A Multi-Scale Model for Large Aluminum Forging Parts

Naval Aviation aircraft procurement faces cost and schedule challenges, largely due to high scrap rate of large airframe aluminum forging parts. The parts were rejected due to geometrical non-conformance, mostly due to distortion induced right after the quenching step. There is a need to develop a prediction tool to run simulations with optimized quenching parameters yielding least post-quenching distortion. Most simulation tools are not sufficiently accurate and do not include all three fields: thermal, mechanical and metallurgical. The Navy seeks an innovative multi-physics-based and machine learning tool that optimizes the quenching process, where the model inputs covers all three fields with a comprehensive understanding and control of residual stresses.   In Phase I, Triton will develop concepts for one or more physics-based simulation tool that models heat transfer, stress/strain evolution and phase transformation. We will demonstrate feasibility of the simulation model and perform proof-of-concept demonstration to asses the design’s Technology Readiness Level (TRL) or Manufacturing Readiness Level (MRL). Triton will also develop a Phase II plan to deliver a prototype.   In Phase II, Triton will further develop our multi-physic simulation model. We will perform experiments on coupon/component/full-scale to verify and validate our simulation model. In addition to assessing and updating the TRL/MRL, we will also demonstrate technology transition and commercialization feasibility.   In Phase III, Triton will transition and commercialize our developed multi-physics simulation tool as an analytical software package. We will deliver a detailed verification and validation plan and demonstrate the application capability for the selected airframe components of any interested aircraft platform.