{"project":{"acronym":"","projectId":91509,"title":"Control of Variability in the Performance of Selective Laser Melting (SLM) Parts through Microstructure Control and Design","primaryTaxonomyNodes":[{"taxonomyNodeId":10880,"taxonomyRootId":8816,"parentNodeId":10879,"level":3,"code":"TX12.4.1","title":"Manufacturing Processes","definition":"This area covers innovative physical manufacturing processes for rapid production, reduced cost, increase accuracy, and defect reduction.","exampleTechnologies":"Additive manufacturing of metallics and nanofiber/fiber /ceramic matrix based composites, especially for large structures; in-space fabrication, assembly and repair; advanced casting and injection molding of metal components, including amorphous metals, metal matrix composites and high-strength aluminum alloys; advanced subtractive manufacturing processes including wire-Electrical Discharge Machining (EDM), water jetting and surface finishing; advanced laminate or sheet metal fabrication.","hasChildren":false,"hasInteriorContent":true}],"startTrl":2,"currentTrl":4,"endTrl":4,"benefits":"This will represent a major contribution to the existing literature on modeling SLM processes which solely focuses on predicting the thermal history. Furthermore, the outcomes of the project will be used to build a repository of process parameters and material properties for NiTi SMAs, and will contribute to increasing the MRL for the Selective Laser Melting of SMAs from its current TRL 1 to TRL 3.","description":"The high variability and low repeatability of metal parts produced using Additive Manufacturing (AM) represent a major barrier in getting AM into the mainstream. Efforts to characterize (and eventually reduce) variability start by predicting the microstructure and performance properties of AM parts. In this proposal, we propose a Phase Field Modeling to characterize the microstructure evolution in Selective Laser Melting (SLM) given the temperature history. The majority of works in the literature focus on predicting the thermal history, and none of these works capture microstructure evolution. In contrast, we will experimentally characterize the thermal history using a custom integrated monitoring system, and then use Phase Field Models to computationally predict the microstructure of the fabricated part. Furthermore, we will capture one layer of uncertainty by modeling the temperature history as a time-based stochastic process with measurement errors. Next, we will conduct systematically designed experiments to validate the predicted microstructures, and identify key process parameters and higher order interactions that significantly contribute to the variability of the microstructure. The outcome of these experiments will be used to construct a Response Surface Model to optimize process parameters (e.g. laser power and scanning speed) such that we achieve desired properties while keeping variability at a minimum and increasing repeatability. The proposed framework will be validated using Nickel Titanium Shape Memory Alloys as a model material that is both highly applicable in aerospace applications and whose macroscopic properties are very sensitive to small variations in process parameters and microstructures. The key aspects of innovation in this project lie in proposing a phase field model-based novel approach to characterize microstructure evolution in SLM, and further integrating this with stochastic processes and uncertainty quantification models to identify and control variability sources. This will represent a major contribution to the existing literature on modeling SLM processes which solely focuses on predicting the thermal history. Furthermore, the outcomes of the project will be used to build a repository of process parameters and material properties for NiTi SMAs, and will contribute to increasing the MRL for the Selective Laser Melting of SMAs from its current TRL 1 to TRL 3.","startYear":2015,"startMonth":1,"endYear":2018,"endMonth":1,"statusDescription":"Completed","principalInvestigators":[{"contactId":5869,"canUserEdit":false,"firstName":"Alaa","lastName":"Elwany","fullName":"Alaa Elwany","fullNameInverted":"Elwany, Alaa","primaryEmail":"elwany@tamu.edu","publicEmail":false,"nacontact":false}],"programDirectors":[{"contactId":84634,"canUserEdit":false,"firstName":"Claudia","lastName":"Meyer","fullName":"Claudia M Meyer","fullNameInverted":"Meyer, Claudia M","middleInitial":"M","primaryEmail":"claudia.m.meyer@nasa.gov","publicEmail":true,"nacontact":false}],"programExecutives":[{"contactId":84634,"canUserEdit":false,"firstName":"Claudia","lastName":"Meyer","fullName":"Claudia M Meyer","fullNameInverted":"Meyer, Claudia M","middleInitial":"M","primaryEmail":"claudia.m.meyer@nasa.gov","publicEmail":true,"nacontact":false}],"programManagers":[{"contactId":183514,"canUserEdit":false,"firstName":"Hung","lastName":"Nguyen","fullName":"Hung D Nguyen","fullNameInverted":"Nguyen, Hung D","middleInitial":"D","primaryEmail":"hung.d.nguyen@nasa.gov","publicEmail":true,"nacontact":false}],"projectManagers":[{"contactId":445731,"canUserEdit":false,"firstName":"Stephen","lastName":"Smith","fullName":"Stephen W