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Multi-Scale Modeling and Multi-Objective Design Framework for Location-Specific Material Behavior in Additively Manufactured Components

增材制造组件中特定位置材料行为的多尺度建模和多目标设计框架

基本信息

批准号：
1825115
负责人：
Somnath Ghosh
金额：
$ 51.46万
依托单位：
Johns Hopkins University
依托单位国家：
美国
项目类别：
Standard Grant
财政年份：
2018
资助国家：
美国
起止时间：
2018-09-15 至 2022-08-31
项目状态：
已结题

来源：
https://www.nsf.gov/awardsearch/showAward?AWD_ID=1825115&HistoricalAwards=false
关键词：
Multi Scale Modeling Objective Design

项目摘要

Additive manufacturing (AM) processes for metallic materials, namely powder-bed fusion, and various powder-feed and wire-feed systems, are bringing dramatic changes to the manufacturing industry. The unprecedented agility achieved through layer-by-layer material addition is enabling near net-shape production of complex components. Despite this promise and progress, the qualification and acceptance of AM parts have been compromised by the lack of consistency in material behavior and life-limiting properties, e.g., undesirable ductility and fatigue behavior. These inconsistencies are often attributed to subtle, yet characteristic variations in the microstructure (morphology and defect structure), possibly a consequence of small perturbations in the AM process parameters. By implementing a multi-pronged approach incorporating innovative methods of integrated computational materials engineering (ICME), such as physics-based multi-scale modeling, multi-objective design, and materials characterization and testing, this research will address this shortcoming by developing a robust framework for location specific material properties and behavior in structures fabricated by AM processes. Ultimately, it will provide guidance on the links between process parameters and product performance and life, paving the acceptance of AM parts in critical applications. The research will promote the sciences associated with ICME; advance the national health, prosperity, and welfare by establishing the provenance of AM manufacturing; and secure the national defense by enabling near on-demand, net-shape production of critical parts in theaters. Collaborative partnerships with Sandia National Laboratories and JHU/Applied Physics Laboratory will be a strength of this research. Graduate students on this project will undergo multi-disciplinary training in state-of-the-art techniques in multi-scale modeling, design optimization, materials characterization and modern manufacturing processes. The collaboration with Sandia and JHU/APL will also provide them exposure to the most advance technological advancements that will help their professional career development. Two specific developmental modules will be realized for AM processed metals and alloys with polycrystalline-polyphase microstructures. They are: (i) development and implementation of parametrically homogenized constitutive/damage models (PHCMs) with explicit representation of microstructural descriptors in the form of representative aggregate microstructural parameters or (RAMPs), and (2) development of PHCM-based robust design methods for location-specific material design in structures designed, e.g., by topology optimization. Furthermore, PHCM-based simulations readily estimate the effect of variations in the microstructure on structure-scale variables like stresses, strains, strength, and even ductility or fatigue life. This will facilitate sensitivity analysis in location-specific material design in AM processed structures that have been conceptualized by design methods like topology optimization. A multi-objective function framework will be incorporated for identifying a Pareto front, defining the achievable cross-property space. The outcome of the detailed material design undertaking will be a structural-scale layout of the microstructure (in terms of RAMPs) for a robust, site-dependent distribution of macro-scale properties. This will guide the selection of AM processes parameters and routes to improve structure-material performance and life.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

金属材料的添加制造(AM)工艺，即粉床熔化，以及各种送粉和送丝系统，正在给制造业带来巨大的变化。通过逐层添加材料获得的前所未有的灵活性使复杂部件的生产近乎净值。尽管有这样的承诺和进步，但由于材料性能和限制寿命的性能(例如，不良的延展性和疲劳行为)缺乏一致性，AM部件的合格和验收受到了影响。这些不一致通常归因于微观结构(形态和缺陷结构)中细微的、但具有特征的变化，可能是AM工艺参数的微小扰动的结果。通过实施多管齐下的方法，整合集成计算材料工程(ICME)的创新方法，如基于物理的多尺度建模、多目标设计、材料表征和测试，本研究将通过开发用于AM工艺制造的结构中特定位置的材料特性和行为的健壮框架来解决这一缺陷。最终，它将为工艺参数与产品性能和寿命之间的联系提供指导，为关键应用中AM部件的接受铺平道路。这项研究将促进与ICME相关的科学；通过建立AM制造的起源来促进国家的健康、繁荣和福利；并通过在影院实现近按需、网络形状的关键部件生产来保障国防安全。与桑迪亚国家实验室和JHU/应用物理实验室的合作伙伴关系将是这项研究的优势。该项目的研究生将在多尺度建模、设计优化、材料表征和现代制造工艺方面接受最新技术的多学科培训。与Sandia和JHU/APL的合作还将使他们接触到最先进的技术进步，这将有助于他们的职业生涯发展。将实现两个具体的开发模块，用于AM加工的具有多晶-多相微结构的金属和合金。它们是：(I)开发和实施参数均匀化本构/损伤模型(PHCM)，以典型的集合体微结构参数(RAMP)的形式显式地表示微结构描述符，以及(2)开发基于PHCM的稳健设计方法，用于结构设计中的位置特定材料设计，例如通过拓扑优化。此外，基于PHCM的模拟很容易估计微结构的变化对结构尺度变量的影响，如应力、应变、强度，甚至延性或疲劳寿命。这将有助于在AM处理的结构中进行位置特定材料设计的敏感度分析，这些结构已通过拓扑优化等设计方法概念化。将纳入一个多目标函数框架，以确定帕累托前沿，定义可实现的跨物业空间。详细材料设计工作的结果将是微观结构的结构尺度布局(就坡度而言)，以实现稳健的、依赖于场地的宏观尺度特性分布。这将指导AM工艺参数和路线的选择，以改善结构-材料性能和寿命。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

期刊论文数量（5）

专著数量（0）

科研奖励数量（0）

会议论文数量（0）

专利数量（0）

A Microstructure-based porous crystal plasticity FE Model for additively manufactured Ti-6Al-4V alloys

DOI：
10.1016/j.ijplas.2022.103254
发表时间：
2022-03
期刊：
International Journal of Plasticity
影响因子：
9.8
作者：
M. Pinz;J. Benzing;A. Pilchak;S. Ghosh
通讯作者：
M. Pinz;J. Benzing;A. Pilchak;S. Ghosh

Data-driven Bayesian model-based prediction of fatigue crack nucleation in Ni-based superalloys

基于数据驱动的贝叶斯模型的镍基高温合金疲劳裂纹形核预测

DOI：
10.1038/s41524-022-00727-5
发表时间：
2022
期刊：
npj Computational Materials
影响因子：
9.7
作者：
Pinz, Maxwell;Weber, George;Stinville, Jean Charles;Pollock, Tresa;Ghosh, Somnath
通讯作者：
Ghosh, Somnath

A Crystal Plasticity Model for Porous HCP Crystals in Titanium Alloys under Multiaxial Loading Conditions