Predicting Deformation and Cracking as a Function of additive manufacturing process parameters, Year 1

Completed TRL 3 (started at 2, targeting 3)

Description

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.

Benefits

The goal is to be able to optimize process parameters of the additive manufacturing process to reduce deformation, cracking, and residual stress leading to mature additive manufacturing for part-level flight design applications. Currently this optimization is done experimentally by manufacturing samples under different parameter settings and then performing stress testing. This is a slow and expensive process. This task is improving simulation models to predict part level deformation and cracking during the Additive Manufacturing process which will reduce the design time of additively manufactured components and will enable machine learning process optimization resulting in increased part reliability.

Details

Technology area	Materials, Structures, Mechanical Systems, and Manufacturing > Manufacturing > Manufacturing Processes
Program	Center Innovation Fund: JPL CIF (JPL CIF)
Lead organization	Jet Propulsion Laboratory, Pasadena, CA
Start date	2017-10-01
End date	2018-09-30

Project contacts

Listed on TechPort itself — the most direct way to ask about this specific project.

Richard A Otis — richard.otis@jpl.nasa.gov

How to get involved

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.

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