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Computational Modeling of Laser Additive Manufacturing Processes

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: F33615-03-M-5214
Agency Tracking Number: F031-1827
Amount: $99,981.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: N/A
Solicitation Number: N/A
Solicitation Year: N/A
Award Year: 2003
Award Start Date (Proposal Award Date): N/A
Award End Date (Contract End Date): N/A
Small Business Information
3025 Harbor Lane N, Suite 300, Plymouth, MN, 55447
DUNS: 199085424
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Kanchan Kelkar
 Principal Engineer
 (763) 519-0105
Business Contact
 Suhas Patankar
Title: President
Phone: (763) 519-0105
Research Institution
The overall goal of the proposed research is to develop a comprehensive, efficient, and well-validated model for the prediction of the shape and thermal history of components manufactured using Laser Additive Manufacturing (LAM) processes. The proposedmodel will use a combined Eulerian-Lagrangian treatment for analyzing the interactions between the gas and particle phases, and the laser beam. The temperature field in the deposition region will be determined by solving the unsteady energy transportequation that accounts for phase change and free surface effects. Detailed information of temperature gradients will be used for predicting the microstructure and residual stresses. Emphasis is placed on computational efficiency. Thus, the Volume-of-Fluidtechnique will be used to predict the shape evolution in a parent grid. A two-domain approach involving local mesh refinement and multigrid solution will be used for accurate analysis of the thermal interaction between the small-scale deposition region andthe large-scale bulk. The model will be validated using data from experiments on practical LAM units. In order to establish the feasibility of the technical approach, Phase I research will focus on the development, validation, and application of the modelsfor a co-axial deposition nozzle and for LAM processing of a thin-walled structure. The proposed model will offer a scientific approach to process design and optimization of LAM processes involving varying processing scales. The cost savings obtainedthrough improvements in powder utilization, turnaround time, and product quality will facilitate wide-scale commercialization of the LAM processes. A conservative estimate of the annual revenue from the commercial version of the model is $500,000/yr.

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

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