Prediction and Control of Selective Laser Melting Product Microstructure

Despite the rapid commercialization of additive manufacturing technology such as selective laser melting, SLM, there are gaps in models for material microstructure and property prediction that slow qualification and certification. Improvements in coupling microstructure prediction models to local process conditions, validation, and control of material microstructure are required to mature the state of the art. To address these needs, CFDRC in partnership with Arizona State University will develop and apply modeling and simulation tools for prediction and control of microstructure in SLM fabricated parts. The Phase I effort will establish critical software elements, modeling methodology, and experimental data analysis required for Phase II. We will demonstrate the feasibility of high-fidelity models that are capable of predicting the formation of key metallurgical microstructures observed in SLM additive manufacturing processes as a function of the local thermal environment at different locations within the as-built component, reduced models for mapping process conditions to additional microstructure features impacting material quality, and potentially controlling material quality throughout a sample as-built part. The Phase II program will focus on the development of efficient, validated high-fidelity simulation codes and reduced models providing the means to reduce variability in as-built material microstructure and properties, and culminate with the delivery to these tools to NASA researchers and other stakeholders.