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Multi-scale modeling and advanced material technology for predictable, robust 3D printing improves higher performance, efficiency, and reliability for greater air fleet readiness.
High efficiency turbines require an approach that circumvents material-related cracking and process-related distortion. Incorporating additively manufactured components into jet engines is hindered by material and process-related challenges due to unpredictable properties. In addition, metal additive processes can generate internal stresses in structures that lead to warping and distortion. Commercially available computer models can help with this. However, there is a lack of commercial computer models that provide predictive power for robust, defect-free printing.
The objective of this project is to develop a generalized process development framework that can be applied to printable alloy systems to measurably improve the performance of AM-built nickel superalloy components.
This project seeks to:
This project will develop and demonstrate a combination of new algorithms and existing process approaches to minimize residual stress and distortion to maximize the performance of complex, thin-walled AM components. Software inputs will be derived from real world data collected from sensors in printing process and specimen testing. Advanced alloy 230 formulation (H230-RAM1) developed by Elementum 3D (E3D) will be used to avoid cracking issues common when printing nickel-based superalloys.