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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.

Field of science

  • /engineering and technology/mechanical engineering/manufacturing engineering/additive manufacturing
  • /natural sciences/computer and information sciences/software
  • /natural sciences/physical sciences/theoretical physics/particles
  • /natural sciences/physical sciences/optics/laser physics

Call for proposal

SP1-JTI-CS-2012-02
See other projects for this call

Funding Scheme

JTI-CS - Joint Technology Initiatives - Clean Sky

Coordinator

UNIVERSITAT 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)

FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V.
Germany
EU contribution
€ 187 075
Address
Hansastrasse 27C
80686 Munchen
Activity type
Research Organisations
Administrative Contact
Maximilian Steiert (Mr.)
FRIEDRICH-ALEXANDER-UNIVERSITAET ERLANGEN-NUERNBERG
Germany
EU contribution
€ 237 530
Address
Schlossplatz 4
91054 Erlangen
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Franziska Müller (Ms.)