This research program addresses the challenges of process optimization through modeling and simulation. Key quality indicators for AM-made parts include: dimensional tolerances, residual stresses/deformation, residual porosity (volume fraction/size/distribution), microstructure (phase content, grain size/morphology/distribution), chemistry and surface finish. The vast number of interdependent process parameters in AM significantly limits the efficacy of a conventional trial-and-error approach to process optimization and design.

Ripple-angle θ comparison of a track with process parameter 195 W and 800 mm/s, (a) experimental result, (b) numerical result.

Measured and predicted 3D profiles and the associated transverse cross-section contours of the multi-track/layer builds (DED).

Advanced multi-physics numerical models of various AM technologies developed at MSAM are being enhanced and validated to offer the potential to significantly compliment the conventional trial-and-error method, leading to breakthroughs in process optimization and technology development.

The Coupled Structural Toplogy Optimization and Support Topology Optimization for Laser Powder Bed Fusion (L-PBF) Additive Manufacturing.

In addition, different materials and different AM processes pose different manufacturing constraints on the lattice structures that can be obtained with acceptable quality. There is a critical need to link lattice structure design with AM capabilities and constraints to ensure that the designed lattice structure can be achieved for a given process technology and meet the designed objectives. MSAM researchers are working on this important research topic.

Simulated randomly packing powder bed (a) and the associated thermal field distribution (b)