Modeling of Layer Additive Manufacturing Processes

Applied Optimization, Inc. herein proposes three technical tasks for modeling of electron-beam free-form fabrication [EBF3] as follows. The first task is to enhance existing capability to simulate melt-pool generated by the electron-beam, and evolution of its shape due to interaction between thermo-mechanical and geometry phenomena. The second task is to enhance the existing simulation capability to control the thermo-mechanical interaction between the electron-beam melt-pool, evolving geometry of multi-layer deposit, microstructure control parameters, thermal gradients and residual stress. The third task is to demonstrate the ability to develop EBF3 process parameters that optimize the solidification conditions and residual stresses for a component of interest to the HEFFASTUS alliance. BENEFIT: Modeling tool that predict processing conditions to attain consistent solidification conditions and control of residual stresses will create ability to produce and certify structural components.  It has applications for design of weld repair, which is important for life extension of critical components.