Predicting deformation and stress as a function of additive manufacturing process parameters for Europa drill

We will combine part-level FEM model of residual stresses with phase-field transformation model to predict deformation and cracking due to thermal stresses from the AM building process. Next steps include fully-coupled, part-level thermo-mechanical simulation of the additive manufacturing process for assessing feasibility of employing an additive part on mission, and development of journal article and infusion into Glassgen's computational materials program, NESC and OSMA NDWG, STMD Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), AMSII.

To use additive manufacturing for a Europa drill bit we need to be able to perform WHOLE part simulations tied across scales: microstructure and macro that predict deformation and cracking. Current state-of-the-art is simulation of only partial parts. Separate models are used at different scales (microstructure, melt-pool, larger thermal) without integration. We will scale & automate layer-by-layer whole part simulation, add advanced physics of evaporation, and overlay microstructural metal phase modeling.

This is early/mid-stage (TRL 2) — 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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