durability of parts processed by traditional methods of casting, forging, rolling, machining and welding. VEXTEC also developed software modules to determine the durability of sophisticated methods such as powder metallurgy, single crystal and various additive methods. University of Tennessee, our research partner, has performed extensive studies to identify the effect of processing attributes on additive manufacturing processing that will be addressed in the proposed software. Phase I will demonstrate a proof concept capability of the first order effects such as processing, geometry and microstructure. The architecture of the methodology to integrate the FEA and microstructural damage models will be developed. This method will be used to perform the durability analysis of an Electron Beam AM titanium specimens to show feasibility. VEXTEC/UT will work Aerojet Rocketdyne, our OEM partner, to determine the elements that need to be improved and additional elements required.