Subproject for Balogun: Rapid Qualification & Certification (RQC) Using Calorimetric, Optical, Mechanical, Microstructural (COMM) Validation

The objective is to advance the state-of-the-art in additive manufacturing of metallic parts rooted in a model and simulation-based approach to deliver components with consistent low variance properties. The approach is to use physics based simulation to model the additive manufacturing (AM) processes, laser melt deposition and selective laser melting. Rationale: melt fusion of metal powders is the core process in additive manufacturing of metallic parts. The quality of these metal powders (and their solidification) directly impacts the performance of the finished products. Because of the large surface-to-volume ratio in fine powders, the prevalent problem of using metal powders is surface contamination, in particular, oxidation that affects not only the kinetics of sintering, but also the mechanical properties of the component. To model such a process induced by, e.g., laser radiation, requires one to consider diffusion under dynamic heating profiles both spatially (microns to cm) and temporally (picoseconds to seconds) in light of parameter uncertainties. The physical realization of these processes poses another set of challenges ranging from real-time tool path generation and control to develop new equipment insights for enhanced geometric part dimensional accuracy, consistent properties, and surface finish.