Reliability Centered Additive Manufacturing Design Framework

To address U.S. Navy needs, Sentient proposes to establish a Design Framework for reliability assurance of additive manufactured (AM) parts using their DigitalCloneTM Component (DCC) software. The framework will be tailored to metal components built through AM processes with complex geometries. Sensors are embedded during AM component build to allow for exploitation of sensor data, physics-based material models, and Bayesian-based algorithms for measurement and operational uncertainty management. Computational material model(s) virtually serialized to each AM part are regularly updated to best capture current health state and adaptively assess reliability. Sentients Design Framework allows for inclusion of life-cycle forecasts during the creation and exploration of the AM design space. In the Phase I, coupon samples with embedded sensors are built and modeled in the DCC framework for validation against physical testing results. A Bayesian-based algorithm for information fusion will be used to validate dynamic fatigue assessment capability for AM part reliability assurance. In Phase II, the framework will be expanded to different AM material processes with more complex geometries and loadings. It will include Multi-Objective Optimization tools for use in design, and reliability monitoring of a small air-to-air heat exchanger with forecasting of life-cycle and performance metrics compared to costs.