Smith","fullNameInverted":"Smith, Stephen W","middleInitial":"W","primaryEmail":"s.w.smith@nasa.gov","publicEmail":true,"nacontact":false}],"website":"https://www.nasa.gov/directorates/spacetech/home/index.html","libraryItems":[],"transitions":[{"transitionId":75500,"projectId":91509,"partner":"Other","transitionDate":"2015-01-01","path":"Advanced From","relatedProjectId":146006,"relatedProject":{"acronym":"","projectId":146006,"title":"Mechanically dynamic nanocomposite aerogels using cellulose nanocrystals","startTrl":1,"currentTrl":3,"endTrl":3,"destinations":[{"lkuCodeId":1543,"code":"EARTH","description":"Earth","lkuCodeTypeId":526,"lkuCodeType":{"codeType":"DESTINATION_TYPE","description":"Destination Type"}}],"startYear":2013,"startMonth":2,"endYear":2013,"endMonth":10,"statusDescription":"Completed","website":"","program":{"acronym":"GRC CIF","active":true,"description":"
Tthe goal of the Center Innovation Fund is to stimulate and encourage creativity and innovation in addressing the technology needs of NASA and the Nation. The GRC Center Innovation Fund is intended to provide GRC Civil Servants, potentially partnering with external organizations and other NASA Centers, with the opportunity to develop new ideas toward this goal, and to pursue their intellectual growth in areas that are deemed to be of strategic importance to the Center. The projects are high payback, highly innovative research proposals that could significantly impact future GRC programs.
","parentProgram":{"acronym":"CIF","active":true,"description":"
Through the Center Innovation Fund, the Space Technology Mission Directorate allocates a small portion of the NASA workforce and procurement budget to internal research and development to feed early stage innovation in technology and exploration. Activities with in the Center Innovation Fund are proposed and led by NASA scientists and engineers. These activities and creative initiatives pursue emerging technologies that leverage talent and capabilities at the NASA Centers.
","programId":64,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36643,"title":"Center Innovation Fund"},"parentProgramId":64,"programId":162,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36645,"title":"Center Innovation Fund: GRC CIF"},"lastUpdated":"2023-9-20","releaseStatusString":"Released","viewCount":35,"endDateString":"Oct 2013","startDateString":"Feb 2013"},"infoText":"Advanced from another project within the program","infoTextExtra":"Another project within the program (Mechanically dynamic nanocomposite aerogels using cellulose nanocrystals)","dateText":"January 2015"},{"transitionId":75501,"projectId":91509,"transitionDate":"2018-01-01","path":"Closed Out","details":"Experimentally capture the thermal history during Selective Laser Melting (SLM). This will be achieved by using 2-wavelengths pyrometry to monitor the temperature at the top layer of the powder-bed fusion SLM process, and using this as boundary condition to an FEA Comsol model to predict the 3-dimensional thermal history, with the consideration of variability. The thermal history then is used in the materials modeling to predict the microstructure and eventually selective properties. •Conduct systematically designed uncertainty quantification (UQ) frameworks to identify key sources of variability in the predicted microstructures. The UQ framework will specifically include three main tasks: (a) constructing computationally efficient surrogate models, (b) conducting model calibration, and (c) Sensitivity Analysis. •Validate the proposed methodology using Ni-rich Shape Memory Alloy (SMAs) as a model material, properties of which are very sensitive to changes in the microstructure. This will help amplify the variability and help identify the sources of variability.2. MOST Related to physics-based microstructure modeling •Predicted the planar vs dendritic growth during SLM of Inconel 718. Related to microstructural characterization •Completed an initial statistical study of the tensile thermomechanical behavior in AM NiTi printed using 35μm and 120μm hatch distances in order to determine how variability in shape memory behavior translates to mechanical behavior. •Performed atom probe tomography on 35μm and 120μm hatch distance samples to obtain information on the morphology and composition of small, <5nm precipitates Related to uncertainty quantification •Development of a multivariate uncertainty propagation framework using generalized Polynomial Chaos Expansions to assess the variability of different thermal outputs of a FEM L-PBF simulation model.","infoText":"Closed out","infoTextExtra":"","dateText":"January 2018"}],"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"program":{"acronym":"STRG","active":true,"description":"
\tThe Space Technology Research Grants Program will accelerate the development of "push" technologies to support the future space science and exploration needs of NASA, other government agencies and the commercial space sector. Innovative efforts with high risk and high payoff will be encouraged. The program is composed of two competitively awarded components.
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