SBIR-STTR Award

A new class of materials, called hierarchical materials, characterized by microstructure rich in features with different length scale, showing revolutionary properties, has emerged recently in multiple application areas, especially in the additive manufactured metals and alloys. Similarly, recent advancement in process control abilities and novel manufacturing technologies have demonstrated great potential to tailor microstructural evolution. Together these two recent developments offer ability to derive hierarchical materials with tailored microstructure; a promising pathway to engineer/design materials with remarkable properties. The lack of microstructure informed computational model to serve as material/component design tools is a critical gap in the field that the proposed research is intend to fill. In this Phase I proposal, we propose a computational model to predict mechanical properties of metals and alloys with hierarchical microstructure using generalized method of cells (GMC) on NASA’s FEAMAC/GMC platform. The proposed building of multiscale model involves two major innovations: 1) an advancement of the crystal plasticity based constitutive modeling framework from its current limited ability to model simple microstructure consisting of single crystal, poly-crystal and/or precipitation hardened metal alloys to hierarchical microstructure that consists of microstructural features of various length scales; a transformational step in the field of elastic-plastic constitutive modeling topic area, and 2) two new testing methods for characterizing elastic-plastic mechanical properties at microstructural length scales; a transformational step in the mechanical testing of materials that could enrich the multiscale model development and validation. In addition, proposed Phase I project extends the application of FEAMAC/GMC multiscale framework to a very different class of materials from its traditional composites and ceramics based material systems applications Potential NASA Applications (Limit 1500 characters, approximately 150 words) Development of metal and metallic alloys with excellent mechanical properties is extremely important for both the aerospace and aeronautical applications. For future aircraft with hybrid electric or all electric propulsion systems, advanced materials technology is needed for power components including electric machines and power cables. The proposed innovation has the potential to make positive impact on all important NASA missions and programs. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The proposed multiscale model with microstructure informed constitutive model will be a powerful useful computational tool in the the field of additive manufacture. It can be used as: 1)accurate stress analysis tool for built structural components, 2) process optimization tool that can yield optimal mechanical properties, 3) a powerful tool for realizing "material by design concept"

Many new revolutionary concepts have emerged recently as viable pathways to invent next generation high performance structural components. With the emergence of additive manufacturing (AM) and its rapid advances for metals and alloys, practical realization of these concepts is imminent. However, the lack of microstructure-informed structural analysis and design tools is a critical gap in the field that the proposed research is intended to fill. Additive Manufacturing LLC, in collaboration with Clarkson University and U.S. Naval Research Laboratory (NRL), proposes the development of a microstructure-informed multiscale structural analysis and design framework (MSADF) for the analysis, design, development, testing and validation of high performance structural components built using next generation revolutionary material systems and design concepts. The MSADF is a software solution that integrates advanced computational and experimental methods to address various challenges arising from the uncertainties associated with the complex heterogeneous microstructure. In essence, it consists of a suite of advanced constitutive models, a multiscale platform such as NASA’s FEAMAC and experimental methods to extract material properties at microstructural length scale. In the proposed Phase II R&D, microstructure informed constitutive models for AM manufactured Ti-64, ME3, and high entropy alloys will be developed and experimentally validated. The performance of MSDAF as an advanced structural analysis tool will be evaluated by performing the analysis of two AM manufactured real life components: a ME3 engine disk and a NAVY bracket. Similarly, to evaluate MSDAF as a design tool, a microstructurally optimal design of the NAVY bracket will be determined. The original and re-designed brackets will be manufactured by choosing appropriate AM process parameters, and their predicted performances will be experimentally validated. Potential NASA Applications (Limit 1500 characters, approximately 150 words) The development of metal and metallic alloys with excellent mechanical properties is extremely important for both the aerospace and aeronautical applications. For future aircraft with hybrid electric or all electric propulsion systems, advanced materials and manufacturing technology are critical for the design, development, and manufacturing of their structural components. The proposed innovation will serve as a vital design tool for its optimal design. It has the potential to make positive impact on all important NASA missions and programs. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The proposed microstructure-informed multiscale structural analysis and design framework will be a powerful tool in the field of additive manufacturing. It can be used as an accurate stress analysis to predict the structural performance of components, a reliable design tool for developing microstructurally optimal high performance components, and an R&D tool for advanced material systems.