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Development of physically based simulation chain for microstructure evolution and resulting mechanical properties focused on additive manufacturing processes

Objective

Powder bed based additive manufacturing processes belong to the key technologies of the future. They allow the production of complex shaped components from powder with nearly no waste. However, to optimize the process and the properties of the components, it is fundamental to identify reasonable process windows, ensuring part integrity and stable mechanical properties without giving up too much flexibility in the additive manufacturing process.
The aim of the project is to establish a full software set, which allows the prediction of resulting mechanical properties of materials produced by additive manufacturing processes as a function of process parameters. In order to realize this task, we couple three simulation tools covering all the essential physical mechanisms on relevant length- and time-scales: The melting, initial grain structure and orientation formation of the powder particles upon laser or electron beam interaction will be simulated via Lattice-Boltzmann approaches; the initial microstructure formation during rapid dendritic solidification at micrometer-dendritic arm-spacing length and solidification time-scales will be covered by the phase-field module; the thermo-mechanical behavior of the resulting grain structure at heat-treatment-time-scales will be simulated using a crystal plasticity Finite Element simulation module.
Furthermore, the development of the simulation models will be accompanied by experiments to define essential material parameters and to calibrate, validate and optimize the derived models. SIMCHAIN is an innovative and unique approach to build a ready to use software set in order to predict the influence of various process parameters on the resulting mechanical properties during additive manufacturing processes. SIMCHAIN prepares the ground for robust process design, as an important step towards design-driven manufacturing for future aero engines parts optimized in weight and function.

Coordinator

UNIVERSITAET BAYREUTH

Address

Universitatsstrasse 30
95447 Bayreuth

Germany

Activity type

Higher or Secondary Education Establishments

EU Contribution

€ 191 700

Administrative Contact

Heike Emmerich (Prof.)

Participants (2)

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FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.

Germany

EU Contribution

€ 187 075

FRIEDRICH-ALEXANDER-UNIVERSITAET ERLANGEN NUERNBERG

Germany

EU Contribution

€ 237 530

Project information

Grant agreement ID: 326020

Status

Closed project

  • Start date

    1 July 2013

  • End date

    31 August 2016

Funded under:

FP7-JTI

  • Overall budget:

    € 946 471,40

  • EU contribution

    € 616 305

Coordinated by:

UNIVERSITAET BAYREUTH

Germany