To develop a modelling tool for the effect of additive manufacturing process parameters on the microstructure and properties of the printed material.

 

Powder-bed metal additive manufacturing processes allow to build three-dimensional parts by successive formation of pools of molten metal, which solidify on the previously built layers. Multiple parameters influence the generated microstructure, including the power input on the deposited metal, the powder particle size, the printing pattern and the layer thickness. Changes in one or several of those parameters affect the grain structure of the material and therefore the resulting mechanical properties of the printed part. Understanding of the relations between the applied process parameters, the generated microstructure and the resulting material properties appears therefore fundamental, not only to predict and optimize the properties of the printed parts, but also to induce gradient properties in a given part, by varying the process parameters during the build job. Process and material modelling tools are reaching the maturity where the interactions between process parameters and obtained microstructure can be predicted, for the complex additive manufacturing processes.

Therefore, it is needed to develop a reliable tool for modelling of the parameter-microstructure-property interactions and to validate this tool by experimental verification on printed specimens.

This activity encompasses the following tasks:

• A review of existing modelling tools ? and their limitations ? for prediction of the interaction between process parameters, developed microstructure and mechanical properties for powder-bed additive manufacturing parts

• Selection of a powder-bed additive manufacturing process and a metallic alloy for which the tool will be developed and validated. Identification of key process parameters influencing the microstructure of additive manufactured material

• Development of the modelling tool for by simulation of the additive manufacturing process on the selected material, varying the selected key process parameters

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