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Modeling of Solid-State Materials Consolidation Repair Process for Static Strength and Fatigue Life Predictions

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N68335-23-C-0115
Agency Tracking Number: N212-113-0518
Amount: $799,995.00
Phase: Phase II
Program: SBIR
Solicitation Topic Code: N212-113
Solicitation Number: 21.2
Solicitation Year: 2021
Award Year: 2023
Award Start Date (Proposal Award Date): 2022-11-08
Award End Date (Contract End Date): 2024-12-09
Small Business Information
1 Airport Place, Suite 1
Princeton, NJ 08540-1111
United States
DUNS: 610056405
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Jim Lua
 (860) 398-5620
Business Contact
 Jim Lua
Phone: (860) 398-5620
Research Institution

Global Engineering and Materials, Inc. (GEM), along with its team members, Professor Hang Yu at Virginia Tech (VT) and Professor Rajiv Mishra at the University of North Texas (UNT), propose to develop a multiphysics based PSPP (process-structure-property-performance) approach and its associated toolkit for tailoring of additive friction stir deposition (AFSD) repair of aluminum components for improved static strength and fatigue life. The salient feature of our multiphysics modeling approach includes thermal, mechanical, and metallurgical interaction to predict bond strength, defects formation, damage initiation, and its propagation in a repaired component. The novelty of the proposed AFSD Repair and Fabrication Analysis Tool (AFSD-RFAT) includes: 1) a high-fidelity, computational fluid dynamics (CFD) based process model that captures thermal response, plastic flow, material mixing, and tool-workpiece interaction; 2) a microstructure evolution model that predicts the grain and precipitate size distribution; 3) a digital constitutive model that creates partitions and local stress-strain relations of distinct zones from the heterogeneous microstructure; 4) a customized Abaqus performance evaluation model with property mapping, bond interface, and initial flaws at stress concentration sites for crack propagation prediction; 5) a multi-stage total life prediction to capture the microstructure-driven crack initiation, plasticity-controlled small crack growth, and the stress ratio dependent long crack growth due to the presence of the residual stress field. In order to validate the physics of each module and the static and fatigue performance of hole repair coupons, advanced in-situ and ex-situ techniques, particle tracing, and high-resolution X-ray computed tomography (X-ray CT) scan will be used to measure the material flow, thermal history, grain structure, precipitates distribution, hardness distribution, residual stress field, initial defects, and fractography. A full validation for each stage of the PSPP modeling tool will be performed using the blend hole restoration data and divot repair data generated by the VT and UNT teams, respectively.

* Information listed above is at the time of submission. *

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