3D Simulation of Laser Additive Manufacturing [ 3D-SLAM ]

Applied Optimization proposes to develop 3D Simulation of LAM, and verify its accuracy by correlating its results with microstructure data at the Boeing Phantom Works, for parts that are different from each other in terms of substrate and rib thicknesses,and build height. The simulation will model laser-powder-substrate interaction, using a combined analytical-numerical approach, such that it is transparent to the user. The shape of powder melt bead will be calculated by considering the effects of surfacetension, and the resultant build height and shape, through multiple passes, will be tracked accurately. Effect of microstructure gradient on the material elastic properties will be included in the calculation of residual stresses in the HAZ. The nearfield, or laser spot region, calculation will be linked to a far field solution, in order to create a complete picture of LAM behavior, as a function of its process parameters. The simulation will include automatic and adaptive mesh generation, and makeuse of commercially available pre- and post processors. We expect the simulation time to be comparable to a present-day casting simulation. The anticipated benefit of 3D Simulation of LAM is the ability to eliminate trial and error in its processdesign, and thereby minimize the buy-to-fly ratio for expensive aerospace parts. This 3D Simulation software has intrinsic commercial viability due to its application to a large number of parts, for which the manufacturing process can be either simplifiedor made feasible by LAM.