Phase II Amount
$1,098,389
The utilization of additive manufacturing for fatigue rated components is severely hampered by the lack of accurate tools for prediction of fatigue life in additively manufactured parts as a function of material, microstructure, residual stresses, defects, etc that arise as part of the AM process. In the proposed effort, MRL will build on the fatigue modeling tools demonstrated in Phase I to demonstrate part-scale fatigue modeling of AM components using a multi-scale hybrid modeling approach. The results of the Phase II effort will further efforts to accurately predict AM fatigue life and support efforts towards certification of critical components produced by AM.
Benefit: While additive manufacturing is a disruptive technology with significant potential for reducing weight, increasing performance, and saving energy across multiple sectors, full adoption cannot be made without accurate estimation of the performance under fatigue loading. Without such tools, all implemented solutions will be sub-optimal and may not leverage the unique possibilities for additive manufacturing in terms of materials and geometric novelty. Accurate fatigue strength prediction will facilitate use in air, space, and ground vehicle lightweighting, with concomitant reductions in emissions and fuel usage. It will also facilitate increased utilization in the medical field, where patient-specific solutions with tailored mechanical properties show great promise for better patient outcomes.
Keywords: Crystal Plasticity, life prediction, microstructure informatics, Fatigue Strength, additive manufacturing, multi-scale modeling, ICME
