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An Efficient Multi-Scale Simulation Architecture for the Prediction of Performance Metrics of Parts Fabricated Using Additive Manufacturing

  • Symposium: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control
  • Published:
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Abstract

In this study, an overview of the computational tools developed in the area of metal-based additively manufactured (AM) to simulate the performance metrics along with their experimental validations will be presented. The performance metrics of the AM fabricated parts such as the inter- and intra-layer strengths could be characterized in terms of the melt pool dimensions, solidification times, cooling rates, granular microstructure, and phase morphologies along with defect distributions which are a function of the energy source, scan pattern(s), and the material(s). The four major areas of AM simulation included in this study are thermo-mechanical constitutive relationships during fabrication and in-service, the use of Euler angles for gaging static and dynamic strengths, the use of algorithms involving intelligent use of matrix algebra and homogenization extracting the spatiotemporal nature of these processes, a fast GPU architecture, and specific challenges targeted toward attaining a faster than real-time simulation efficiency and accuracy.

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Acknowledgments

The authors would like to thank Dr. Khalid Rafi at Nanyang Technological University, Mr. Hengfeng Gu at North Carolina State University, and Dr. Haijun Gong and Mr. Ashabul Anam at University of Louisville for their insightful discussions with the authors. Funding: The authors would like to gratefully acknowledge the funding support from the Office of Naval Research (N000141110689 & N000140710633), the Air Force Research Laboratory (as a subcontractor to Mound Laser & Photonics Center on three SBIR projects), the National Institute of Standards and Technology (70NANB12H262), and the National Science Foundation (CMMI-1234468).

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Authors and Affiliations

  1. Department of Mechanical Engineering, J.B. Speed School of Engineering, University of Louisville, Louisville, KY, 40292, USA

    Deepankar Pal (Assistant Professor)

  2. Research & Development Division, 3DSIM LLC, 201 E. Jefferson St., Louisville, KY, 40202, USA

    Nachiket Patil (Senior Research Engineer), Kai Zeng (Graduate Research Assistant) & Chong Teng (Senior Research Engineer)

  3. Department of Industrial Engineering, J.B. Speed School of Engineering, University of Louisville, Louisville, KY, 40292, USA

    Kai Zeng (Graduate Research Assistant) & Brent Stucker (Professor)

Authors
  1. Deepankar Pal
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  2. Nachiket Patil
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  3. Kai Zeng
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  4. Chong Teng
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  5. Brent Stucker
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Corresponding author

Correspondence to Deepankar Pal.

Additional information

Manuscript submitted December 31, 2014.

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Pal, D., Patil, N., Zeng, K. et al. An Efficient Multi-Scale Simulation Architecture for the Prediction of Performance Metrics of Parts Fabricated Using Additive Manufacturing. Metall Mater Trans A 46, 3852–3863 (2015). https://doi.org/10.1007/s11661-015-2903-7

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  • DOI: https://doi.org/10.1007/s11661-015-2903-7

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