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Title: Building blocks for a digital twin of additive manufacturing

Abstract

Properties and serviceability of additively manufactured components are affected by their geometry, microstructure and defects. These important attributes are now optimized by trial and error because the essential process variables cannot currently be selected from scientific principles. A recourse is to build and rigorously validate a digital twin of the additive manufacturing process that can provide accurate predictions of the spatial and temporal variations of metallurgical parameters that affect the structure and properties of components. Key building blocks of a computationally efficient first-generation digital twin of laser-based directed energy deposition additive manufacturing utilize a transient, three-dimensional model that calculates temperature and velocity fields, cooling rates, solidification parameters and deposit geometry. The measured profiles of stainless steel 316L and Alloy 800H deposits as well as the secondary dendrite arm spacing (SDAS) and Vickers hardness measurements are used to validate the proposed digital twin. The predicted cooling rates, temperature gradients, solidification rates, SDAS and micro-hardness values are shown to be more accurate than those obtained from a commonly used heat conduction calculation. Finally, these metallurgical building blocks serve as a phenomenological framework for the development of a digital twin that will make the expanding knowledge base of additive manufacturing usable in amore » practical way for all scientists and engineers.« less

Authors:
 [1];  [1];  [1];  [1];  [1];  [2];  [1]
+ Show Author Affiliations
  1. Pennsylvania State Univ., University Park, PA (United States)
  2. Indian Inst. of Technology (IIT), Bombay (India)
Publication Date:
Research Org.:
Pennsylvania State Univ., University Park, PA (United States)
Sponsoring Org.:
USDOE Office of Nuclear Energy (NE), Nuclear Energy University Program (NEUP); USDOE
OSTI Identifier:
1533480
Alternate Identifier(s):
OSTI ID: 1550319
Grant/Contract Number:  
NE0008280
Resource Type:
Accepted Manuscript
Journal Name:
Acta Materialia
Additional Journal Information:
Journal Volume: 135; Journal Issue: C; Journal ID: ISSN 1359-6454
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Materials science; Metallurgy & metallurgical engineering; 3D printing; Deposit geometry; Solidification parameters; Secondary dendrite arm spacing; Micro-hardness

Citation Formats

Knapp, G. L., Mukherjee, T., Zuback, J. S., Wei, H. L., Palmer, T. A., De, A., and DebRoy, T. Building blocks for a digital twin of additive manufacturing. United States: N. p., 2017. Web. doi:10.1016/j.actamat.2017.06.039.
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Knapp, G. L., Mukherjee, T., Zuback, J. S., Wei, H. L., Palmer, T. A., De, A., & DebRoy, T. Building blocks for a digital twin of additive manufacturing. United States. https://doi.org/10.1016/j.actamat.2017.06.039
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Knapp, G. L., Mukherjee, T., Zuback, J. S., Wei, H. L., Palmer, T. A., De, A., and DebRoy, T. Thu . "Building blocks for a digital twin of additive manufacturing". United States. https://doi.org/10.1016/j.actamat.2017.06.039. https://www.osti.gov/servlets/purl/1533480.
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@article{osti_1533480,
title = {Building blocks for a digital twin of additive manufacturing},
author = {Knapp, G. L. and Mukherjee, T. and Zuback, J. S. and Wei, H. L. and Palmer, T. A. and De, A. and DebRoy, T.},
abstractNote = {Properties and serviceability of additively manufactured components are affected by their geometry, microstructure and defects. These important attributes are now optimized by trial and error because the essential process variables cannot currently be selected from scientific principles. A recourse is to build and rigorously validate a digital twin of the additive manufacturing process that can provide accurate predictions of the spatial and temporal variations of metallurgical parameters that affect the structure and properties of components. Key building blocks of a computationally efficient first-generation digital twin of laser-based directed energy deposition additive manufacturing utilize a transient, three-dimensional model that calculates temperature and velocity fields, cooling rates, solidification parameters and deposit geometry. The measured profiles of stainless steel 316L and Alloy 800H deposits as well as the secondary dendrite arm spacing (SDAS) and Vickers hardness measurements are used to validate the proposed digital twin. The predicted cooling rates, temperature gradients, solidification rates, SDAS and micro-hardness values are shown to be more accurate than those obtained from a commonly used heat conduction calculation. Finally, these metallurgical building blocks serve as a phenomenological framework for the development of a digital twin that will make the expanding knowledge base of additive manufacturing usable in a practical way for all scientists and engineers.},
doi = {10.1016/j.actamat.2017.06.039},
journal = {Acta Materialia},
number = C,
volume = 135,
place = {United States},
year = {Thu Jun 22 00:00:00 EDT 2017},
month = {Thu Jun 22 00:00:00 EDT 2017}
}
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Journal Article:
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https://doi.org/10.1016/j.actamat.2017.06.039
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