Recent Contracts

Innovative Approach to Rapidly Qualify Ti-6Al-4V Metallic Aircraft Parts Manufactured by Additive Manufacturing (AM) Techniques – (Phase II). N68335-15-C-0211 (NAVAIR) 2017-2019; (Phase I) 2015-2016 

Additive Manufacturing (AM) is of increasing interest for production of Naval aircraft components. The geometric complexity, mechanical properties, and cost competitiveness for small lot production make AM techniques particularly suited for Ti-6Al-4V aircraft applications. However, microstructural and material property variability issues inherent to AM make rapid qualification of metal AM parts difficult. 3DSIM has significant experience with thermal modeling of metal laser sintering of Ti64, including prediction of Ti64 phases and phase transitions. These models have been validated experimentally over several years of research at the University of Louisville. To fully predict microstructural evolution in Ti64, accurate prediction of the initial crystal microstructure and subsequent solid state phase transitions is required. However, accurate prediction of initial microstructure is difficult to validate using Ti64 due to solid state phase transformations. To address Phase I objectives, 3DSIM proposes to: develop algorithms which predict microstructural characteristics, including phase evolution, grain size and grain orientation, from metal AM thermal histories; conduct validation of the predicted microstructural characteristics by comparison with as-built microstructures for metal laser sintered CoCrMoC parts; and conduct validation of the predicted microstructural characteristics by comparison with as-built microstructures for LENS-deposited Ti64 parts.

Predictive Modeling Tools for Metal-Based Additive Manufacturing: A Composable Simulation Model for Metal Powder-bed Fusion Additive Manufacturing Processes – (Phase II). 70NANB16H191 (NIST) 2016-2018; (Phase I) 2015-2016 

Additive manufacturing lacks efficient, composable physics-based computational frameworks to predict quality and performance for arbitrary geometry, orientation, location and process parameter combinations. A new set of composable computational tools capable of accurately predicting the geometrical accuracy, residual stress and microstructure of the parts made using metal based AM has been developed. The tool(s) demonstrate scaling and composability of models to support geometry-independent reusability while providing a range of parameter values (e.g. user-defined build orientation, laser power, scan speed, hatch pattern, recoat time, material properties, powder layer thickness, choice of mesh motifs, and more) supporting reliability and accuracy.

Rapid, Low Cost, High-quality Component Qualification Using Multi-scale, Multi-physics Analytical Toolset for the Optimizaation of Metal Additive Manufacturing Process Parameters – (Phase I). N68335-17-C-0021, (NAVAIR), (Phase I) 2016-2017


Completed contracts, including academic contracts contributing to 3DSIM Development:

  • Acoustic Resonance Techniques for Qualification of Metal AM – Office of Naval Research (ONR), 2014-2017
  • Development of Distortion Prediction and Compensation Methods for Metal Powder-Bed Additive Manufacturing – America Makes via GE Global Research,  2014-2016
  • Measurement Science for Advanced Manufacturing (MSAM) – National Institute of Standards and Technology (NIST) via America Makes, 2014-2015
  • Data Management Tools for Metallic Additive Manufacturing – Phase I, Air Force, 2015-2016
  • Ti64/CoCrMo Powder Properties Sensitivity Study – NAVAIR, 2015
  • Development and Validation of a 3D Simulation Architecture for High-efficiency Modeling of Additive Manufacturing Technologies – Defense Advanced Research Projects Agency (DARPA) – 2014-2015
  • CoCrMo Process Parameters Sensitivity Study – GE Power & Water, 2014-2015
  • Computational Process Model Development – Direct Digital Manufacturing (DDM) Phase II SBIR, Air Force Research Laboratory (AFARL) via Mound Laser & Photonics Center, 2013-2015; (Phase I, 2012)
  • Rapid Qualification Methods for Powder Bed Direct Metal AM Processes – America Makes via Case Western Reserve, 2013-2015
  • Modeling and Experimental Validation of the Selective Laser Melting Process for Nickel-Based Superalloys – National Institute of Standards and Technology (NIST), 2013-2015
  • Collaborative Research:  Modeling and Characterization of Transition Joints made by Friction Surfacing based Additive Manufacturing (FSAM) – National Science Foundation – (NSF), 2012-2015
  • Methods to rapidly optimize materials for Additive Manufacturing processes –  Air Force Phase I SBIR, Air Force Research Laboratory (AFRL) via Mound Laser & Photonics Center, 2013-2014
  • Modeling and Closed Loop Control of Multi-Material Ultrasonic Consolidation – Office of Naval Research (ONR), 2011-2014
  • Modeling of DMLS Ti6/4 Arbitrary Powders – Air Force Research Laboratory (AFRL) via Mound Laser & Photonics Center, 2013
  • Additive Manufacturing Research — Office of Naval Research, 2010-2013.
  • Further Development and Transition of a Novel, Integrated Ultrasonic Consolidation, Fused Deposition Modeling and Direct Write System – Office of Naval Research (ONR), 2010-2011

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