Optimal Design for Metal Additive Manufacturing: An Integrated Computational Materials Engineering (ICME) Approach

JOM, vol. 72, pp. 1092–1104

Abstract

Abstract We present our latest results on linking the process–structure–properties–performance (PSPP) chain for metal additive manufacturing (AM), using a multi-scale and multi-physics integrated computational materials engineering (ICME) approach. The abundance of design parameters and the complex relationship between those and the performance of AM parts have so far impeded the widespread adoption of metal AM technologies for structurally critical load-bearing components. To unfold the full potential of metal AM, establishing a full quantitative PSPP linkage is essential. It will not only help in understanding the underlying physics but will also serve as a powerful and effective tool for optimal computational design. In this work, we illustrate an example of ICME-based PSPP linkage in metal AM, along with a hybrid physics-based data-driven strategy for its application in the optimal design of a component. Finally, we discuss our outlook for the improvement of each part in the computational linking of the PSPP chain.

Authors 7

1. S. Amir H. Motaman corresponding Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany

2. Fabian Kies Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany

3. Patrick Köhnen Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany

4. Maike Létang Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany

5. Mingxuan Lin Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany

6. Andrey Molotnikov

   RMIT University

   Affiliation as printed

   Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, Australia

   Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, VIC, Australia

7. Christian Haase corresponding Aachen ICME Group Steel Institute

   RWTH Aachen University

   Affiliation as printed

   ICME Group, Steel Institute, RWTH Aachen University, Aachen, Germany