Probabilistic approaches for robust thermal process prediction in laser powder bed fusion additive manufacturing

Additive manufacturing (AM) has attracted much attention for its ability to fabricate nearly fully dense, geometrically complex metal components, which are often not feasible employing traditional manufacturing techniques. However, the adoption of AM for safety-critical spaceflight applications is currently hindered by the extensive fatigue testing required for the certification of AM components. The need for such strict testing derives from the current lack of understanding of the process-structure-fatigue relationship for AM. Namely, variations in the processing conditions contribute to microstructure variability, which leads to the scatter in fatigue life for parts built under different processing conditions. Thus, to gain a better understanding of this enigmatic relationship, NASA has advocated simulation-based certification, which utilizes extensive physics-based modeling and simulation, as a more cost and time-effective alternative to experimental testing.

To enable this simulation-based certification paradigm, the project aims to develop an integrated part-scale process-structure-fatigue simulation framework to predict the fatigue behavior of Inconel 718 processed by Laser Powder Bed Fusion (L-PBF) AM. This framework will comprise of three distinct models, including a coupled heat transfer and fluid flow finite element model to predict the melt pool profile, an epitaxial columnar grain growth model to predict the associated microstructure, and a coupled crystal plasticity finite element and fatigue crack incubation (FCI) model. The developed simulation tool is expected to provide accurate FCI life predictions of an AM part, given the input process parameters of an L-PBF process. Consequently, this simulation tool will address the scatter in the fatigue life of AM parts, help NASA gain a better understanding of the enigmatic process-structure-fatigue relationship, and contribute to NASA's goal of certifying parts in a more cost and time-effective manner. As a result, this will allow NASA to employ AM to improve the performance, weight, and cost of the flight for innovative space missions.

This simulation tool will address the scatter in the fatigue life of additive manufacturing (AM) parts, help NASA gain a better understanding of the enigmatic process-structure-fatigue relationship, and contribute to NASA's goal of certifying parts in a more cost and time-effective manner. As a result, this will allow NASA to employ AM to improve the performance, weight, and cost of the flight for innovative space missions.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.