Fatigue Prediction for Additive Manufactured (AM) Metallic Components

Sentient proposes to develop a physics-based integrated computational materials engineering (ICME) framework (DigitalClone® Additive) to support the rapid qualification of AM components, including microstructural features, and macro-level fatigue performance. Sentient will apply their extensive experience with the DigitalClone technology to conduct multiscale modeling of AM process and resulting microstructure and fatigue life. Sentient’s DigitalClone is a physics-based computational modeling and design framework that simulates the microstructure of different components and their behavior, calculates internal stresses caused by different applied loading conditions, accumulates internal damages resulting in crack nucleation and propagation, and investigates the performance and life prediction. In Phase I, Sentient will demonstrate the technical feasibility of reconstructing AM microstructure, predicting fatigue life, and detailing the plans to integrate different modules for predicting fatigue performance of AM components. Specifically, in the Phase I base period, microstructure of different AM “dogbone” coupons will be simulated and validated against physical testing. Then, the microstructure domain will be converted to finite element-based domain and mesh, followed by finite element analysis of mechanical response uniaxial tensile test in this project.