ICME-based design of Magnesium alloys for additively manufactured structures and repairs

Under this STTR program, QuesTek Innovations will utilize its knowledge and expertise in Integrated Computational Materials Engineering (ICME) to develop high-performance, additively manufacturable Mg alloys for application in repairs or as a lightweight structural component in aircraft. The need for accelerated development and desired performance ranging from mechanical properties, AM processability to oxidation and corrosion properties necessitate the implementation of an ICME framework to computationally design an improved alloy composition and associated processing. QuesTek will leverage its expertise in computational materials design, utilizing CALculation of PHAse Diagrams (CALPHAD)-based modeling techniques to evaluate a multidimensional composition space to design an alloy with optimal microstructural features to achieve the desired properties of high strength, low density, and improved oxidation and corrosion resistance. QuesTek will partner with Prof. Dan Thoma’s group at the University of Wisconsin-Madison who are uniquely qualified to perform accelerated, high-throughput material synthesis (via elemental powder blending) utilizing directed energy deposition. Additionally, QuesTek will partner with Prof. Michele Manuel at the University of Florida to leverage her extensive expertise in design and development of Mg alloys. In Phase I of the program, the team will computationally design a novel Mg alloy, develop DED processing conditions to prototype the designed alloy, and perform microstructural characterization and mechanical testing. Future phases of the program will involve evaluation of scaled up prototypes and direct component manufacturing techniques such as Laser Powder-bed fusion (L-PBF) techniques using industrial alloy powder production.