Sentient proposes to develop a physics-based integrated computational materials engineering (ICME) framework (DigitalClone Additive) to support the rapid qualification of AM components, including microstructural features, and macro-level fatigue performance. Sentient will apply their extensive experience with the DigitalClone technology to conduct multiscale modeling of AM process and resulting microstructure and fatigue life. Sentients DigitalClone is a physics-based computational modeling and design framework that simulates the microstructure of different components and their behavior, calculates internal stresses caused by different applied loading conditions, accumulates internal damages resulting in crack nucleation and propagation, and investigates the performance and life prediction. In Phase I, Sentient will demonstrate the technical feasibility of reconstructing AM microstructure, predicting fatigue life, and detailing the plans to integrate different modules for predicting fatigue performance of AM components. Specifically, in the Phase I base period, microstructure of different AM dogbone coupons will be simulated and validated against physical testing. Then, the microstructure domain will be converted to finite element-based domain and mesh, followed by finite element analysis of mechanical response uniaxial tensile test in this project.
Benefit: Additive Manufacturing (AM) shows great promise for reducing development time and cost for a variety of naval and aerospace products. However, AM processes and components must be formally qualified before their extensive use. The current qualification approach for AM components is built-specific, requiring extensive empirical testing, including expensive component-level and system-level testing. Therefore, the US NAVY is seeking for a comprehensive toolset to predict the fatigue life of flight-critical metallic components fabricated by additive manufacturing. The proposed modeling technique can play a key role in reducing the time and cost of qualifying critical parts fabricated by AM at the point of need.
Keywords: microstructure, microstructure, DigitalClone Digital Twin, additive manufacturing, reduce cost, fatigue life and performance, physics based computational modeling, reduce development time
