Reliability Centered Additive Manufacturing Design Framework
Navy SBIR FY2015.2


Sol No.: Navy SBIR FY2015.2
Topic No.: N152-109
Topic Title: Reliability Centered Additive Manufacturing Design Framework
Proposal No.: N152-109-0762
Firm: Analatom Incorporated
3210 Scott Blvd.
Santa Clara, California 95054-3007
Contact: Patrick Harris
Phone: (408) 980-9516
Abstract: Analatom and Applied Research Laboratory Penn State University proposes to apply modern concepts from simulation, corrosion modeling, control theory along with Prognostics Health Management (PHM) in the development of an end-to-end, prognostics-based Additive Manufacturing (AM) materials assessment architecture. The project team will consider four potential levels of implementation that includes molecular dynamics simulation of material corrosion and cracking defects, AM advanced statistical process control and monitoring, enhancing end-use items with corrosion, strain sensors and operational environment assessment techniques. Selection of appropriate applied levels architecture will be dependent on the desired target application. Emphasis will be placed on developing a flexible computational framework that incrementally learns optimal parameters and discerns parameter sets that lead to degradation profiles. During Phase I we will develop an approach for a Reliability-Centered AM Computational Design Framework (RCAM CDF) focused on selective laser melt (SLM) AM processes for metallic components. This design framework will initially include minimum part geometry for a load bearing coupon structure, with defect types and densities induced by design of the AM build fabrication process, followed by laser Computed Tomography (CT) inspection of the components, with subsequent in situ structural monitoring sensors (corrosion, strain) to record the accelerated lifetime and fatigue testing.
Benefits: With improved understanding of process control and design space for AM processes, the overall benefits of AM could be realized. This vision would further expand the utilization of AM technologies by incorporating a method to assess the reliability, inspectability and repairability to AM generated parts of their operational lifetime. The need for increased reliability will be of critical importance for the commercialization of Additive Manufacturing technologies for the DoD, aerospace, and numerous other industries as future trends move to replace the traditional commercial pilot with a ground-based pilot. A reliability-based, computational design framework will find application in virtually all future design and development activities, and ultimately will become an essential component for all digital designs incorporating AM fabrication processes.

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