Minimizing Residual Stresses in Metal Additive Manufacturing using Multiscale and Multiphysics Topology Optimization

The proposed project aims at developing a tool for multiscale, multiphysics, time-dependent problems (TA 11.3.7.1). It is hypothesized that that the overall geometry of structures produced by additive manufacturing (AM), affects the residual stresses. The goal of the tool will be to produce a constrained geometry that minimizes the residual stresses caused by AM, without losing overall stiffness from an applied loading. The method proposed will make use of NASA's micromechanics analysis code (MAC) that implements the generalized method of cells (GMC) to model the structure accounting for the heterogeneous and anisotropic effects of AM at the microscale. At the macroscale, time-dependent heat transfer methods will be used alongside finite element methods (FEM) to quantify the final residual stresses and deformation. A topology optimization (TO) method will then be wrapped around this to optimize the geometry for minimum residual stresses. The tool proposed could be used for analyzing, designing and optimizing structures manufactured with AM methods. It will help mitigate some of the negative side effects of AM (residual stresses) while still maintaining the advantages of AM. The optimized structure should have greater stiffness to weight ratios (critical for flight missions), and due to the minimal residual stresses produced, should be sufficiently strong enough to last longer (resistance to unexpecting cracking and fatigue) than other structures produced by AM methods. These structures may be used as a critical component in space exploration missions. The tool will not be constrained to AM processes but can be generalized to fiber-reinforced composites, and other structures such as metal foams.

The tool proposed could be used for analyzing, designing and optimizing structures manufactured with AM methods. It will help mitigate some of the negative side effects of AM (residual stresses) while still maintaining the advantages of AM. The optimized structure should have greater stiffness to weight ratios (critical for flight missions), and due to the minimal residual stresses produced, should be sufficiently strong enough to last longer (resistance to unexpecting cracking and fatigue) than other structures produced by AM methods. These structures may be used as a critical component in space exploration missions. The tool will not be constrained to AM processes but can be generalized to fiber-reinforced composites, and other structures such as metal foams.

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