Prediction of Microstructure Evolution in DMLM processed Inconel 718 with Part Scale Simulation

The objective of this research is to develop a part-scale process-microstructure simulation tool to predict the microstructure evolution including phase stability of Inconel 718 processed by powder bed laser fusion process integrating finite element method (FEM) thermal analysis, CALPHAD-based phase transformation simulation (CALPHAD: Calculation of Phase Diagrams),and grain texture modeling. A great interest of NASA is improving the performance of structural components for high temperature applications such as jet engine parts, where both creep and strength are critical and need to be designed for. The methodology developed in the proposed research will introduce an efficient way to govern the in-situ microstructure evolution during laser process, which will directly drive the optimization for better mechanical properties of AM parts. It is expected that the achievement of the proposed research will have significant impact on NASA’s strategic plan to employ AM to drastically improve the performance, weight, and cost of flight hardware for space mission.