A Physics-Based, Probabilistic Modeling Approach to Design, Manufacture, and Certify AM Components

Additive manufacturingAdditive manufacturing (AM) has captured the imagination of many in the materials, manufacturing, and designDesign communities. While AM has shown significant potential to produce complex geometries from a wide range of materials, the stringent requirements of production components necessitate advances in the way components are designed, manufactured, and certified. Dynamic properties of AM components are known to be significantly hindered by the presence of build defects. An integrated computational materials engineering (ICMEIntegrated Computational Materials Engineering (ICME)) approach to AM has been pursued through which build defects can be accurately predicted on a component location-specific basis. This capability is leading to a model-based material definitionModel-based material definition (MBMD) approach to process designDesign and control, and subsequent component qualification and certificationCertification. The development and demonstration of component and process manufacturing designDesign examples of this approach for a nickel-base superalloyNickel-base superalloy powder case application will be provided.