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Additive Manufacturing of Metals: Modeling Applications in Material and Part Qualification

Kyle Johnson, Sandia National Laboratories

Theron Rodgers, Sandia National Laboratories

Lauren Beghini, Sandia National Laboratories

Recent advances in Additive Manufacturing (AM) technology have revolutionized manufacturing and offer many advantages such as increased geometric complexity, rapid prototyping and production, and locally-tailored properties. However, barriers to part qualification still exist in the form of defects such as porosity and lack of fusion zones, high residual stresses, and microstructures that deviate significantly from those observed in wrought materials. Modeling offers a pathway to predict some of these features and provide insight into the associated phenomena, thereby offering opportunities for process optimization as well as designs accounting for material variability and uncertainty.

This symposium will serve as an avenue for researchers in AM to present their latest results addressing material and part qualification in metal AM processes. Investigations into process-structure-property-performance (PSPP) relationships resulting from intense local heating and thermal gradients, fluid flow from molten and vaporized metal, rapid solidification, recrystallization, and solid-state phase transformations are encouraged. Also of interest are reduced order models for efficiently predicting phenomena at the part scale and process optimization for specific quantities of interest. All numerical discretization methods are welcome.

Planned technical sessions include, but are not limited to:

·     Residual Stress Evolution and Control

·     Defect Prediction

·     As-built Material and Part Performance

·     Microstructure Prediction and Optimization

·     Reduced Order Models for Efficient Part-Scale Simulation