Modeling of Microstructural Irregularities in Additively Manufactured Materials

The objectives of this SBIR include the development of a modeling framework to predict mechanical properties of as-manufactured AM parts accounting for microstructure. The final product will (1) accept a reconstruction of the interior and exterior geometry of structural component including accurate 3D measurement of defects using x-ray computed tomography (CT); (2) allow for input of material properties from experimental evaluation, and (3) conduct finite element simulation of the structural component to predict its stiffness and strength/fatigue behavior. Due to observed effects of defect location, size and shape upon structural behavior, modeling of critical discrete defects will be targeted. Phase I effort will focus on developing the concepts needed to perform accurate analysis of the structural behavior. These technical objectives are in-line with our general philosophy of integrated structural methods and prognostics, including: high-resolution nondestructive evaluation (NDE) enabling accurate 3D measurement of defect location and size with automated transition to structural models; measuring the material properties meeting the material input data requirements for analysis of structural integrity; comprehensive structural analysis platform able to capture effects of defects and predict component structural integrity. We developed unique capabilities and novel solution methods in all these critical areas and their effective integration.