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Sentient Science - A Multiscale Modeling Suite for Process and Microstructure Prediction in Metal Additive Manufacturing

Award Information
Agency: National Aeronautics and Space Administration
Branch: N/A
Contract: 80NSSC20C0029
Agency Tracking Number: 184053
Amount: $749,602.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: T12
Solicitation Number: STTR_18_P2
Timeline
Solicitation Year: 2018
Award Year: 2020
Award Start Date (Proposal Award Date): 2020-01-10
Award End Date (Contract End Date): 2022-01-09
Small Business Information
672 Delaware, Buffalo, NY, 14209-0000
DUNS: 089822014
HUBZone Owned: Y
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Jingfu Liu
 (716) 276-0168
 jliu@sentientscience.com
Business Contact
 Melissa McReynolds
Phone: (716) 239-8215
Email: mmcreynolds@sentientscience.com
Research Institution
 University ofNebraska - Lincoln
 Nebraska Hall (NH) W340
Lincoln, NE, 68588-0526
 Federally funded R&D center (FFRDC)
Abstract
In the Phase I period, Sentient upgraded its DigitalClone for Additive Manufacturing (AM) technology and successfully demonstrated and validated its ldquo;Process modelrdquo; and ldquo;Microstructure modelrdquo; for simulating metal AM processes. Sentient has partnered with University of Nebraska ndash; Lincoln for model validation.Specifically, Sentient has implemented a new ldquo;Process modelrdquo; to predict part-level residual stress and distortion for parts built using AM processes. The new model shows high simulation efficiency and accuracy. In addition, Sentient has improved the simulation speed of its ldquo;Microstructure modelrdquo; by 100% for predicting the grain structure and porosity.The proposed DigitalClone for Additive Manufacturing (DCAM) simulation suite will fill the technical gap NASA is currently facing, and meetnbsp;NASArsquo;s requirement very well. The proposed solution allows NASA to: 1) simulate the part-level distortion and residual stress with respect to various key process parameters; 2) simulate the microstructurenbsp;of as-built AM components with respect to key parameters and locations of interest; and 3) simulate the fatigue performance of as-built AM components at specific mechanical loading conditions. This physics-based simulation suite has been well demonstrated in different AM platforms (i.e. powder bed fusion and direct energy deposition) and several alloys systems that NASA is interested in. Those materials include Inconel 625, Inconel 718, 17-4 PH, 15-5 PH stainless steel, Ti64, and AlSi10Mg alloy. Additionally, the simulation suite can be applied to any new alloy with minimum calibration needed. This physics-based simulation suite directly benefits NASA via allowing computational testing for new component design, new materials, and new process, which will significantly reduce cost and time compared to conventional physical testing.In the Phase II effort, Sentient will focus on developingnbsp;of prototype softwarenbsp;and further validatingnbsp;different materials and components.nbsp;nbsp;

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

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