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Completed TRL 3 (started at 2, targeting 3)
Combine part-level FEM model of residual stresses with CALPHAD-based phase transformation model to predict deformation and cracking due to thermal stresses, as well as precipitation of brittle intermetallic compounds, during the AM building process. Predict part level deformation and cracking during the Additive Manufacturing process. Optimize process parameters of the additive manufacturing process to reduce deformation, cracking, and residual stress and to mature additive manufacturing for part-level flight design applications.
One of the challenges in additive manufacturing is that residual stresses induced during the build process can affect dimensional stability and, at the extreme, lead to fracture and failure. The ability to rapidly screen new designs for additive manufacturing, at the part-level, will dramatically accelerate the iterative design process for this technology, and may disrupt the trade space for existing technologies.
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