Sunday, January 15, 2017 6:52:13 PM
"...To that effect, a suite of integrated computational materials engineering (ICME) models are being developed and implemented to develop the knowledge needed to drive the desired changes. But, models cannot be relied upon solely to achieve this rapid qualification approach. Targeted testing must be performed in order to develop a deep understanding of the model capabilities in order to frame the range of applicability. Targeted testing and in-process sensing must be performed in order to inform the models such that they can be calibrated, validated, and verified. The models must be framed in a probabilistic setting in order to ascertain the sensitivity of the predictions to the parameters of interest and to understand the expected variability as a result of the random nature of the inputs. At the same time, in situ process monitoring is being implemented in order to provide evidence in the form of In-Process Quality Assurance™ (IPQA®) that the process is under control for the purpose of certification. It is this suite of activities and the knowledge generated that makes the rapid qualification possible. The goal is to be able to reduce the qualification process time by 40 % and costs by 20 %..."
"...The framework presented in Fig. 2 contains within the dotted line box the set of ICME tools needed to achieve rapid qualification. A micro-model which describes the melting of the powder and solidification of the material to form the part, and a macro-model which describes the residual stresses that build up as a result of the rapid cooling and solidification of the material. Both of these models were developed by ESI to simulate the powder-bed laser additive manufacturing process. QuesTek® developed the models to predict the material microstructure that develops as a result of the heat treatment process along with a model to predict the tensile properties of the resulting microstructure. Sigma Labs and Stratonics developed techniques for in situ monitoring of the process. Sigma Labs uses a pyrometer to monitor the response of the melt pool whereas Stratonics uses a digital imaging technique to capture the response of the melt pool. Furthermore, Sigma Labs has implemented their In-Process-Quality-Assurance (IPQA) technologies to determine if and when the process may be out of control. Honeywell is implementing non-destructive evaluation (NDE) methods to determine if defects that may develop in the part during the manufacturing process can be detected by inspection. SwRI® is developing the probabilistic design and uncertainty quantification tools to be able to define the minimum predicted material property and risk derived from the novel manufacturing process. Lastly, Honeywell is developing the overall rapid qualification framework to bring all these technologies together in order to demonstrate an acceptable means of compliance with extensive use of simulation models.
GLTA
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